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Contents
Intellectual Property Rights Notice............................................................................. v
Technical Support............................................................................................................ ix
1
OS-T: 1340 Fatigue (Stress - Life) Method....................................................................... 239
Fatigue using S-N (Stress - Life) Method.................................................................. 239
Fatigue Process Manager (FPM) using S-N (Stress - Life) Method................................. 249
OS-T: 1350 Fatigue (Strain - Life) Method........................................................................263
Fatigue using E-N (Strain - Life) Method.................................................................. 263
Fatigue Process Manager (FPM) using E-N (Strain - Life) Method..................................273
OS-T: 1360 NLSTAT Analysis of Gasket Materials in Contact................................................289
OS-T: 1365 NLSTAT Analysis of Solid Blocks in Contact...................................................... 302
OS-T: 1370 Complex Eigenvalue Analysis of a Reduced Brake System.................................. 316
OS-T: 1371 Brake Squeal Analysis of Brake Assembly........................................................321
OS-T: 1372 Rotor Dynamics of a Hollow Cylindrical Rotor................................................... 327
OS-T: 1375 Response Spectrum Analysis of a Structure..................................................... 334
OS-T: 1380 Computation of Equivalent Radiated Power...................................................... 344
OS-T: 1385 Heat Transfer Analysis on Piston Rings with GAP Elements................................. 349
OS-T: 1390 Pretensioned Bolt Analysis of an IC Engine Cylinder Head, Gasket
and Engine Block System............................................................................................... 357
OS-T: 1392 Node-to-Surface vs Surface-to-Surface Contact................................................ 379
OS-T: 1393 Basics of Contact Properties and Debugging.................................................... 390
2
OS-T: 2020 Increasing Natural Frequencies of an Automotive Splash Shield with Ribs............. 563
OS-T: 2030 Control Arm with Draw Direction Constraints................................................... 577
OS-T: 2040 Spot Weld Reduction using CWELD and 1D...................................................... 585
OS-T: 2050 Pattern Repetition.........................................................................................589
OS-T: 2060 Symmetry and Draw Direction Constraints Applied Simultaneously...................... 598
OS-T: 2070 Reduced Model using DMIG........................................................................... 605
OS-T: 2080 Hook with Stress Constraints......................................................................... 618
OS-T: 2090 Extrusion Constraints.................................................................................... 625
OS-T: 2095 Frequency Response Optimization of a Rectangular Plate................................... 631
OS-T: 2098 Excavator Arm............................................................................................. 651
Combination Optimization...........................................................................................691
3
OS-T: 4095 Size Optimization using External Responses (DRESP3)...................................... 883
Shape Optimization.......................................................................................................890
Index.................................................................................................................................995
4
Intellectual Property Rights Notice
Copyrights, Trademarks, Trade Secrets, Patents & Third Party Software Licenses
Note: Pre-release versions of Altair software are provided ‘as is’, without warranty of any
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Note:
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Additionally, Altair software is protected under patent #6,859,792 and other patents pending. All other
marks are the property of their respective owners.
ALTAIR ENGINEERING INC. Proprietary and Confidential. Contains Trade Secret Information.
Not for use or disclosure outside of Altair and its licensed clients. Information contained in Altair
software shall not be decompiled, disassembled, “unlocked”, reverse translated, reverse engineered,
or publicly displayed or publicly performed in any manner. Usage of the software is only as explicitly
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To contact an Altair support representative, reference the following table or the information available on
the HyperWorks website: www.altairhyperworks.com/ClientCenterHWSupportProduct.aspx.
Israel israelsupport@altair.com
Malaysia aseansupport@altair.com
For questions or comments about this help system, send an email to connect@altair.com.
In addition, the following countries have resellers for Altair Engineering: Colombia, Czech Republic,
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Spain, Taiwan, United Kingdom, USA
1. To access model files, visit Altair Connect or the Altair Client Center.
A user ID and password are required to access the model files. Follow the instructions at the
website to obtain login credentials.
2. Select the required file package and download it onto your system.
Note: The files may require unzipping before proceeding with the tutorials. When
extracting zipped files, preserve any directory structure included in the file package.
Run OptiStruct from
HyperMesh 2
Run OptiStruct from HyperMesh
• Launching HyperMesh and Setting the OptiStruct User Profile (p. 13)
• Opening the Model (p. 14)
• Submitting the Job (p. 15)
• Post-processing the Results (p. 17)
This tutorial demonstrates how to launch an OptiStruct job from within HyperMesh. A HyperMesh
database containing a fully defined OptiStruct finite element model is retrieved and an OptiStruct job is
launched from the OptiStruct panel in HyperMesh.
OptiStruct Tutorials
Run OptiStruct from HyperMesh p.13
If the job is successful, new results files should be in the directory where the plate.fem was written.
The plate.out file is a good place to look for error messages that could help debug the input deck if
any errors are present.
The default files written to the directory are:
plate.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
plate.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
plate.h3d
HyperView binary results file.
plate.res
HyperMesh binary results file.
plate.stat
Summary, providing CPU information for each step during analysis process.
The tutorial Running OptiStruct from HyperMesh demonstrates how OptiStruct could be launched from
within HyperMesh. OptiStruct also can be run at the command line (Unix or MSDOS). This tutorial
assumes you already have the running file, plate.fem, in either your Unix or MSDOS directory. This
tutorial also assumes you know the location of the solver script.
In this tutorial, $HWSDIR describes the directory containing the OptiStruct executable. On
Unix machines, the script is normally located in the HyperWorks installation directory under
<install_directory>/scripts/. On Windows, it is normally located in the HyperWorks installation
directory under <install_directory>/hwsolvers/scripts/.
See Run OptiStruct in the User Guide for more detailed information.
Basic Small Displacement
Finite Element Analysis 4
Basic Small Displacement Finite Element Analysis
• OS-T: 1000 Linear Static Analysis of a Plate with a Hole (p. 20)
• OS-T: 1010 Thermal Stress Analysis of a Coffee Pot Lid (p. 35)
• OS-T: 1020 Normal Modes Analysis of a Splash Shield (p. 45)
• OS-T: 1030 3D Inertia Relief Analysis (p. 55)
• OS-T: 1040 3D Buckling Analysis (p. 64)
• OS-T: 1050 Connection of Dissimilar Meshes using CWELD Elements (p. 73)
• OS-T: 1060 Analysis of a Composite Aircraft Structure using PCOMPG (p. 83)
• OS-T: 1070 Analysis of an Axi-symmetric Structure (p. 95)
• OS-T: 1080 Coupled Linear Heat Transfer/Structure Analysis (p. 103)
• OS-T: 1085 Linear Steady-state Heat Convection Analysis (p. 116)
• OS-T: 1090: Linear Transient Heat Transfer Analysis of an Extended Surface Heat Transfer
Fin (p. 127)
• OS-T: 1100 Thermal Stress Analysis of a Printed Circuit Board with Anisotropic Material
Properties (p. 152)
• OS-T: 1110 Modal Analysis Setup (p. 159)
OptiStruct Tutorials
Basic Small Displacement Finite Element Analysis p.20
1. In the Model Browser, right-click and select Create > Material from the context menu.
A default material displays in the Entity Editor.
2. For Name, enter steel.
3. Set Card Image to MAT1.
4. Enter the material values next to the corresponding fields.
a) For E (Young's Modulus), enter 2.1E+05.
A new material, steel, has been created. The material uses OptiStruct's linear isotropic material model,
MAT1.
A new property, plate_hole, has been created as a 2D PSHELL. Material information is also linked to this
property.
Figure 4:
The component plate_hole has been updated with a property of the same name, and is now the current
component. This component uses the plate_hole property definition with a thickness value of 10.0. The
material steel is referenced by this component.
Creating Constraints
1. In the Model Browser, Load Collectors folder, right-click on spcs and select Make Current to set
spcs as the current load collector.
2. From the menu bar, click BCs > Create > Constraints to open the Constraints panel.
4. Hold Shift while clicking-and-dragging your mouse to select the nodes on the two ends of the
plate.
5. Constrain dof1, dof2, dof3, dof4, dof5, and dof6 and set all of them to a value of 0.0.
• 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.
6. Click create.
Constraints are applied to the selected nodes.
7. Click return to go back to the main menu.
4. Hold Shift while clicking-and-dragging your mouse to select the nodes around the hole.
Figure 12: Nodes Selected for the Application of Loads around the Hole
6. Click create.
Point forces, with the given magnitude in the z-direction, are applied to the selected nodes about
the hole.
7. Click return to go back to the main menu.
An OptiStruct subcase has been created which references the constraints in the load collector spcs and
the forces in the load collector forces.
4. Click Save.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to analysis.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to launch the OptiStruct job.
If the job is successful, new results files should be in the directory where the plate_hole.fem was
written. The plate_hole.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
The default files written to the directory are:
plate_hole.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
plate_hole.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
plate_hole.h3d
HyperView binary results file.
plate_hole.res
HyperMesh binary results file.
plate_hole.stat
Summary, providing CPU information for each step during analysis process.
HyperView is a complete post-processing and visualization environment for finite element analysis
(FEA), multibody system simulation, video and engineering data.
a) Under Result type set the first first pull-down menu to Element Stresses (2D & 3D) (t)
and set the second pull-down menu to vonMises.
b) Set the Averaging method to None.
4. Click Apply.
A contoured image representing von Mises stresses should be visible. Each element in the model
is assigned a legend color, indicating the von Mises stress value for that element, resulting from
the applied loads and boundary conditions.
5. In the View Controls toolbar, click the XY Top Plane View icon to change the view the model.
Figure 17: The vonMises Stress Plot for the Given Subcase
Try to answer the following questions to test your understanding of the current problem.
• What is the maximum von Mises stress value?
• At what location does the model have its maximum stress?
• Does this make sense based on the boundary conditions applied to the model?
The resulting contours represent the displacement field resulting from the applied loads and boundary
conditions.
Try to answer the following questions to test your understanding of the current problem.
• What is the maximum Displacement value?
• At what location does the model have its maximum displacement?
• Does this make sense based on the boundary conditions applied to the model?
A deformed plot of the model with the displacement contour should be visible, overlaid on the original
undeformed mesh in isometric view.
Figure 18: Isometric View of the Deformed Plot Overlaid on the Undeformed Mesh (Model Unit is Set to 500)
1. In the Model Browser, right-click and select Create > Material from the context menu.
A default material displays in the Entity Editor.
2. For Name, enter plastic.
3. Set Card Image to MAT1.
4. Enter the material values next to the corresponding fields.
A new material, plastic, has been created. The material uses OptiStruct's linear isotropic material
model, MAT1.
Notice: The Value field next to Material is set to <Unspecified>. This indicates that no
material properties are being referenced by this property.
Figure 20: Selecting the Material plastic for the Property PSHELL
Figure 21: The PSHELL Property Entry Fields in the Entity Editor
The property collectors and component collectors, PSHELL and PSHELL1, now reference the material
plastic. The component collectors that reference the corresponding properties are automatically
updated with the specified material. If you access the Entity Editor and edit either of these property or
component collectors, notice that the Material fields are now all set to plastic.
5. From the menu bar, click BCs > Create > Constraints to open the Constraints panel.
6. Using the entity selector, select the nodes indicated in Figure 24.
Figure 24: Creating Constraints Opposite the Spout Cut-Out to Model Hinges
An OptiStruct subcase has been created which references the constraints in the load collector
constraints and the forces in the load collector THERMAL_LOADING.
4. Click Save.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to analysis.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to launch the OptiStruct job.
If the job is successful, new results files should be in the directory where the lid_complete.fem was
written. The lid_complete.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
The default files written to the directory are:
lid_complete.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
lid_complete.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
lid_complete.h3d
HyperView binary results file.
lid_complete.res
HyperMesh binary results file.
lid_complete.stat
Summary, providing CPU information for each step during analysis process.
Figure 27: Isometric View of Deformed Plot Overlaid on Original Undeformed Mesh with Model Units Set to 2.
Try to answer the following questions to test your understanding of the current problem.
• Does the deformed shape look correct for the boundary conditions applied to the mesh?
In this analysis, the region around the hinges may be a concern. There are relatively high stress values
that must be resolved. For instance, if testing shows that the coffee pot lid wears out around the hinge
area over time, these thermal stresses could possibly cause that fatigue.
To be able to distinguish the spiders clearly in the model, you will use the Shaded Elements and Mesh
Lines icon .
The dependent nodes of the rigid elements have all six degrees of freedom constrained. Therefore, each
"spider" connects nodes of the shell mesh together in such a way that they do not move with respect to
one another. Revert to the Wireframe Elements Skin Only mode by clicking on the icon.
1. From the menu bar, click Mesh > Edit > 1D Elements > Rigids to open the Rigids panel.
2. Click review.
3. Select one of the rigid elements.
In the modeling window, HyperMesh displays the IDs of the rigid element and the two end nodes
and indicates the independent node with an 'I' and the dependent node with a 'D'. HyperMesh
also indicates the constrained degrees of freedom for the selected element, through the dof check
boxes in the Rigids panel. All rigid elements in this model should have all DOFs constrained.
4. Click return to go back to the main menu.
1. In the Model Browser, right-click and select Create > Material from the context menu.
A default material displays in the Entity Editor.
2. For Name, enter steel.
3. Set Card Image to MAT1.
4. Enter the material values next to the corresponding fields.
a) For E (Young's Modulus), enter 2E+05.
b) For NU, (Poisson's Ratio), enter 0.3.
c) For RHO (Mass Density), enter 7.85E-009
A material density is required for the normal modes solution sequence.
A new material, steel, has been created. The material uses OptiStruct's linear isotropic material model,
MAT1.
Figure 30: Updating the Thickness Value for Design and Nondesign Property Entries
To perform a Normal Modes Analysis, a real eigenvalue extraction (EIGRL) card needs to be referenced
in the subcase. The real eigenvalue extraction card is defined in HyperMesh as a load collector with an
EIGRL card image. This load collector should not contain any other loads.
Figure 32: A New Load Collector "EIGRL" is Created in the Model Browser
Creating Constraints
1. Create a load collector, named constraints.
2. From the menu bar, click BCs > Create > Constraints to open the Constraints panel.
3. With the nodes selector active, select the two nodes at the center of the rigid spiders.
An OptiStruct subcase has been created which references the constraints in the load collector
constraints and the real eigenvalue extraction data in the load collector EIGRL.
If the job is successful, new results files should be in the directory where the sshield_complete.fem
was written. The sshield_complete.out file is a good place to look for error messages that could help
debug the input deck if any errors are present.
The default files written to the directory are:
sshield_complete.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
sshield_complete.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
sshield_complete.h3d
HyperView binary results file.
sshield_complete.res
HyperMesh binary results file.
sshield_complete.stat
Summary, providing CPU information for each step during analysis process.
Mode .
6. Click Apply.
7. Under Undeformed shape, set Show to Wireframe.
A deformed plot of the model overlaid on the original undeformed mesh is displayed in the
modeling window.
8. In the Results Browser pull-down menu, you can change the view between various subcases using
the Load Case and Simulation Selection drop-down menus, as shown below:
Figure 37:
11. To control the animation speed, use the Animation Controls on the Animation toolbar, as shown
below:
Figure 38:
Summary
In this analysis, it was assumed that the bolts were significantly stiffer than the shield. If the bolts
needed to be made of aluminum and the shield was still made of steel, would the model need to be
modified, and the analysis run again?
It is necessary to push the natural frequencies of the splash shield above 50 Hz. With the current
model, there should be one mode that violates this constraint: Mode 1. Design specifications allow the
inner disjointed circular rib to be modified such that no significant mass is added to the part. Is there
a configuration for this rib within the above stated constraints that will push the first mode above 50
Hz? See tutorial OS-T: 2020 Increasing Natural Frequencies of an Automotive Splash Shield with Ribs to
optimize rib locations for this part.
The figure below illustrates the structural model used for this tutorial.
Figure 39: Structural Model with Static Loads and Support Constraints Applied
The ie_carm.hm database is loaded into the current HyperMesh session, replacing any existing
data. The database only contains geometric data.
b) Deselect the degrees of freedom dof4 through dof6 by right-clicking to uncheck each box.
c) Set load types = to SUPORT1.
The load type is modified to perform inertia relief analysis.
d) Click create.
3. Create constraint 2.
a) Using the entity selector, select the node and the rearward attachment point of the control
arm of the chassis.
This can be seen in Figure 41 as 2nd constraint.
b) Deselect dof1.
c) Click create.
4. Create constraint 3.
a) Using the entity selector, select the top node in the rigid which would fasten the bottom of
the shock assembly to the control arm.
Tip: Switch to the Wireframe Elements Skin Only mode by clicking on the
icon to view the rigid.
b) Deselect dof2.
c) Click create.
An OptiStruct subcase has been created which references the forces in the load collector static_loads
and the inertia relief support points in the load collector SPCs.
Tip: Use Next and Prev to browse through the different control card pages.
If the job is successful, new results files should be in the directory where the ie_carm.fem was written.
The ie_carm.out file is a good place to look for error messages that could help debug the input deck if
any errors are present.
The default files written to the directory are:
ie_carm.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
ie_carm.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
ie_carm.h3d
HyperView binary results file.
ie_carm.res
HyperMesh binary results file.
ie_carm.stat
Summary, providing CPU information for each step during analysis process.
Note: Both the play speed and starting point of the animation can be controlled using
the Animation Controls.
3. With the animation running, use the lower slider bar in the Animation Controls panel to adjust the
speed of the animation.
Figure 46:
Note: Beginning with 8.0, there is a parameter PARAM, INREL, -2 that can activate
inertia relief analysis without the need for a SUPORT/SUPORT1 entry. You can activate
that parameter by clicking on the PARAM field on the Control Cards panel. In this
tutorial, our intention was to show the steps in creating SUPORT1 cards; therefore the
parameter was not used.
As an additional exercise, you could run this tutorial using the above mentioned
parameter. In that case, you would not create SUPORT1 cards or choose that load
collector in the subcase.
Figure 47: Structural Model with Static Loads and Constraints Applied
1. In the Model Browser, Load Collector folder, right-click on SPC and select Make Current from the
context menu.
Figure 49:
2. From the menu bar, click BCs > Create > Constraints to open the Constraints panel.
3. Select all of the nodes on the bottom face of the beam.
a) Click nodes > on plane.
b) Verify that the N1 selector is active, then click any three nodes on the plane.
c) Click select entities.
All of the nodes on the plane are selected.
Figure 50:
Figure 52:
Figure 53:
3. In the Save As dialog, specify location to write the OptiStruct model file and enter buckling for
filename.
For OptiStruct input decks, .fem is the recommended extension.
4. Click Save.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to analysis.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to launch the OptiStruct job.
If the job is successful, new results files should be in the directory where the buckling.fem was
written. The buckling.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
The default files written to the directory are:
buckling.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
buckling.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
buckling.h3d
HyperView binary results file.
buckling.res
HyperMesh binary results file.
buckling.stat
Summary, providing CPU information for each step during analysis process.
Figure 55:
5. Select Element Stresses (2D and 3D) as the Result type and set the sub type to von Mises.
6. Click Apply.
This should show the contour of von Mises stress.
Figure 56:
Creating Properties
The database contains two unconnected components: solid_fine and solid_coarse. These unconnected
components are to be connected by CWELD elements using the grid to element option. In order to
achieve this, membrane elements need to be created on the matching faces of the solid_coarse and
solid_fine components.
1. In the Model Browser, right-click and select Create > Property.
A default PSHELL property template displays in the Entity Editor.
2. For Name, enter membrane_coarse.
3. For Card Image, select PSHELL from the drop-down menu.
4. For Material, click Unspecified > Material.
5. In the Select Material dialog, select steel and click OK.
6. Check the box next to MID2_opts.
An option list appears beneath MID2_opts.
7. Click the switch next to USER and select BLANK from the pop-up menu.
Notice the MID2 field disappears from the card image.
Figure 58:
Figure 59:
12. In the Model Browser, right-click and select Create > Property.
A default PSHELL property template displays in the Entity Editor.
13. For Name, enter membrane_fine.
14. Input the corresponding values for membrane_fine exactly the same as for membrane_coarse.
15. In the Model Browser, right-click and select Create > Component.
16. For Name, enter membrane_coarse.
17. For Property, click Unspecified > Property.
18. In the Select Property dialog, select membrane_coarse and click OK.
Figure 60:
24. Click dest component = and select membrane_coarse from the list of components.
25. Click move.
The elements are now part of the membrane_coarse component.
26. Click return.
27. On the Tool page, select faces.
28. Click delete faces.
29. Click return to exit the panel.
30. In the Model Browser, right-click and select Create > Component.
31. For Name, enter membrane_fine.
32. For Property, click Unspecified > Property.
33. In the Select Property dialog, select membrane_fine and click OK.
34. On the Tool page, select faces.
35. Click comps, select the solid_fine component, and click select > find faces.
Membrane elements are created on the faces of solid_fine component and they appear on the
modeling window.
36. Click return.
37. Right-click ^faces component and click Isolate.
This displays only ^faces component in the modeling window.
38. From the Tool page, select the organize panel.
39. Select only the elements that lie on the matching face as shown below. (Use a method similar to
the one mentioned in Step 23).
Figure 62: Selecting Elements on Matching Face for Solid Fine Component
40. Click dest component= and select membrane_fine from the list of components.
41. Click move.
The elements are now part of the membrane_fine component.
42. Click return.
43. From the Tool page, select the faces panel.
44. Click delete faces and click return to return to the main menu.
45. In the Model Browser, right-click and select Components > Hide.
46. Click the icon highlighted in red below to keep only the membrane elements in display.
4. Click Save.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to analysis.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to launch the OptiStruct job.
If the job is successful, new results files should be in the directory where the dissimilar.fem was
written. The dissimilar.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
The default files written to the directory are:
dissimilar.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
dissimilar.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
dissimilar.h3d
HyperView binary results file.
dissimilar.res
HyperMesh binary results file.
dissimilar.stat
Summary, providing CPU information for each step during analysis process.
4. Select the first pull-down menu below Result type: and select Displacement (v).
5. Click Apply.
The resulting colors represent the displacement field resulting from the applied loads and
boundary conditions.
7. Choose the second layout in the first row of the pop-up window.
This changes the modeling window in two separate windows. The left window will have the
previously loaded model and the right window will be blank.
8. Load the control example in the right side window to compare the results.
9. Click the right-hand pane in the display area.
A blue line appears around the window to show that it is selected.
10. Click the Load Result icon in the toolbar.
11. Click Load Model and select the file control.h3d you saved to your working directory from
the optistruct.zip file as both the model and results file.
12. Click Apply.
13. Right-click on the left pane and activate menu over Apply Style To > Current Page > All
Selected.
This option applies results from the current window to the new window. You can now visually
compare the displacement results from the dissimilar mesh model with a uniform mesh model.
3. Under Result type, select Element Stresses (2D & 3D)(t) and vonMises.
4. In the field below Averaging method, select None.
5. Click Apply.
6. Right-click on the left pane and activate menu over Apply Style To > Current Page > All
Selected.
You can now visually compare the von Mises stress results from the dissimilar model with a
uniform mesh model.
The model for this tutorial is shown below. Since the structure, loads, and boundary conditions
are symmetrical about the x-axis, only one half of the structure is modeled with suitable boundary
conditions applied to enforce half symmetry.
2. Select the frame.hm file you saved to your working directory from the optistruct.zip file. Refer
to Accessing the Model Files.
3. Click Open.
The frame.hm database is loaded into the current HyperMesh session, replacing any existing data.
The database only contains geometric data.
All of the components are modeled with the PCOMP property which lists the plies (stacking sequence)
from the bottom surface upwards, with respect to the element's normal direction, as shown in
Figure 66.
Components in this model that have names starting with the word "Flange" represent junctions in which
different components are connected together. While reviewing, closely watch the flange area formed
by the Skin and Rib components (highlighted in the following figure). Review the ply lay-up of the
Skin_inner, Rib, Flange1_Rib_Skin, and Flange2_Rib_Skin components (laminate layout is shown in the
bottom portion of the following figure).
Note: Few plies are common for the Skin_inner, Flange1_Rib_Skin, Flange2_Rib_Skin, and
Skin_outer components, but appear in different stacking sequence in each component. For
example, the 4th ply in Skin_inner is the 3rd ply in Flange2_Rib_Skin and the 2nd ply in the
Skin_outer components.
Figure 67: Ply stacking for the Skin_inner, Rib, Skin_outer, Flange1_Rib_Skin, and Flange2_Rib_Skin Components
7. You can also review the other components. Once the review is completed, select File > Exit to
exit the HyperLaminate GUI and return to HyperMesh.
If the job is successful, new results files should be in the directory where the frame_PCOMP.fem was
written. The frame_PCOMP.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
The default files written to the directory are:
frame_PCOMP.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
frame_PCOMP.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
frame_PCOMP.h3d
HyperView binary results file.
frame_PCOMP.res
HyperMesh binary results file.
frame_PCOMP.stat
Summary, providing CPU information for each step during analysis process.
4. Select the first switch below Result type and select Composite Stresses(s).
5. Select the second switch and select the P1 (major) Stress.
6. Select 3 for the Layers option.
7. In the field below Averaging method, select None.
Figure 69:
8. Click Apply.
This contours the maximum principle stress for the 3rd ply of all the components in the model.
9. Click the Isometric View icon in the Standard Views toolbar to see the model, as shown in
the following figure.
The stress value does not vary gradually in the top face region, but suddenly decreases to a lower value
across the Flange2_Rib_Skin component.
Looking at the table of laminate properties of Flange1_Rib_Skin again, observe that the 3rd ply
property of the Flange2_Rib_Skin component is of a matrix material and the third plies in the
components adjacent to it (Flange1_Rib_Skin and Skin_outer) are of a carbon fiber material. The
sudden changes in the stress values occur because we are looking at stress on two different materials.
This example shows that, for the results to be meaningful during post-processing of the PCOMP results,
you have to correlate the ply results to their corresponding ply property.
This highlights that, during the post-processing of PCOMP components, plotting results based on
just the ply number is not sufficient. You have to keep track of ply properties (material, thickness,
orientation, failure index, etc.) on your own during post-processing with this method. In cases that
use large and complex models, it becomes tedious to track the individual ply properties during post-
processing.
This drawback to using PCOMP can be avoided with the use of the PCOMPG card for property definition.
Using the PCOMPG card, you can assign a global ply number for each ply and post-process the results
based on global ply number. The following steps explain the procedure to redefine the model with
PCOMPG property.
Tip: Click to return to the previous page where HyperMesh is open, if you are
using HyperMesh Desktop.
Now you create new PCOMPG components with global ply numbers defined as shown in Figure 71.
As discussed earlier, the 4th ply in Skin_inner is the 3rd ply in Flange2_Rib_Skin and the 2nd ply in
Skin_outer components. Therefore, all of these plies will be defined with the same global ply ID 4.
Similarly, all other plies are to be defined, as shown in Figure 71.
6. Expand the laminates portion of the tree structure on the left-hand side of the screen.
7. Right-click PCOMPG.
A menu appears.
8. Click New.
This creates new component, which is named NewLaminate1 by default, and the tree structure is
expanded.
9. Rename the component to Skin_inner_GPLY by right-clicking and select Rename in the text field
and overwrite the default component name.
10. In the Add/Update plies section, under the field GPLYID, enter 1.
11. Select the pull-down menu below Material and select carbon_fiber.
12. Below the Thickness T1 field, enter 1.2.
13. Below the Orientation field, enter 45.
14. Select the pull-down menu below SOUT and select YES.
17. Click Update Laminate at the bottom of the window to update the lay-up information.
The graphical display of lay-up information now appears in the field below the Review tab, on the
right side of the GUI.
18. Create a new PCOMPG component with name Rib_GPLY and the ply lay-up, as shown in the
following table:
The new component Flange1_Rib_Skin_GPLY was created. Its first 5 plies are the same as
Skin_inner_GPLY and its last 2 plies are the 3rd and 4th plies of the Rib component.
To reduce the number of steps in this tutorial, the ply lay-up information of other components
is already defined with PCOMPG property and appropriate laminate information in the
updated_PCOMPG_properties.fem file you saved to your working directory from the
optistruct.zip file. This file is imported into HyperMeshto update (overwrite) the properties
instead of manually updating them.
The updated_PCOMPG_properties.fem file is saved in OptiStruct input file format. Open this in
any text editor to review how the components are defined with PCOMPG properties. A section of the
file is shown below.
22. Click File > Exit to exit the HyperLaminate GUI and return to HyperMesh.
23. Click File > Import > Solver Deck.
24. Click the toggle to expand the Import options and check the box next to FE overwrite.
This option overwrites the old PCOMP properties with PCOMPG properties defined in the
updated_PCOMPG_properties.fem file.
25. Click on the folder icon next to File, select the updated_PCOMPG_properties.fem file and click
Import.
26. Click Close.
If the job is successful, new results files should be in the directory where the frame_PCOMPG.fem was
written. The frame_PCOMPG.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
The default files written to the directory are:
frame_PCOMPG.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
frame_PCOMPG.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
frame_PCOMPG.h3d
HyperView binary results file.
frame_PCOMPG.res
HyperMesh binary results file.
frame_PCOMPG.stat
Summary, providing CPU information for each step during analysis process.
4. Select the first switch below Result type and select Composite Stresses (s).
5. Select the second switch and select P1 (major) Stress.
6. For the Layers field, select PLY 3.
7. For Averaging method, select None.
8. Click Apply.
This plots the maximum principle stress for global ply 3. The results are not plotted in the regions
where global ply 3 is not present.
9. Click the Isometric View icon in the Standard Views toolbar.
Figure 74:
Post-processing the results based on global ply number eliminates the need to track the ply
number and corresponding ply properties on the components. The results are displayed based on
the global ply number, irrespective of the ply order, so you can chose any one global ply number
and view results across the whole component. If a particular ply is not present in any given
region, no result is displayed.
2. Select the axi-symmetry_full_geometry.hm file you saved to your working directory from the
optistruct.zip file. Refer to Accessing the Model Files.
3. Click Open.
The axi-symmetry_full_geometry.hm database is loaded into the current HyperMesh session,
replacing any existing data. The database only contains geometric data.
If the job is successful, new results files should be in the directory where the axi-
symmetry_full_geometry.fem was written. The axi-symmetry_full_geometry.out file is a good place
to look for error messages that could help debug the input deck if any errors are present.
Displacement and stress results are output for each subcase to the axi-symmetry_full_geometry.h3d
file from OptiStruct. This section describes how to view those results in HyperView.
3. Select the first pull-down menu below Result Type and select Displacement [v].
4. Select the second pull-down menu below Result Type and select Mag.
Figure 77:
Tip: To view the displacement variation across the thickness, one half of the structure
can be masked.
Figure 78:
Figure 79:
Before proceeding to the next section, look at the criteria for modeling an axi-symmetry problem.
Even if the geometry is symmetrical about an axis, if any of the loads or boundary conditions are not
symmetrical about the same axis, then it cannot be modeled as an axi-symmetry model. Therefore, the
models shown below are examples that cannot be modeled as axi-symmetry models.
Figure 80: Left: Non Axi-symmetric Loads; Right: Non Axi-symmetric Boundary Conditions
All of the nodes in the model are assigned to a cylindrical coordinate system. The z-axis of the
cylindrical coordinate system coincides with the axis about which the model is symmetrical. Now,
constraining the nodes that are assigned to the cylindrical coordinate system in tangential degrees of
freedom enforces the axi-symmetry boundary condition.
Creating Constraints
1. Expand the Load Collectors folder in the Model Browser.
2. Right-click on SPCs and click Make Current to make SPCs the current component, if not already
done.
3. Click BCs > Create > Constraints to open the Constraints panel.
4. Make sure the entity selection switch is set to nodes.
5. Click the yellow button nodes to open the extended entity selection window and select all.
6. Constrain dof2.
• 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.
This applies these constraints to the selected nodes.
8. Click return to go back to the main menu.
Next you will submit the job, as was complete in Exercise 1.
9. From the Analysis page, enter the OptiStruct panel.
10. Solve the job with file name as axi-symmetry_model.fem by following the same steps as
explained in the earlier section.
If the job is successful, new results files can be seen in the directory where the OptiStruct model
file was written. The axi-symmetry_model.out file is a good place to look for error messages that
will help to debug the input deck if any errors are present.
If the job is successful, new results files should be in the directory where the axi-symmetry_model.fem
was written. The axi-symmetry_model.out file is a good place to look for error messages that could
help debug the input deck if any errors are present.
4. Activate the new window by clicking in the modeling window of the new window.
5. Click to open the Load Model and Results panel.
6. Click the Load model icon on the toolbar and load the axi-symmetry_model.h3d.
This loads the complete path of the selected .h3d file in the field. Also, note that the same file
path is loaded next to the field Load results.
7. Click Apply.
8. Click XZ Left Plane View to display the Left view.
9. Click the Contour icon on the toolbar and contour the displacements.
10. Compare the displacement results of the axi-symmetry model with the result from the full model.
The results should match, as shown in the below picture. Similarly, stress and other results will
also match.
As shown in the figure below, the pipe is fixed on the ground at one end and the heat flux is applied on
the other end.
A linear steady-state heat conduction solution is defined first. Then it is referred by a structure solution
by TEMP to perform the coupled thermal/structural analysis. The problem is defined in HyperMesh and
solved with OptiStruct implicit solver. The heat transfer and structure results are post processed in
HyperView.
11. For Card Image, select PSOLID from the drop-down menu and click Yes to confirm.
The property of the solid steel pipe has been created as 3D PSOLID. Material information is linked
to this property.
5. Click the entity selection switch and select nodes from the pop-up menu.
6. Click nodes >> by sets.
7. Select the predefined entity set heat and click select.
The selected nodes on the fixed end should be highlighted.
8. Uncheck the boxes in front of dof1, dof2, dof3, dof4, dof5, and dof6 and enter 0.0 in the entry
fields.
9. Click load types = and select SPC from the pop-up list.
10. Click create.
This applies these thermal constraints to the selected nodal set.
11. Click return to go to the Analysis page.
If the job is successful, new results files should be in the directory where the pipe_complete.fem was
written. The pipe_complete.out file is a good place to look for error messages that could help debug
the input deck if any errors are present.
4. Select Subcase 1 - heat transfer as the current load case in the Results tab, as shown below.
5. In the Contour panel, select the first pull-down menu below Result type and select Element
Fluxes (V).
6. Click Apply.
A contoured image representing thermal fluxes should be visible.
7. Select the first pull-down menu below Result type and select Grid Temperatures (s).
8. Click Apply.
Both flux and temperature results are shown below.
The temperature on the inside surface of the pipe is 60°C. The outside surface is exposed to the
surrounding air, which is at 20°C. The temperature distribution within the pipe can be determined by
solving the linear steady state heat conduction and convection solution.
4. Select the thermal.fem file you saved to your working directory from the optistruct.zip file.
Refer to Accessing the Model Files.
5. Click Open.
6. Click Import, then click Close to close the Import tab.
A new material, steel, is created with both structural and thermal properties.
5. In the Model Browser, right-click and select Create > Property.
A default PSHELL property displays in the Entity Editor.
6. For Name, enter solid.
7. For Card Image, select PSOLID and click Yes to confirm.
8. For Material, click Unspecified > Material.
9. In the Select Material dialog, select steel and click OK.
The property of the solid steel pipe has been created as 3D PSOLID. Material information is linked
to this property.
Figure 99: Selected Surface Nodes on the Solid Element Outside the Pipe
2. Select elems.
3. Click elems > by group.
4. Check the box in front of CONVECTION and click select.
5. Click config= and select slave4.
6. Click type= and select CHBDYE4.
7. Click edit and go to the CHBDYE Card Image panel.
8. Check the box in front of CONV.
9. Click TA1 and input the ambient node ID 4679, as shown below.
If the job is successful, new results files should be in the directory where the thermal_complete.fem
was written. The thermal_complete.out file is a good place to look for error messages that could help
debug the input deck if any errors are present.
4. Select the first pull-down menu below Result type and select Grid Temperatures(s).
5. Click Apply.
You may have to use Edit Legend in the Contour panel to get the contour, as shown in Figure 103.
A contour plot of grid temperatures is created.
6. Select the first pull-down menu below Result type and select Element Fluxes (V).
7. Click Apply.
You may have to use Edit Legend in the Contour panel to get the contour. Both temperature and
flux contour plots are shown in Figure 103.
The fins draw heat away from the outer surface of the system and dissipate it to the surrounding air.
The process of heat transfer out of the fin depends upon the flow of air around the fin (Free or forced
convection). In the current tutorial, the focus is on transient heat transfer through heat flux loading and
free convection dissipation.
An extended surface heat transfer fin made of steel is illustrated in Figure 104. To meet certain
structural design requirements, the fin is bent at 90° at approximately a quarter of its length.
Tip: A free convection analysis is conducted in this tutorial; however, if forced fluid flow
(forced convection) is allowed over the outer surface of the system, then offsetting the
fins from each other periodically, interrupts the growth of a thermal boundary layer and a
reduction in flow velocity occurs due to form drag, resulting in a higher heat transfer rate.
Figure 104: Extended Surface Heat Transfer Fin for Convective and Conductive Transient Heat Transfer
The extended surface heat transfer fin shown in Figure 104 is meshed with CHEXA elements in
HyperMesh and a transient heat transfer analysis is performed in HyperMesh using the Altair OptiStruct
2
solver. A typical heat flux load of 100 KW/m is applied to the face connected to the outer surface of the
system. An ambient temperature of 25°C is assumed and all material properties are assumed to remain
constant with temperature and time. Free (Natural) convection is assumed over the entire surface of the
material, wherein heat transfer between the surface of the fin and the surrounding air occurs due to a
complex mechanism of density differences as a result of temperature gradients.
Tip: In its simplest form, natural convection can be explained as the transfer of heat from
the hot surface to a layer of cold air just above it, leading to an increase of temperature
within that layer causing a drop in air density. The hot air (less dense) then rises vacating
space for a layer of cold air (more dense) that takes its place and so on in a continuous
pattern until (if) steady-state is reached. In reality, however, the process of natural
convection is highly complex due to the complexities in fluid flow and extensive experimental
correlation is required for accurate analysis.
Prerequisites
1. The latest version of HyperMesh, HyperView and OptiStruct software installations. Transient heat
transfer analysis is available only in HyperMesh version-12.0.110, HyperView version-12.0.110
and OptiStruct version-12.0.202 and later.
2. The heat_transfer_fin.fem solver deck is available from the optistruct.zip file. Refer to
Accessing the Model Files.
Figure 105: Heat Exchanger Fin Model for Transient Heat Transfer Analysis
The basic finite element equation for transient heat transfer analysis is given by:
(1)
Where,
Conductivity matrix
The differential equation (Equation 1) is solved to find nodal temperature at the specified time steps.
The difference between Equation 1 and the steady-state heat transfer equation is the term, that
captures the transient nature of the analysis.
Checkpoint
Steady-state heat transfer analysis, generally, is sufficient for a wide variety of applications. However,
in situations where the system properties vary significantly over time the transient nature of heat
transfer must be considered. Some examples are the relatively slow heating up of airplane gas turbine
compressor disks compared to the turbine casing leading to aerodynamic issues during takeoff or the
analysis of the time taken for the onset of frostbite in fingers or toes.
5. Click Open.
6. Click Import, then click Close to close the Import tab.
Figure 106:
Since you are conducting a purely heat transfer analysis, structural isotropic properties (for
example, MAT1 card) are not required. Also, it is assumed that the thermal material properties
(MAT4) are temperature independent.
A new material, steel, is created with thermal properties necessary for a transient heat transfer
analysis.
Now, create the solid property for this model referencing the PSOLID entry and connect the
material, steel, to this property; the property can then be assigned to the existing component.
5. In the Model Browser, right-click and select Create > Property.
A default PSHELL property displays in the Entity Editor.
6. For Name, enter solid.
7. For Card Image, select PSOLID and click Yes to confirm.
8. For Material, click Unspecified > Material.
9. In the Select Material dialog, select steel and click OK.
Figure 107:
Figure 108:
This encompasses a total time period of 500 seconds in which to capture the behavior of the
system.
Figure 109:
6. Click Close.
Figure 110:
6. Next, create the amplitude (constant part) of the time variant ambient temperature using an SPCD
Data Entry. Click BCs > Create > Constraints.
7. The ambient temperature is set by using the SPCD Data Entry to control an existing node outside
the actual structure. In the Constraints panel, click nodes > by id, enter 5672 in the id= field and
press Enter.
The ambient node is highlighted in the Entity Editor above the structure.
8. Enter 5.0 in the size= field and uncheck the boxes beside all the degrees of freedom (dof1
through dof6) and enter 0.0 in all the fields next to the dof#.
9. For load types =, select SPCD.
10. Click create/edit and enter 25.0 in the D field on the SPCD Data Entry.
This creates an SPCD referencing the ambient node specifying a temperature of 25°C.
11. Click return twice to go back to the Analysis page.
12. Next, create another load collector to define the time variant nature of the ambient temperature.
This is done by specifying a TABLED1 entry referenced by the previously created TLOAD1 entry.
13. Create a new load collector named Ambient SPCD Table, and set the Card Image as TABLED1.
14. For TABLED1_NUM, enter 2 and press Enter.
15. In the table, enter x(1) = 0.0, y(1) = 1.0, x(2) = 500.0, and y(2) = 1.0.
16. Click Close.
Tip: In this tutorial, a constant ambient temperature (the values of y(1) and y(2) are
the same leading to a constant temperature distribution over the first 500 seconds) is
defined; however, this demonstrates the procedure to use a TABLED1 entry to specify
a time variant ambient temperature as well. To do this, specify different values for the
y# fields and depending on the type of variation required, select from LINEAR or LOG
options.
Checkpoint
The SPCD and its corresponding table are linked to the previously created TLOAD1 entry.
17. In the Model Browser, click the Ambient SPCD TLOAD1 load collector.
It is displayed in the Entity Editor.
18. For EXCITEID, select the Ambient SPCD load collector from the menu.
19. For TYPE, select DISP, then click TID and select the Ambient SPCD Table load collector menu.
All entities referenced by SPCD entries should also be constrained by SPC data entries. The value
of the corresponding SPC referencing an ambient point controlled via an SPCD by TLOAD1/2
entries should be equal to zero (0.0).
20. Create a new load collector named Ambient SPC and for Card Image, select None.
21. Make sure that the newly created load collector Ambient SPC is current and click BCs > Create >
Constraints and click nodes in the Constraints panel.
22. Select by id from the extended menu, enter 5672 and press Enter.
The ambient node is highlighted in the modeling window above the structure.
23. Enter 5.0 in the size= field and uncheck the boxes beside all the degrees of freedom (dof1
through dof6) and enter 0.0 in all the fields next to the dof#.
24. For load types =, select SPC.
25. Click create/edit and enter 0.0 in the D field on the SPC Data Entry.
This creates an SPC referencing the same ambient node that is controlled by the SPCD Data Entry.
26. Click return twice to go back to the Analysis page.
Figure 115: Displaying the Current Load Collector - Heat Flux QBDY1
4. An interface is now created between the heat flux source and the solid elements on the
surface of the fin. This is done by clicking BCs > Create > Interfaces and specifying
conduction_interface in the Name field of the Create group dialog.
5. For Card Image, select CONDUCTION from the drop-down menu and click Yes to confirm.
6. For Slave Entity IDs, click on the yellow Elements panel.
A panel appears under the modeling window.
7. Click on the switch button beside elems and select faces from the list.
8. Click the highlighted solid elems and select by sets from the selection menu.
9. Check the box next to Element_set_Flux and click select.
The predefined element set is now highlighted in white on the model.
Tip: The break angle helps find adjacent solid faces for the same element set,
however, since this surface element set generation requires only one face, the value of
the break angle is not germane in this situation.
10. Click nodes and select the nodes in the Figure 117.
Figure 117: Selecting the Nodes on the Highlighted Surface for Conduction Surface Element Creation
11. Click add and return to go back to the Create group dialog.
12. Click Close.
A conduction interface is created because QBDY1 data can only reference surface elements and the
conduction interface helps us create a set of surface elements at the surface where heat flux is
input.
13. Next, create the amplitude (constant part) of the time variant heat flux using a QBDY1 Data Entry.
Do this by clicking on BCs > Create > Flux.
Tip: In this tutorial, a linearly incremental heat flux load (the values of y(1) and y(2)
are 0 and 1 leading to a linearly increasing heat flux distribution over the first 500
seconds) is defined.
Checkpoint
The QBDY1 flux load and its corresponding table are linked to the previously created TLOAD1 entry.
21. In the Model Browser, click the Heat Flux TLOAD1 load collector.
The entry is displayed in the Entity Editor below.
22. For Card Image, select TLOAD1.
23. For EXCITEID, select the Heat Flux QBDY1 load collector from the pop-out table and click OK.
24. For TYPE, select LOAD, then click TID and select the Heat Flux Table from the pop-out table
and click OK.
7. Click nodes next to face nodes, this highlights the same element set in black. Click any four
nodes on all highlighted faces of the model as shown in Figure 123 and Figure 124 and specify a
break angle of 89°.
Tip: The break angle helps find adjacent solid faces for the same element set, all
adjacent faces with the angle between surface normals less than the specified break
angle are selected for surface element creation.
Figure 123: Selecting the Nodes on Four of the Seven Highlighted Surfaces for Convection Surface Element
Creation
Figure 124: Selecting Nodes on the Three Remaining Highlighted Surfaces for the Creation of a Convection
Interface
The newly created CHBDYE surface elements are displayed in yellow, as shown in Figure 125
below.
Figure 125: Newly generated CHBBDYE Surface Elements are Displayed in Yellow on the Model
12. Click elems >> by group and select convection_interface from the menu.
13. Click config= and select slave4.
14. Click type= and select CHBDYE4.
15. Click edit and go to the CHBDYE Card Image panel.
16. Check the box beside CONV. Click TA1 and input the ambient node ID 5672.
17. Click return twice to go back to the Analysis page.
The DLOAD entry is created as a linear combination of two TLOAD1 entries - Heat Flux TLOAD1 and
Ambient SPCD TLOAD1.
Note: FLUX and THERMAL output can also be requested in control cards panel on
Analysis page.
If the job is successful, new results files should be in the directory where the
heat_transfer_fin_complete.fem was written. The heat_transfer_fin_complete.out file is a good
place to look for error messages that could help debug the input deck if any errors are present.
Viewing Results
Grid temperatures, element temperature gradients and flux contour results are computed for the
transient heat transfer analysis and HyperView are used to post-process the results.
1. From the OptiStruct panel, click HyperView.
HyperView is launched and the results are loaded. A message window appears to inform of the
successful model and result files loading into HyperView.
2. Click Close to close the message window, if one appears.
3. On the Results toolbar, click to open the Contour panel.
4. Select the first pull-down menu below Result type and select Grid Temperatures(s).
Figure 129: Grid Temperature Contour for the Final Time Step (500 seconds) - WITH FREE CONVECTION
Checkpoint
In Figure 129, this is the grid point temperature plot after 500 seconds. The system is input a linearly
2
increasing heat flux from 0 to 0.1 W/mm from 0 to 500 seconds respectively. Therefore, a physical
correlation can be the effect of starting an IC engine to full capacity wherein the flux transmitted to
the outer surface linearly increases with time. Note that the flux patterns in actuality may be different
and may fluctuate based on the duration of the power cycles. The maximum temperature of 81.3°C
predictably occurs at the elements closest to the heat flux loading site and the minimum temperature of
29.5°C occurs at elements farthest from the heat source.
6. Click Apply, select Time = 2.0000000E+01 from the Results Browser.
A contour plot of grid temperatures is created, as shown in Figure 130.
Figure 130: Grid Temperature Contour Plot after 20 Seconds - WITH FREE CONVECTION
7. Select the first pull-down menu below Result type and select Element Fluxes (V).
8. Click Apply, select Time = 5.0000000E+02 from the Results Browser to view the element flux
results after 500 seconds in Figure 132.
In a practical setting, you can also see the effect of free convection in the reduction of temperature at
the outer surface of the system. Convection (due to the extended surface area) allows a larger amount
of heat to be drawn out of the system when compared to the absence of an extended surface fin. This
is evident in the temperature of the outer surface of the system after 500 seconds in the absence of
convection heat loss.
Figure 131: Grid Temperature Contour Plot after 500 Seconds - WITHOUT FREE CONVECTION
The maximum temperature at the outer surface of the heat source system is 125.3°C which is an
increase of 44°C in 500 seconds. Therefore using an extended surface fin is a very effective way to
reduce the temperature of a system.
The concentrated, intense heating that occurs during the soldering process creates stresses in the
substrate material. In this exercise, you will simulate this process and determine if the stresses and
strains resulting from this process are acceptable or not.
The model makes use of solid hexahedral (CHEXA8) elements with a thin skin of shell elements (CQUAD4)
on the outside faces.
The consistent unit system used in this simulation are: kg, mm, GPa, kN and °C
Figure 133:
3. Click Open.
The circuit_board.hm database is loaded into the current HyperMesh session, replacing any
existing data. The database only contains geometric data.
G11 17.0
G22 16.2
G33 7.00
G44 4.93
G55 4.70
G66 2.03
5. Enter the following values for the thermal expansion rates and reference temperature:
A1 1.6e-5
A2 1.9e-5
A3 8.0e-5
TREF 10.0
Figure 134:
G11 17.0
G22 16.2
G33 4.90
A1 1.6e-5
A2 1.9e-5
TREF 10.0
Figure 135:
7. Repeat steps 1 to 6 to create another property with name Solids, with Card Image set as
PSOLID and Material as PCB_solids.
8. In the Model Browser, click the pcb_solids component.
The component entry is displayed in the Entity Editor below.
9. For Property, click Unspecified > Property.
10. In the Select Property dialog, select Solids and click OK to complete the property selection.
11. Repeat steps 8 to 10 for both solder_pads and shell_faces selecting shell for the property name.
Figure 136:
5. Click BCs > Create > Constraints to open the Constraints panel.
6. Click nodes > by sets.
7. Select the constrain_nodes entity set and click select.
8. Leave all 6 degrees of freedom selected and click create.
9. Click return to go back to the main menu.
6. Click select.
7. Verify that constant value (the field label specifies value=) is selected and enter 345.0.
8. Verify the load types= is set to TEMP.
9. Click create to create the temperature_loads.
10. Click return to go back to the main menu.
If the job is successful, new results files should be in the directory where the circuit_board.fem was
written. The circuit_board.out file is a good place to look for error messages that could help debug
the input deck if any errors are present.
The channel_brkt_modal.hm file is used for this tutorial. It contains the bracket and channel assembly
pictured below.
To complete the setup of the model for a modal analysis with OptiStruct, you need to define a normal
modes SUBCASE, containing METHOD and SPC statements.
Figure 138:
Figure 139:
You are going to create the SPC constraints on the nodes along the lines on the perimeter of the
channel's bottom surface, as shown in the image below.
4. Click BCs > Create > Constraints to open the Constraints panel.
5. Switch the entity selector to lines.
6. Select the six lines on the perimeter of the channel's bottom surface.
To view the selected lines clearly, switch to Transparent Elements mode, as shown below:
Figure 141:
Notice: The OUTPUT button is green. This indicates the card is exported to the
OptiStruct input file.
If the job is successful, new results files should be in the directory where the modal_analysis.fem was
written. The modal_analysis.out file is a good place to look for error messages that could help debug
the input deck if any errors are present.
• OS-T: 1300 Direct Frequency Response Analysis of a Flat Plate (p. 166)
• OS-T: 1305 Modal Frequency Response Analysis of a Flat Plate (p. 177)
• OS-T: 1310 Direct Transient Dynamic Analysis of a Bracket (p. 189)
• OS-T: 1315 Modal Transient Dynamic Analysis of a Bracket (p. 197)
• OS-T: 1320 Nonlinear Gap Analysis of an Airplane Wing Rib (p. 206)
• OS-T: 1325 Random Response Analysis of a Flat Plate (p. 219)
• OS-T: 1330 Acoustic Analysis of a Half Car Model (p. 226)
• OS-T: 1340 Fatigue (Stress - Life) Method (p. 239)
• OS-T: 1350 Fatigue (Strain - Life) Method (p. 263)
• OS-T: 1360 NLSTAT Analysis of Gasket Materials in Contact (p. 289)
• OS-T: 1365 NLSTAT Analysis of Solid Blocks in Contact (p. 302)
• OS-T: 1370 Complex Eigenvalue Analysis of a Reduced Brake System (p. 316)
• OS-T: 1371 Brake Squeal Analysis of Brake Assembly (p. 321)
• OS-T: 1372 Rotor Dynamics of a Hollow Cylindrical Rotor (p. 327)
• OS-T: 1375 Response Spectrum Analysis of a Structure (p. 334)
• OS-T: 1380 Computation of Equivalent Radiated Power (p. 344)
• OS-T: 1385 Heat Transfer Analysis on Piston Rings with GAP Elements (p. 349)
• OS-T: 1390 Pretensioned Bolt Analysis of an IC Engine Cylinder Head, Gasket and Engine Block
System (p. 357)
• OS-T: 1392 Node-to-Surface vs Surface-to-Surface Contact (p. 379)
• OS-T: 1393 Basics of Contact Properties and Debugging (p. 390)
OptiStruct Tutorials
Advanced Small Displacement Finite Element Analysis p.166
The flat plate is subjected to a frequency-varying unit load excitation using the direct method. Post-
processing is done in HyperView and HyperGraph to visualize deformations, mode shape response, and
frequency-phase output characteristics.
Creating Constraints
1. In the Model Browser, expand Load Collector, right-click spcs > Make Current.
Figure 143:
Figure 144: Illustration of which nodes to select for applying single point constraints
9. Constrain dof1, dof2, dof3, dof4 and dof5 (you only need to uncheck dof6).
• 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.
10. Click create.
The selected nodes will be free to rotate about the z-axis since dof6 was not checked.
11. Click return to go back to the main menu.
7. Uncheck all the dof's except dof3, and click the = to the right of dof3 and enter a value of 20.
8. Click load types= and verify that DAREA is selected from the extended entity selection menu.
9. Click create, and then click return.
The unit load is applied to the selected node.
4. For Card Image, and select RLOAD2 from the drop-down list.
5. For EXCITEID, click Unspecified > Loadcol.
6. In the Select Loadcol dialog, select unit-load from the list of load collectors and click OK to
complete the selection.
7. Similarly select the tabled1 load collector for the TB field.
The type of excitation can be an applied load (force or moment), an enforced displacement,
velocity or acceleration. The field Type in the RLOAD2 card image defines the type of load. The
type is set to applied load by default.
Figure 146:
15. Scroll down the list using the arrow in the left corner and check the box next to G.
A new PARAM card appears in the work area screen.
16. Click below G_V1 and input a value of 0.06 into the field box.
This value specifies a uniform structural damping coefficient and is obtained by multiplying the
critical damping [] ratio by 2.0.
17. Scroll down using the arrow in the left corner and check the box next to WTMASS.
A new window appears in the work area screen.
18. Click below WTM_V1 and input a value of 0.00259 into the field box.
Three PARAM statements now appear in the pop-up menu on the work screen. This factor is used
to input all mass entries in weight units. Using this PARAM multiplies all terms in the mass matrix
by this factor.
Figure 147:
If the job is successful, new results files should be in the directory where the
flat_plate_direct_response.fem was written. The flat_plate_direct_response.out file is a good
place to look for error messages that could help debug the input deck if any errors are present.
The default files written to the directory are:
flat_plate_direct_response.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
flat_plate_direct_response.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
flat_plate_direct_response.h3d
HyperView binary results file.
flat_plate_direct_response.res
HyperMesh binary results file.
flat_plate_direct_response.stat
Summary, providing CPU information for each step during analysis process.
This displayed page 2, which shows Subcase 1 (subcase1) - Displacement of grid 17 (see
Figure 150).
8. Select the Next Page icon again to display page 3 containing Subcase 1 (subcase1) -
Displacement of grid 19 (see figure).
Line 4, first field shows node number, then x, y, and z displacement phase angles and x, y and z
rotation angles.
The flat plate is subjected to a frequency varying unit load excitation using the modal method. Post-
processing tools will be used in HyperView and HyperGraph to visualize deformations, mode shape
response, and frequency-phase output characteristics.
Figure 152:
5. In the Model Browser, right-click and select Create > Load Collector.
6. For Name, enter unit-load.
7. Click Color and select a color from the color palette.
A new load collector, unit-load is created.
8. Click the Display Numbers icon to open the Numbers panel.
Creating Constraints
1. In the Model Browser, right-click the load collector spcs and select Make Current.
2. Click BCs > Create > Constraints to open the Constraints panel.
3. Click the entity selection switch and select nodes from the pop-up menu.
4. Click nodes and select nodes 5, 29, 30, 31 and 32 (see Figure 153).
Figure 153: Illustration of Nodes to Select for Applying Single Point Constraints
4. Uncheck all the dof's except dof3, and click the = to the right of dof3 and enter a value of 1.
5. Click load types= and verify that DAREA is selected from the extended entity selection menu.
6. Click create, and then click return.
The unit load is applied to the selected node.
4. For Card Image, and select RLOAD2 from the drop-down list.
5. For EXCITEID, click Unspecified > Loadcol.
6. In the Select Loadcol dialog, select unit-load from the list of load collectors and click OK to
complete the selection.
7. Similarly select the tabled1 load collector for the TB field.
The type of excitation can be an applied load (force or moment), an enforced displacement,
velocity or acceleration. The field Type in the RLOAD2 card image defines the type of load. The
type is set to applied load by default.
If the job is successful, new results files should be in the directory where the
flat_plate_modal_response.fem was written. The flat_plate_modal_response.out file is a good
place to look for error messages that could help debug the input deck if any errors are present.
The default files written to the directory are:
flat_plate_modal_response.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
flat_plate_modal_response.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
flat_plate_modal_response.h3d
HyperView binary results file.
flat_plate_modal_response.res
HyperMesh binary results file.
flat_plate_modal_response.stat
Summary, providing CPU information for each step during analysis process.
Figure 156:
There are two sets of results on this page. The top graph shows Phase Angle verses Frequency
(log). The bottom graph shows Magnitude verses Frequency (log) (see figure) for Displacement of
grid 15.
8. Directly underneath the blue graph border, click the Next Page icon .
Page 2 displays, which shows Subcase 1 (subcase1) - Displacement of grid 17.
9. Click the Next Page icon again to display page 3 containing Subcase 1 (subcase1) -
Displacement of grid 19.
Line 4, first field shows node number, then x, y and z displacement phase angles and x, y and z
rotation phase angles.
The bracket is constrained at the bottom of the two legs. Transient dynamic loads are to be applied at
the grid points of the top, flat surface of the bracket around the hole in the negative z direction. The
time history of the loading is shown in Figure 161. The direct transient analysis is run for a total time
of 4 seconds with the time being divided into 800 increments (that is time step is 0.005). Structural
damping has been considered for the model. A concentrated mass element is defined at the center of
the spider and z displacements are monitored at the concentrated mass at the center of this hole.
Figure 162:
7. Click Close.
The load collector TABLED1 that defines the time history of the loading has been created.
8. Click Close.
A default load step template is now displayed in the Entity Editor below the Model Browser.
2. For Name, enter transient.
3. For Analysis type, select Transient(direct) from the drop-down menu.
4. For SPC, select SPC from the Select Loadcol pop-out window.
5. For DLOAD, select tload1 from the Select Loadcol pop-out window.
6. Activate TSTEP(TIME) and select the load collector tstep created previously.
A subcase is created that specifies the loads and boundary conditions for direct transient dynamic
analysis.
If the job is successful, new results files should be in the directory where the
bracket_transient_direct.fem was written. The bracket_transient_direct.out file is a good place
to look for error messages that could help debug the input deck if any errors are present.
The default files written to the directory are:
bracket_transient_direct.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
bracket_transient_direct.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
bracket_transient_direct.h3d
HyperView binary results file.
bracket_transient_direct.res
HyperMesh binary results file.
bracket_transient_direct.stat
Summary, providing CPU information for each step during analysis process.
Figure 164:
Figure 165:
6. Click to fit the y-axis (that is Z displacement) of node 395 in the GUI.
7. You can change the color and/or line attributes of the curve if you wish to.
Figure 166: Z-displacement Time History of the Concentrated Mass at Center of Spider for Direct Transient
Dynamic Analysis
As can be observed from the above image, the displacements of node 395 are in the negative z-
direction as the loading is in the -z direction too. The displacements eventually damp out due to
the structural damping present in the model.
The bracket is constrained at the bottom of the two legs. Transient dynamic loads are to be applied at
the grid points of the top, flat surface of the bracket around the hole in the negative z-direction. The
time history of the loading is shown in Figure 168. The modal transient analysis is run for a total time of
4 seconds with the time being divided into 800 increments (that is time step is 0.005). Modal damping
has been defined as 2% critical damping for all the modes. Modes up to 1000 Hz have been considered.
A concentrated mass element is defined at the center of the spider and z-displacements are monitored
at the concentrated mass at the center of this hole.
Figure 169:
7. Click Close.
The load collector TABLED1 that defines the time history of the loading has been created.
Figure 170:
8. Uncheck all degrees of freedom (dof), except dof3 by clicking the box next to each, indicating that
dof3 is the only active degree of freedom.
9. For dof3, enter a value of -1500.
10. For load types=, select DAREA.
11. Click create.
This creates a force of 1500 units applied to the selected nodes in the negative z direction.
12. Click return to go back to the main menu.
Figure 171:
A subcase is created that specifies the loads, boundary conditions, and damping for modal transient
dynamic analysis.
If the job is successful, new results files should be in the directory where the
bracket_transient_modal.fem was written. The bracket_transient_modal.out file is a good place to
look for error messages that could help debug the input deck if any errors are present.
The default files written to the directory are:
bracket_transient_modal.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
bracket_transient_modal.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
bracket_transient_modal.h3d
HyperView binary results file.
bracket_transient_modal.res
HyperMesh binary results file.
bracket_transient_modal.stat
Summary, providing CPU information for each step during analysis process.
5. Under Curves, individually select the X Trans and Y Trans curves and click Off.
Figure 173:
7. You can change the color and/or line attributes of the curve, if you wish.
Z-displacement time history of the concentrated mass at center of spider for direct transient dynamic
analysis.
As can be observed from the above image, the displacements of node 395 are in the negative z-
direction as the loading is in the -z direction too. The displacements eventually damp out due to the
structural damping present in the model.
Figure 174:
There are four shell components in the model: the mounting flange, the web, the top and bottom
flanges, and the lug. Gap elements have already been defined in the model and they connect the web
to the lug. Coupling forces are applied to the lug and pressure loading has been defined on the top and
bottom flanges of the rib joint. The mounting flange is constrained in all degrees of freedom at the four
mounting hole locations and the lug is constrained for the z-displacements and rotations to prevent rigid
body motion.
8. Click Geometry > Create > Systems > Axis Direction to open the Systems panel.
9. The cyan halo around the yellow nodes button indicates that it is the current option. Select the
center node on the upper lug.
10. Click origin and select the center node again.
11. Click x-axisand select any node on the circumference.
12. For xy plane, select any node on the plane of the lug, as shown in Figure 176:
20. Click the entity selection switch on the top left of the panel and select elems.
21. Click elems >> by window from the pop-up menu.
22. Select the gap elements that are connected to the top lug, as shown in Figure 177.
Figure 178:
Figure 179:
7. Click Mesh > Create > 1D Elements > Gaps to open the Gaps panel.
8. Select the update subpanel.
9. Click elems >> by collector.
10. Select gap by checking the box beside it.
11. Click the green select button.
12. Click property= and click on gap_prop.
13. Click update.
If the job is successful, new results files should be in the directory where the rib_linear.fem was
written. The rib_linear.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
The default files written to the directory are:
rib_linear.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
rib_linear.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
rib_linear.h3d
HyperView binary results file.
rib_linear.res
HyperMesh binary results file.
rib_linear.stat
Summary, providing CPU information for each step during analysis process.
Figure 181:
4. Select the first pull-down menu below Result type and select Element Stresses (2D & 3D).
5. Select the second pull-down menu below Result type and select vonMises.
6. Above the Results Browser in the left hand panel are the Load Case and Simulation Selection
drop-down menus. Select Subcase 1 (Coup_Vert) from the Load Case drop-down menu.
Figure 182:
7. Click the XY Top Plane View icon to display a top view of the Web.
8. Click Apply.
This should show the contour of stresses on the Web component under the coupled loading.
Figure 183: Stress Results on the Web From Linear Gap Analysis
Figure 184:
Figure 185:
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to analysis.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to launch the OptiStruct job.
If the job is successful, new results files should be in the directory where the rib_nonlinear.fem was
written. The rib_nonlinear.out file is a good place to look for error messages that could help debug
the input deck if any errors are present.
The default files written to the directory are:
rib_nonlinear.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
rib_nonlinear.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
rib_nonlinear.h3d
HyperView binary results file.
rib_nonlinear.res
HyperMesh binary results file.
rib_nonlinear.stat
Summary, providing CPU information for each step during analysis process.
Figure 187:
4. Select the first pull-down menu below Result type and select Element Stresses (2D & 3D).
5. Select the second pull-down menu below Result type and select vonMises.
6. Above the Results Browser in the left hand panel are the Load Case and Simulation Selection
drop-down menus. Select Subcase 1 (Coup_Vert) from the Load Case drop-down menu.
Figure 188:
7. Click the XY Top Plane View icon to display a top view of the Web.
8. Click Apply.
This should show the contour of stresses on the Web component under the coupled loading.
Figure 189: Stress Results on the Web From Nonlinear Gap Analysis
Analysis Review
Even though the deformation patterns are similar for both linear and nonlinear analyses, the stress
patterns differ. Though the horizontal loads are in opposing directions in the lug, the stress distribution
in the web for the linear run are the same around both the lug holes which is not correct. This happens
as all the gaps are in a closed condition for the linear analysis. Nonlinear gap analysis gives more
accurate representation. The gap status, open or closed, depending on loading condition can also be
observed from the .out file:
ITERATION 0
NONLINEAR ITERATION SUMMARY Subcase 1
The PSD (power spectral density) for displacement at node 19 is output in the .rand file, and the peak
values of PSD and RMS (root mean square) results are output to a .peak file. PSD and RMS stress
results are output to a .op2 file and post-processed in HyperView.
Figure 190:
The frequency analysis setup is already made for this model where the one end of plate is clamped and
the loading is applied on the other end (two different sources of the loading, thus two subcases). The
loading frequency is defined by the FREQ1 card; from 20 to 1000 Hz with an interval of 20. The same
loading frequency is applied on both the subcases.
Figure 191:
Figure 192:
If the job is successful, new results files should be in the directory where the direct_psd.fem was
written. The direct_psd.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
The default files written to the directory are:
direct_psd.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
direct_psd.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
direct_psd.h3d
HyperView binary results file.
direct_psd.res
HyperMesh binary results file.
direct_psd.stat
Summary, providing CPU information for each step during analysis process.
Also, the following files will be output and which are specific to the random response analysis.
direct_psd.peak
ASCII result file, containing RMS and peak values of PSD.
direct_psd.rand
ASCII result file, containing PSD results.
direct_psd.mvw
HyperView script file. This file will automatically create the plot of PSD over the frequency for the
results contained in .rand file.
direct_psd.op2
Binary file containing RMS and PSD results.
Figure 194:
Figure 195:
The half car model is excited at the bottom of the car, as shown by a red constraint symbol (triangle)
in Figure 196. The excitation provided is with the application of a unit load along the direction of the
height of the car (Z-axis).
2. Select the Half_Car.hm file you saved to your working directory from the optistruct.zip file.
Refer to Accessing the Model Files.
3. Click Open.
The Half_Car.hm database is loaded into the current HyperMesh session, replacing any existing
data. The database only contains geometric data.
Figure 197:
8. Fill in the fields for Rho and C respectively as 1.2e-13 and 3.4e5.
9. In the Model Browser, right-click and select Create > Property.
10. For Name, enter Shells.
11. For Card Image, select PSHELL from the drop-down menu.
12. For Material, click Unspecified > Material.
13. In the Select Material dialog, select MAT1_shells from the list of materials and click OK to
complete the selection.
14. Enter the thickness for the shell component by clicking T, and entering 2.0.
15. In the Model Browser, right-click and select Create > Property.
16. For Name, enter Solids.
17. For Card Image, select PSOLID from the drop-down menu.
18. For Material, click Unspecified > Material.
19. In the Select Material dialog, select MAT10_Solids.
20. For FCTN, select PFLUID.
21. Click on the fluid component.
The component entry is displayed in the Entity Editor.
22. For Property, click Unspecified > Property.
23. In the Select Property dialog, select the property solids.
24. Click on the structure component.
The component entry is displayed in the Entity Editor.
25. For Property, click Unspecified > Property.
26. In the Select Property dialog, select the property shells.
1. In the Model Browser, right-click and select Create > Load Collector from the context menu.
A default load collector displays in the Entity Editor.
2. For Name, enter unit-load.
3. Click Color and select a color from the color palette.
4. Set Card Image to None.
5. Verify unit_load is the current load collector. If it is not the current load collector, right-click on
unit_load in the Model Browser and select Make Current from the context menu.
Tip: In the Model Browser, Load Collectors folder, the current load collector is bold.
Figure 198:
8. Click return.
Figure 199:
8. In the Model Browser, right-click and select Create > Load Collector.
9. For Name, enter freq1.
10. Click Color and select a color from the color palette.
11. For Card Image, select FREQi from the drop-down menu.
12. Check the box next to FREQ1.
13. For NUMBER_OF_FREQ1, enter a value of 1, press ENTER.
14. Click next to the Data field and enter, F1= 0.0, DF= 1.0, and NDF= 200.
This provides a set of frequencies beginning with 0.0, incremented by 1.0 and 200 frequencies
increments and the card appears as shown below on the GUI.
Figure 200:
15. In the Model Browser, right-click and select Create > Load Collector.
16. For Name, enter eigrl1.
17. Click Color and select a color from the color palette.
18. For Card Image, select EIGRL from the drop-down menu.
19. For V2, enter a value of 600.0.
20. For ND, enter a value of 50.
This specifies a range of frequency between an initial frequency and 600 Hz for eigenvalue
extraction using the Lanczos method.
21. Similarly, follow steps 8.1 to 8.6 to create another load collector named eigrl2.
Figure 201:
22. In the Model Browser, right-click and select Create > Load Step.
23. For Name, enter subcase1.
24. Click Color and select a color from the color palette.
25. For Analysis type, select Freq.resp (modal) from the drop-down menu.
26. For METHOD(STRUCT), select eigrl1 from the list of load collectors.
27. For METHOD(FLUID), select eigrl2 from the list of load collectors.
28. For DLOAD, select rload1 from the list of load collectors.
29. For FREQ, select freq1 from the list of load collectors.
An OptiStruct subcase has been created which references the constraints, the unit load in the load
collector rload1 with a set of frequencies defined in load collector freq1 and modal method defined
in the load collector eigrl.
30. In the Model Browser, right-click and select Create > Set.
31. For Name, enter SETA.
32. For Card Image, select None from the drop-down menu.
33. Leave the Set Type switch set to non-ordered type.
34. For Entity IDs, click the yellow Nodes panel and select nodes with ID 18881.
35. Click proceed.
1. In the Model Browser, right-click and select Create > Load Collector.
2. For Name, enter freq1.
3. Click Color and select a color from the color palette.
4. For Card Image, select FREQi from the drop-down menu.
5. Check the FREQ1 option and enter 1 in the NUMBER_OF_FREQ1 field.
6. Click and enter information in the pop-out window.
Figure 202:
If the job is successful, new results files should be in the directory where the Half_car.fem was
written. The Half_car.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
The default files written to the directory are:
Half_car.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
Half_car.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
Half_car.h3d
HyperView binary results file.
Half_car.res
HyperMesh binary results file.
Half_car.stat
Summary, providing CPU information for each step during analysis process.
Figure 204:
Figure 205:
There are two sets of results on this page. The top graph shows Phase Angle verses Frequency
(log). The bottom graph shows Magnitude verses Frequency (log) (see figure below) for Pressure
at grid 18881.
Figure 206:
The S-N approach is based on elastic cyclic loading, inferring that the S-N curve should be confined
to numbers greater than 1000 cycles. This ensures that no significant plasticity is occurring. This is
commonly referred to as high-cycle fatigue.
Figure 207: Low Cycle and High Cycle regions on the S-N curve
Since S-N theory deals with uniaxial stress, the stress components need to be resolved into one
combined value for each calculation point, at each time step, and then used as equivalent nominal
stress applied on the S-N curve.
In OptiStruct, various stress combination types are available with the default being "Absolute maximum
principle stress". In general "Absolute maximum principle stress" is recommended for brittle materials,
while "Signed von Mises stress" is recommended for ductile material. The sign on the signed parameters
is taken from the sign of the Maximum Absolute Principal value.
The three aspects to the fatigue definition are the fatigue material properties, the fatigue parameters
and the loading sequence and event definitions.
FATDEF Defines the elements and associated fatigue properties that will be
used for the fatigue analysis.
PFAT Defines the finish, treatment, layer and the fatigue strength
reduction factors for the elements.
Fatigue Parameters
FATPARM Defines the parameters for the fatigue analysis. These include
stress combination method, mean stress correction method
(Figure 210), Rainflow parameters, Stress Units.
FATSEQ Defines the loading sequence for the fatigue analysis. This card
can refer to another FATSEQ card or a FATEVNT card.
The following files found in the optistruct.zip file are needed to perform this tutorial. Refer to
Accessing the Model Files.
Exercise
In this tutorial, a control arm loaded by brake force and vertical force is used, as shown in Figure 212.
Two load time histories acquired for 2545 seconds with 1 HZ, shown in Figure 213, are adopted. The SN
curve of the material used in the control arm is shown in Figure 215. Because a crack always initiates
from the surface, a skin meshed with shell elements is designed to cover the solid elements, which can
improve the accuracy of calculation as well.
The model being used for this exercise is that of a control arm, as shown in Figure 212. Loads and
boundary conditions and two static loadcases have already been defined on this model.
The first step in defining the loading sequence is to define the TABFAT cards. This card represents the
loading history.
1. Make sure the Utility menu is selected in the View menu. Click View > Browsers >
HyperMesh > Utility.
2. Click on the Utility menu beside the Model tab in the browser. In the Tools section, click on TABLE
Create.
3. Set Options to Import table.
4. Set Tables to TABFAT.
5. Click Next.
6. Browse for the loading file.
7. In the Open the XY Data File dialog box, set the Files of type filter to CSV (*.csv).
8. Open the load1.csv file you saved to your working directory from the optistruct.zip file.
9. Create New Table with Name table1.
10. Click Apply to save the table.
The load collector table1 with TABFAT card image is created.
11. Browse for a second loading file load2.csv.
12. Create New Table with Name table2.
13. Click Apply to save the table.
The load collector table2 with TABFAT card image is created.
14. Exit from the Import TABFAT window.
Tables appear under Load Collector in the Model Browser.
Note: A file in DAC format can very easily be imported in HyperGraph and converted
to CSV format to be read in HyperMesh.
SRI1 1420.58
B1 -0.076
NC1 5.0e8
SE 0.1
4. Set Result type to Damage and click Apply to contour the elements.
Exercise
The S-N approach is based on elastic cyclic loading, inferring that the S-N curve should be confined
to numbers greater than 1000 cycles. This ensures that no significant plasticity is occurring. This is
commonly referred to as high-cycle fatigue.
Figure 218: Low Cycle and High Cycle Regions on the S-N Curve
Since S-N theory deals with uniaxial stress, the stress components need to be resolved into one
combined value for each calculation point, at each time step, and then used as equivalent nominal
stress applied on the S-N curve (Figure 219).
In OptiStruct various stress combination types are available, with the default being "Absolute maximum
principle stress". In general "Absolute maximum principle stress" is recommended for brittle materials,
while "Signed von Mises stress" is recommended for ductile material. The sign on the signed parameters
is taken from the sign of the Maximum Absolute Principal value.
In this tutorial, you will be able to evaluate fatigue life with the S-N method through process manager
step by step.
3. Make sure the task Import File is selected in the Fatigue Analysis tree.
4. For the Model file type, select OptiStruct.
5.
Click the Open model file icon .
fatsub_fpmtut is selected as the active fatigue subcase. Definitions in the following processes
(analysis parameters, fatigue elements and properties, loading sequences, etc.) will be for this
subcase.
5. Click Apply.
This saves the current definitions and guides you to the next task Analysis Parameters of the
Fatigue Analysis tree.
Gate
0.0
Certainty of survival
0.5
4. Click Apply.
This saves the current definitions and guides you to the next task Elements and Materials of the
Fatigue Analysis tree. For details, consult the HyperWorks 2019 help.
Note: For a file of DAC format, it can very easily be imported in HyperGraph and
converted to CSV format for use by FPM.
Loading Sequences
In this step, one event consisting of two load time history is created; in other words, the linear
superposition of the stress caused by the two load time history is requested during analysis. Using this
event, one load sequence is constructed.
1. Make sure the task Loading Sequences is selected in the Fatigue Analysis tree.
2. Click Add.
A Loading Definition window opens.
3. For Select static loadcase, select SUBCASE1.
4. For Select load-time history, select lth1.
5. For Scale, enter the value 3.0.
6. Make sure Create new is selected using the radio buttons.
7. Enter Event1 for the newly created fatigue event name.
1. Make sure the task Submit Analysis is selected in the Fatigue Analysis tree.
2.
Click the Save .fem file icon .
A Save As browser window opens.
3. Set the directory in which to save the file, and for File name, enter ctrlarm_fpmtut.fem.
4. Click Save to close the window.
5. Click Save to save the OptiStruct model file.
6. For Run Option, select analysis.
7. Click Submit.
This launches OptiStruct 2019 to run the fatigue analysis. If the job is successful, the new results
files should be in the directory from which ctrlarm_fpmtut.fem was selected.
The default files written to the directory are:
3. Check the top 0.1%, 1.0%, 5.0% average life, and Top 1, 2, 3 most damage elements lives.
4. Toggle the Result type to view the damage results summary.
5. Click Load H3D Results (HV).
This launches HyperView to load the ctrlarm_fpmtut.h3d results file for more detailed results.
6. Click Close to unload Fatigue Process Manager.
If an S-N analysis indicates a fatigue life less than 10,000 cycles, it is a sign that an E-N method may
be a better choice. The E-N method, while computationally more expensive than S-N, should give a
reasonable estimate for high-cycle fatigue as well.
Figure 233: Low Cycle and High Cycle Regions on the S-N Curve
Since E-N theory deals with uniaxial strain, the strain components need to be resolved into one
combined value for each calculation point, at each time step, and then used as equivalent nominal
strain applied on the E-N curve (Figure 234).
In OptiStruct various strain combination types are available with the default being "Absolute maximum
principle strain". In general "Absolute maximum principle stain" is recommended for brittle materials,
while "Signed von Mises strain" is recommended for ductile material. The sign on the signed parameters
is taken from the sign of the Maximum Absolute Principal value.
The three aspects to the fatigue definition are the fatigue material properties, the fatigue parameters
and the loading sequence and event definitions.
FATDEF Defines the elements and associated fatigue properties that will be
used for the fatigue analysis.
PFAT Defines the finish, treatment, layer and the fatigue strength
reduction factors for the elements.
MATFAT Defines the material properties for the fatigue analysis. These
properties should be obtained from the material's E-N curve
(Figure 234). The E-N curve, typically, is obtained from completely
reversed bending on mirror polished specimen.
Fatigue Parameters
FATPARM Defines the parameters for the fatigue analysis. These include
stress combination method, mean stress correction method
(Figure 236), Rainflow parameters, and Stress Units.
FATSEQ Defines the loading sequence for the fatigue analysis. This card
can refer to another FATSEQ card or a FATEVNT card.
TABLEFAT Defines the y values for each point on the time loading history
(Figure 237).
Exercise
In this tutorial, a control arm loaded by brake force and vertical force is used, as shown in Figure 238.
Two load time histories acquired for 2545 seconds with 1 HZ, shown in Figure 239 and Figure 240,
are adopted. The material of the control arm is aluminum, whose E-N curve is shown in Figure 241.
Because a crack always initiates from the surface, a skin meshed with shell elements is designed to
cover the solid elements, which can improve the accuracy of calculation as well.
The model being used for this exercise is that of a control arm as shown in Figure 238. Loads and
boundary conditions and two static loadcases have already been defined on this model.
The first step in defining the loading sequence is to define the TABFAT cards. This card represents the
loading history.
1. Make sure the Utility menu is selected in the View menu. Click View > Browsers >
HyperMesh > Utility.
2. Click on the Utility menu beside the Model tab in the browser. In the Tools section, click on TABLE
Create.
3. Set Options to Import table.
4. Set Tables to TABFAT.
5. Click Next.
6. Browse for the loading file.
7. In the Open the XY Data File dialog box, set the Files of type filter to CSV (*.csv).
8. Open the load1.csv file you saved to your working directory from the optistruct.zip file.
9. Create New Table with Name table1.
10. Click Apply to save the table.
The load collector table1 with TABFAT card image is created.
11. Browse for a second loading file load2.csv.
12. Create New Table with Name table2.
13. Click Apply to save the table.
The load collector table2 with TABFAT card image is created.
14. Exit from the Import TABFAT window.
Tables appear under Load Collector in the Model Browser.
Note: A file in DAC format can very easily be imported in HyperGraph and converted
to CSV format to be read in HyperMesh.
The material curve for the fatigue analysis can be defined on the MAT1 card.
SF 1002.000
B -0.095
C -0.690
EF 0.350
NP 0.110
KP 966.000
NC 2E+08
SEE 0.100
SEP 0.100
1. In the Model Browser, click on the Create > Load Collector material.
2. For Name, enter fatdef.
3. Set the Card Image to FATDEF.
If the job is successful, new results files should be in the directory where the .fem was written. The
.out file is a good place to look for error messages that could help debug the input deck if any errors
are present.
5. Set Result type to Damage and click on Apply to contour the elements.
If an S-N analysis indicates a fatigue life less than 10,000 cycles, it is a sign that E-N method might be
a better choice. E-N method, while computationally more expensive than S-N, should give reasonable
estimate for high-cycle fatigue as well.
Figure 244: Low Cycle and High Cycle regions on the S-N curve
Since E-N theory deals with uniaxial strain, the strain components need to be resolved into one
combined value for each calculation point, at each time step, and then used as equivalent nominal
strain applied on the E-N curve (Figure 245).
In OptiStruct, various strain combination types are available with the default being "Absolute maximum
principle strain". In general "Absolute maximum principle stain" is recommended for brittle materials,
while "Signed von Mises strain" is recommended for ductile material. The sign on the signed parameters
is taken from the sign of the Maximum Absolute Principal value.
In this tutorial, you will be able to evaluate fatigue life with the E-N method.
The following files found in the optistruct.zip file are needed to perform this tutorial. Refer to
Accessing the Model Files.
Exercise
A control arm loaded by brake force and vertical force is used, as shown in Figure 246. Two load time
histories acquired for 2545 seconds with 1 HZ, shown in Figure 247 and Figure 248, are applied. The
material of the control arm is aluminum, whose E-N curve is shown in Figure 249. Because a crack
always initiates from the surface, a skin meshed with shell elements is designed to cover the solid
elements, which can improve the accuracy of calculation as well.
3. Make sure the task Import File is selected in the Fatigue Analysis tree.
4. For the Model file type, select OptiStruct.
5.
Click the Open model file icon .
A Select File browser window opens.
6. Select the ctrlarm.fem file you saved to your working directory from the optistruct.zip file and
click Open.
7. Click Import.
This loads the control arm model. It includes a whole definition of two static subcases, elements
sets, and material static properties, etc.
8. Click Apply.
This guides you to the next task Fatigue Subcase of the Fatigue Analysis tree.
Gate
0.0
Certainty of survival
0.5
4. Click Apply.
This saves the current definitions and guides you to the next task Elements and Materials of the
Fatigue Analysis tree. For details, consult the HyperWorks 2019 help.
1. Make sure the task Elements and Materials is selected in the Fatigue Analysis tree.
2. Click Add.
A Material Data window opens.
3. For Element entity type, select Property - PSHELL.
4. For Element entity name, select shell.
This is the skin coating the solid control arm.
5. Make sure Ultimate tensile strength (UTS) is selected to define the material data.
6. For UTS, enter the value 600.
7. For Input method of defining EN curve, select Estimate From UTS.
8. Click the Show EN curve definition icon .
An EN method description window introducing how to generate the EN material parameter opens.
9. Click Close.
10. For Material type, select Aluminum and Titanium Alloys and click Estimate.
All the data for EN curve definition are automatically estimated.
11. Click Plot EN Curve at the bottom of the window to show the EN curve.
12. Close the EN Curve plot window.
13. For Layer of stress results in shell elements, select TOP.
14. For Surface finish, select No Finish.
15. For Surface treatment, select No Treatment.
16. Leave the field after Fatigue strength reduction factor blank.
17. Click Save to save the definition of the EN data for the selected elements.
18. Click Apply.
This saves the current definitions and guides you to the next task Load-Time History of the Fatigue
Analysis tree.
1. Make sure the task Load-Time History is selected in the Fatigue Analysis tree.
2. Click Add by File.
A Load Time History window opens.
3. For Load-time history name, enter lth1.
4. For Load-time history type, select CSV.
5.
Click the Open load-time file icon .
An Open file browser window opens.
6. Browse for load1.csv.
7. Click Open > Import.
8. Click Save to write the new load-time history into HyperMesh database.
9. Create another load-time history named lth2 by importing the file load2.csv.
10. Click Plot L-T to show the load-time history.
11. Close the Load Time History window.
12. Click Apply.
This saves the current definitions and guides you to the next task Loading Sequences of the
Fatigue Analysis tree.
Note: For a file of DAC format, it can very easily be imported in HyperGraphand
converted to CSV format for use by FPM.
Loading Sequences
In this step, one event consisting of two load time history is created; in other words, the linear
superposition of the stress caused by the two load time history is requested during analysis. Using this
event, one load sequence is constructed.
1. Make sure the task Loading Sequences is selected in the Fatigue Analysis tree.
2. Click Add.
A Loading Definition window opens.
3. For Select static loadcase, select SUBCASE1.
4. For Select load-time history, select lth1.
5. For Scale, enter the value 5.0.
6. Make sure Create new is selected using the radio buttons.
7. Enter Event1 for the newly created fatigue event name.
1. Make sure the task Submit Analysis is selected in the Fatigue Analysis tree.
2.
Click the Save .fem file icon .
A Save As browser window opens.
3. Set the directory in which to save the file, and for File name, enter ctrlarm_fpmtut.fem.
4. Click Save to close the window.
5. Click Save to save the OptiStruct model file.
6. For Run Option, select analysis.
7. Click Submit.
This launches OptiStruct 2019 to run the fatigue analysis. If the job is successful, the new results
files should be in the directory from which was selected.
The default files written to the directory are:
3. Check the top 0.1%, 1.0%, 5.0% average life, and Top 1, 2, 3 most damage elements lives.
4. Toggle the Result type to view the damage results summary.
5. Click Load H3D Results (HV).
This launches HyperView to load the ctrlarm_fpmtut.h3d results file for more detailed results.
6. Click Close to unload Fatigue Process Manager.
Figure 263 below illustrates the structural model used for this tutorial: A 1mm thick cylindrical gasket is
sandwiched between two co-axial steel cylindrical tubes. The outer cylinder is subjected to a pressure
of 300 MPa on the outer surface as shown. Using symmetry boundary conditions, only a quarter of the
geometry has been modeled. The gasket is connected to the inner and outer cylinders using contact.
This loads the 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 for
OptiStruct.
X Y
0.0 0.0
0.005 200.0
0.05 450.0
0.135 700.0
0.22 820.0
0.287 830.0
7. Click Close.
For details on pressure-closure definitions of gaskets, refer to the HyperWorks 2019 online help.
X Y
08 0
12 0
135 0
9. Next, create the second unloading curve named unload-curve2 with the following X-Y data:
X Y
17 0
2 0
22 0
10. Finally, create the third unloading curve named unload-curve3 with the following X-Y data:
X Y
0.23 0.0
0.265 360.0
0.287 830.0
TABLU(1) unload-curve1
TABLU(2) unload-curve2
TABLU(3) unload-curve3
Figure 264:
9. Next, assign this property to the gasket component. Click on the component GASKET in the Model
Browser.
10. For Property, select gasket_prop property.
Figure 265:
Figure 266:
Figure 267:
13. Similarly, repeat the steps and create GASKET_top and GASKET_bottom surfaces for the top and
bottom surfaces of the GASKET component, respectively.
Now, an interface between the top cylinder and gasket are created.
14. In the Model Browser, right-click and select Create > Contact.
15. For Name, enter SOLID1_GASKET.
16. Click Color and select a color from the color palette.
17. For Card Image, select CONTACT from the drop-down menu.
18. For MSID (master surface), select the SOLID1_bottom surface.
19. For SSID (slave surface), select the GASKET_top surface.
20. For TYPE, select STICK from the drop-down menu.
Figure 268:
Next, an interface between the bottom cylinder and gasket are created.
21. In the Model Browser, right-click and select Create > Contact.
22. For Name, enter SOLID2_GASKET.
23. Click Color and select a color from the color palette.
24. For Card Image, select CONTACT from the drop-down menu.
25. For MSID (master surface), select the SOLID2_top surface.
26. For SSID (slave surface), select the GASKET_bottom surface.
27. For TYPE, select STICK from the drop-down menu.
Next, you create the interface between the bottom cylinder and gasket.
28. Click on create and for name, enter SOLID2_GASKET.
29. For type, enter CONTACT and click create.
30. Click on add to select the master and slave surfaces for this interface.
31. For master, select the SOLID2_top surface and click update.
32. For slave, select the GASKET_bottom surface and click update.
Figure 269:
Figure 270:
If the job is successful, new results files should be in the directory where the gasket_complete.fem
was written. The gasket_complete.out file is a good place to look for error messages that could help
debug the input deck if any errors are present.
Figure 275 illustrates the structural model used for this tutorial, which is two square solid blocks made
of elasto-plastic steel material. The dimensions of the blocks and the material parameters are outlined
below.
In the first nonlinear subcase, pressure loading is be applied to the top solid block, the top corners
of which are constrained in X and Y directions. The top solid is in contact with the bottom solid, the
bottom corners of which are constrained in X, Y and Z directions. The second nonlinear subcase is
to simulate the unloading and is a continuation of the nonlinear solution sequence from the previous
loading subcase.
Top block 72 mm x 72 mm
1. In the Model Browser, right-click and select Create > Load Collector.
2. For Name, enter stress-strain.
3. Click Color and select a color from the color palette.
4. For Card Image, select TABLES1 from the drop-down menu.
5. For TABLES1_NU, enter 2 (number of rows in the table), and press Enter.
6. Click the Table icon next to the Data field and enter the following values (x and y fields) in
the pop-up window.
Figure 276:
Figure 277:
Figure 278:
Figure 279:
Figure 280:
Figure 281:
Figure 282:
If the job is successful, new results files should be in the directory where the nlstat_complete.fem
was written. The nlstat_complete.out file is a good place to look for error messages that could help
debug the input deck if any errors are present.
Figure 287: Contour of Contact Pressure in the Block Interface After the 1st (Loading) Subcase
nd
Next, change the subcase to the 2 that is unloading subcase and plot the displacement contour to see
the change in displacements in the blocks subject to unloading.
The simplified brake system consists of a brake pad with frictional surface and back plate, and a
contact plate. They were all modeled with solid elements. Spring elements (CELAS1) were created
between the brake pad and the contact plate to measure the normal contact forces, as shown in
Figure 289. The friction forces on the pad and the contact plate are proportional to the normal contact
forces. The stiffness matrix terms representing the relationship between friction forces and normal
displacements on the contact grids were saved in a DMIG Bulk Data file DMIG.pch. Assume the brake
pad is in full contact with the plate at all time. The back plate of the brake pad and the contact plate
were constrained to the ground.
Figure 290:
9. Click PARAM.
10. Check the small box in front of parameter G.
11. Click [G_V1] and input 0.2 as the structural damping coefficient.
12. Check the small box in front of parameter FRIC.
13. Click [VALUE] and input 0.05.
Friction factor 0.05 is used to scale the friction coefficient from DMIG Data Entry.
14. Click return twice and go back to the Analysis page.
4. Click Save.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to analysis.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to launch the OptiStruct job.
If the job is successful, new results files should be in the directory where the brake_complex.fem was
written. The brake_complex.out file is a good place to look for error messages that could help debug
the input deck if any errors are present.
Figure 292:
th
As you can see, the 5 mode was divergent while all of the other modes were stable. The friction
coefficient parameter can be reduced by setting the PARAM,FRIC factor from a value of 0.05 to
0.01, and all roots become stable. It illustrates that there is a stability threshold between the
friction factor 0.05 and 0.01. It can be determined by resetting the scale factor of PARAM, FRIC
and rerunning the model till the damping value of this mode approaches zero.
2. Load the brake_complex.h3d file into HyperView to review complex eigenvectors.
For this model OptiStruct will predict an unstable mode and the instability is seen to occur at the point
of mode coalescence, i.e., a pair of modes occur at the same frequency (mode coupling), and one of
them is unstable. The unstable mode can be identified during complex eigenvalue extraction because
the real part of the eigenvalue corresponding to an unstable mode is positive.
You can further design brake system which can be stabilized by changing the shape of the brake pads
or material properties of the brake components to decouple the modes (which is not shown in this
tutorial). The purpose of this tutorial is to conduct brake squeal analysis and identify the unstable
modes (if they exist).
Figure 294:
Figure 295:
Figure 296:
Tip:
a. The prescribed rotation should be large enough to ensure the contact between
the disc and the pad is in kinetic friction, but small enough to ensure small
displacement NLSTAT.
b. Kinetic friction is a constant value (independent of velocity), hence prescribing
rotation using SPCD is equivalent to prescribing rotational speed. The important
outcome is that the contact nodes are in kinetic friction mode and it does not
matter how fast or how far you move this using SPCD.
Tip: Create STATSUB (BRAKE) manually if this is not yet supported in HyperMesh.
If the job is successful, new results files should be in the directory where the brsq.fem was written.
The brsq.out file is a good place to look for error messages that could help debug the input deck if any
errors are present.
Figure 298:
Figure 299:
For rotating components, additional forces like the gyroscopic force and circular damping force exist
and are critical in the study of their response. It is important to determine these effects of rotating
components on the system as a whole. Here the complex eigenvalue analysis for 0, 10K, 30K, and 50K
RPM are run.
The objective is to determine critical frequencies, and generate Campbell diagram when subjected to a
static imbalance from the rotor. At the critical frequency you observe forward/backward cylindrical and
conical whirl (mode shapes).
Figure 301:
4. Select the rotor.fem file you saved to your working directory from the optistruct.zip file. Refer
to Accessing the Model Files.
5. Click Open.
6. Click Import, then click Close to close the Import tab.
If the job is successful, new results files should be in the directory where the rotor_async.fem was
written. The rotor_async.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
Figure 303:
Figure 304:
The Frequencies which you get from the Synchronous Rotor dynamic analysis give you the
critical frequencies. The complex modes contain the imaginary part, which represents the cyclic
frequency, and the real part which represents the damping of the mode. If the real part is
negative, then the mode is said to be stable. If the real part is positive, then the mode is unstable.
3. Compare to verify the Critical Frequencies which you obtained from the intersection points of Step
10.1 and the frequencies you obtained in the rotor_sync.out file.
4. Load the rotor_async.h3d file into HyperView to review and verify below Cylindrical and Conical
mode shapes.
Cylindrical
Cylindrical Conical Modes Conical Modes
Modes
Modes Forward Forward Backward
RPM Backward
Mode #: 3 Mode #: 5 Mode #: 6
Mode #: 4
In the model used shown below in Figure 306, a building structure is modeled using CBEAM elements
having solid circular x-section (that is type 'ROD'). The base of the building structure will be constrained
for all degrees of freedom and the structure will be excited in the global Z direction.
1. In the Model Browser, right-click and select Create > Load Collector.
2. For Name, enter eigrl_card.
3. Click Color and select a color from the color palette.
4. For Card Image, select EIGRL from the drop-down menu.
5. Click ND and enter a value of 10.
Creating Constraints
1. In the Model Browser, right-click and select Create > Load Collector from the context menu.
A default load collector displays in the Entity Editor.
2. For Name, enter constraints.
3. Click Color and select a color from the color palette.
4. For Card Image, select None from the drop-down menu.
5. Go to the Analysis page.
6. Click constraints.
7. In the create subpanel, confirm the entity is set to nodes
8. Check all dofs (that is, dof1 to dof6) with the value 0.000, confirm load types is set to SPC, and
click create.
The constraints are created as shown in the figure below.
1. In the Model Browser, right-click and select Create > Load Collector from the context menu.
A default load collector displays in the Entity Editor.
2. For Name, enter rspec_card.
3. For Card Image, selectRSPEC.
4. For directional combination method, DCOMB, select ALG.
5. For modal combination method, MCOMB, select SRSS.
6. Click CLOSE and enter a value of 1.000 in the input box.
7. For RSPEC_NUM_DTISPEC, enter 1.
8. Click next to Data. In the pop-out window, select dti_card for the DTISPEC field, and for
SCALE, enter the value 9800.0.
9. Since the direction of excitation for the structure is the Global Z direction, enter 0.0 for X(0), 0.0
for X(1), and 1.0 for X(2), respectively.
10. Click Close to exit the window.
6. Click next to the Data field and enter the values 0.0, 0.02, 50.0 and 0.02 for f(1), g(1), f(2)
and g(2), respectively in the window.
7. Click Close to exit the window.
1. To output stress from the Analysis page, enter the control cards panel.
2. Click next to the page which has the GLOBAL_OUTPUT_REQUEST panel.
3. Click GLOBAL_OUTPUT_REQUEST, scroll down the list to STRESS and check it.
4. For OPTION(1), select ALL.
5. Click return twice to exit the control cards panel.
14. Click Save as following the input file: field. A Save file browser window opens.
15. Select the directory where you would like to write the file and enter the name for the file in the
File name: field.
Note: Save the file in a folder different from the folders under HyperWorks installation
folder.
Note: The name and location of the file displays in the input file: field.
3. To contour stresses, expand the Scalar folder under Results, expand Element Stresses (1D) and
contour the stress you want to see.
Shown below is the contour of CBAR/CBEAM Long.Stress SAMAX.
The model is a front cover of catalytic converter in a car exhaust system, as shown in Figure 313. The
frequency analysis setup is already made for this model where the cover is constrained at two ends, and
the excitation loading is applied at the center of the cover. The loading frequency is defined by FREQ1
card; from 120.0 to 400.0 Hz with an interval of 1.0. You need to define ERP panels (ERPPNL) and ERP
output request.
2. Select the cover.fem file you saved to your working directory from the optistruct.zip file. Refer
to Accessing the Model Files.
3. Click Open.
The cover.fem database is loaded into the current HyperMesh session, replacing any existing
data. The database only contains geometric data.
The grid contribution of each grid in addition to the ERP results for the panel is output to an .h3d
file. ERP panel results are output to punch format.
If the job is successful, new results files should be in the directory where the cover_ERP.fem was
written. The cover_ERP.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
5. Select Equivalent Radiated Power (ERP_elem) as Result type and then select Panel.
6. Click Apply.
ERP results on panel should be plotted.
7. Select Equivalent Radiated Power (ERP_elem) as Result type and then select Grid
Contributions.
8. Click Apply.
The contour of grid contributions to ERP should be loaded.
The heat transfer conduction property of gap elements has been created.
Figure 319:
A default component template is now displayed in the Entity Editor below the Model Browser.
2. For Name, enter PGAP.
3. For Property, click Unspecified > Property.
4. In the Select Property dialog, select PGAP and click OK.
PGAP should be set to current component automatically.
Figure 320:
As described at the beginning of the tutorial, the heat transfer boundary condition SPC_heat
and heat flux input flux are predefined in the model. An OptiStruct steady state heat conduction
loadstep, referring to SPC_heat and flux, has been defined as well. The heat transfer results are
requested in Loadsteps panel. Refer to tutorial OS-T: 1080 Coupled Linear Heat Transfer/Structure
Analysis for the details on how to define heat transfer boundary condition, heat flux, and the
output request.
Without PGAPHT, the heat cannot be transferred through the gap elements. In this case, the outer
ring remains zero degree and the inner ring takes all heat, as shown in the temperature results in
Figure 323. Run the completed model and compare the results with PGAPHT to the results below.
If the job is successful, new results files should be in the directory where the Rings_complete.fem was
written. The Rings_complete.out file is a good place to look for error messages that could help debug
the input deck if any errors are present.
4. Select Subcase 1 - heat transfer as the current load case in the Load Case and Simulation
Selection window.
5. Select the first pull-down menu below Result type and select Grid Temperatures(s).
6. Click Apply.
A temperature contour plot is now available.
7. Select the first pull-down menu below Result type and select Element Fluxes(V).
8. Click Apply.
Both temperature and flux results are shown below.
Figure 326: Model Showing the Cylinder Head, Engine Block and Head Bolts
The model consists of eight predefined components along with their corresponding property and
material allocations. A contact surface (PT_Surf) has been defined, which is used for 3D pretensioning
of an existing pretension surface. The pretension sections for 1D pretensioning have also been created
on two of the four bolts and the sectioned bolts are reconnected using 1D beam elements (via rigids).
A predefined visualization aid is also available under View, which allows the user to easily look at
the pretensioned sections of the four bolts. Contact surfaces and Contact Interfaces (TYPE=FREEZE)
between the various parts have also been created so you can focus on the Pretensioning aspect of the
tutorial.
In Step 1, upon preliminary assembly of the structure, the nuts on respective bolts are tightened,
usually by applying prescribed torque (which translates into prescribed tension force according to the
pitch of the thread).
As a result, the working part of the bolt becomes shorter by a distance . This distance depends upon
the applied force, the compliance of the bolt and of the assembly being pretensioned.
At the end of Step 1, the amount of shortening for each bolt is established and "locked", simply by
leaving the nuts at the position that they reached during the pretensioning step.
In Step 2, with the shortening of all the bolts "locked", other loads are applied to the assembly
(Figure 328). At this stage the stresses and strains in the bolts will usually change, while the length of
material removed remains constant for each bolt.
Figure 328: Step 2 of Pretensioned Assembly - Application of Working Loads with 'Locked' Bolt Shortening
Gasket behavior is nonlinear and it may undergo cycles of loading and unloading which lead to changes
in its properties at each step. In this tutorial, which focuses on 1D and 3D pretensioning, the loading
and unloading paths for the gasket material are pre-populated in the MGASK Data Entry via the TABLES#
entries referenced by corresponding load collectors. As a quasi-static analysis is running, the initial
applied pressure load is compared with corresponding values within the loading/unloading path tables
and the initial material properties of the gasket are determined. The nonlinear properties of the gasket
via the MGASK Data Entry are a function of pressure and the closure distance (Refer to MGASK Bulk Data
Entry for more information). FREEZE contact has been predefined for all parts in contact.
3. Make sure that the values on the MAT1 Bulk Data Entry for the material properties of steel are
input as shown below.
6. Click on MGASK.
7. Make sure that the values on the MGASK Bulk Data Entry for the material properties of the gasket
are input as shown below.
Tip: The TABLD and TABLU(1) fields (Gasket loading and unloading paths) in
Figure 332 are defined by TABLES1 Bulk Data Entries in separate load collectors named
Gask_Load and Gask_Unload1, respectively.
8. Click on Gask_Load in the Load Collector folder and then click the table icon next to the
Data field.
9. Make sure that the values on the TABLES1 Bulk Data Entry defining the gasket loading paths are
input as shown below.
10. Similarly, make sure that the values on the TABLES1 Bulk Data Entry defining the gasket unloading
paths (load collector Gask_Unload1) are input as shown below.
Tip: You can review, in a similar manner, the remaining predefined data entries like
properties and load collectors. The procedure for load collector review is not as straight
forward, as shown above in some cases; however, this has been thoroughly illustrated
in various other tutorials for the user's benefit.
11. The gasket normal direction is now reviewed by clicking on normals in the Tools panel.
12. To select the gasket component, use the Show/Hide tool (Figure 335 ) to hide the cylinder head
thereby exposing the gasket to view.
13. Click on the Show/Hide icon, and right-click on the cylinder head to hide it from view.
The gasket should now be visible.
Figure 336: Exposing the Gasket Component to View Using the Masking Tool
14. In a similar fashion, hide (right-click) the engine block from view to be able to better visualize the
gasket normals.
15. Click the Show/Hide icon again to deselect it and select the gasket directly from the modeling
window and click display normals.
The gasket normals can be seen in the modeling window, as shown in Figure 337. Notice that all
the normals point in the negative Z direction.
This concludes the review section of the tutorial. You will now focus on generating contact interfaces,
contact surfaces and applying pretensioning to the head bolts.
in an earlier subcase and it is subsequently referenced to in the subcase where its effect is sought
(STATSUB(PRETENS)).
1. In the Model Browser, right-click on Component and select Show from the context menu.
2. Hide the CYLINDER_HEAD component by clicking the Elements icon next to it in the Model
Browser.
Tip: View1, A predefined visualization option, is included with this model under View
in the Model Browser. Click on the monitor shaped icon next to View1; this loads a
predefined view in the Model Browser allowing you to view all four bolts in the Y-
Z plane. Two bolts have disc-shaped sections cut-off along its length. These bolts
are then reconnected using 1D beam elements (CBEAM) and two rigid spiders (RBE2)
per bolt. 1D pretensioning can now be applied to these two bolts. 3D pretensioning
requires the creation of a surface at which pretensioning forces can be applied.
3. From the menu bar, click Tools > Pretension Manager to access the Pretension Manager.
4. Click on Add 1D Bolts and select the two 1D beam elements in bolts 1 and 2 (Figure 18).
Tip: Care must be taken not to use CTRL+left mouse click while zooming in and
positioning the elements in the graphics area for selection. Using CTRL+left mouse
click can lead to the model being rotated about an axis and thus disengaging from the
Y-Z plane of View1. It is recommended to only use CTRL+right mouse click (dragging
action) while working in View1.
5. Select both fields under the Load Type column in the Pretension Manager window (Click on the
first field and then while holding down the CTRL key, click on the second field). Click on the
downward facing arrow next to the second field and select Force from the drop-down menu.
6. In a similar fashion, enter 4500.0 for both bolts in the Load Magnitude column.
7. Click Apply. A pretensioning force of 4500.0 N is applied to both 1D bolts, as shown in Figure 19.
8. Click on Add 3D Bolts and select Select Existing Surface from the drop-down menu.
9. Click on the Wireframe elements skin only icon to view the predefined contact surface PT_Surf
on the third bolt.
Tip: If the predefined surface is not visible, then switch on (show) the PT_Surf entry
in the Model Browser by clicking on the icon next to it.
10. Click on the displayed predefined surface in the bolt, as shown in Figure 20 and click proceed.
11. Select Force under the Load Type column and enter 4500.0N for the Load Magnitude column and
click Apply.
A pretensioning force of 4500.0 N is applied normal to the PT_Surf surface, as shown in Figure 21.
Figure 344: Applying a pretensioning force of 4500 N to the predefined surface PT_Surf on the third bolt
12. Click on Add 3D Bolts and select Create New Surface from the drop-down menu.
13. Utilize the click and drag technique (while holding down the shift key) described previously to
select the top of the fourth bolt, as shown in Figure 22.
14. Click on nodes in the panel below the graphics area and select all the nodes in the surface
perpendicular to the Y-Z plane, as shown in Figure 23.
The same click and drag technique can be used to select these nodes (draw a window
encompassing the line as the perpendicular surface is a line in the Y-Z plane).
17. Click OK in the Pretension Manager to view all four bolts with their respective pretensioning
forces, as shown in Figure 25.
5. Select Nonlinear quasi-static from the drop-down menu next to Loadstep type: in the Loadstep
Type tab.
6. Switch to the Load References tab and click on NLPARM in the list of subcase entries.
7. Click on Nlparm in the Available nonlinear parameters: section and then click on the right facing
arrow to add it to the selected nonlinear parameter: section.
8. Similarly, click on SPC in the Subcase Entry list and add the Available SPC constraint to the
Selected SPC constraints: section.
9. Follow the instructions in Steps 6 or 7 to add PRETENS_1 to the list from the PRETENSION
Subcase Entry section.
10. Click OK after all three subcase entries are added to the Pretension loadstep.
11. Right-click on Loadsteps in the Loadsteps Browser and select New loadstep.
12. In the Loadstep name: field, enter Pressure and click Create.
13. Select Nonlinear Quasi-static from the drop-down menu next to Loadstep type: in the Loadstep
Type tab.
14. Switch to the Load References tab and click on NLPARM in the list of subcase entries.
15. Click on Nlparm in the Available nonlinear parameters: section and then click on the right facing
arrow to add it to the selected nonlinear parameter: section.
16. Similarly, click on SPC in the subcase entry list and add the Available SPC constraint to the
Selected SPC constraints: section.
17. Follow the instructions in Steps 6 or 7 to add PRETENSION to the list from the
STATSUB(PRETENS) subcase entry section.
18. Again, follow the instructions in Steps 6 or 7 to add PRESSURES to the list from the LOAD
subcase entry section.
19. Click on the CNTNLSUB subcase entry and check the box next to CNTNLSUB, additionally select
YES rom the pull-down menu next to CNTNLSUB.
20. Click OK after all five subcase entries are added to the Pressure loadstep.
21. Click Close to exit the Load Step Browser.
If the job is successful, new results files should be in the directory where the Pretension.fem was
written. The Pretension.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
4. Select the first pull-down menu below Result type: and select Displacement(v).
Figure 353: Displacement Contour for the Pressure Subcase after Pretensioning
In Figure 29, the displacement plot after running the pressure subcases can be seen. The
maximum displacement is around 0.089 mm and it occurs in the region near the pretensioned bolt
heads.
6. Select Gasket Thickness-direction Pressure in the Contour panel and click Apply.
A contour plot of gasket pressure in the thickness direction is created, as shown in Figure 30. The
other components are hidden to be able to better view the pressure variation on the gasket.
Figure 354: Gasket pressure in the thickness direction for the Pressure subcase
Checkpoint
The maximum pressure on the Gasket in the thickness direction is equal to 0.21 MPa.
The model consists of two cubes in contact and enforced displacement on the top compressing the
structure.
7. Click Elements and select all elements from the bottom part of the structure.
8. Select three nodes on the surface that are in contact with the top part. Make sure the three nodes
are all part of one element.
9. Click return to finish.
10. Repeat steps 3 through 9 to create the top part.
3. In the next panel, select the settings to request contact related output, as shown below.
9. Click Next to locate the GAPPRM control card and click HMGAPST.
10. Set the VALUE to YES.
Outputs the open/closed status of the CGAPG elements.
If the job is successful, new results files should be in the directory where the Contact_N2S.fem was
written. The Contact_N2S.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
4. Load the other model in the new window by clicking and selecting contact_N2S.h3d.
9. Right-click in the window that shows the contour and select Apply Style > Current Page > All
selected to view the same results for both models.
A contour plot of normal contact traction shows for both runs. The traction for the S2S run is
much more uniform than for N2S by comparing the maximum and minimum values.
Figure 366: Applying the Setup in One Window to the Rest of the Page
Figure 367: Contour of the Normal Contact Traction for S2S on the Left and N2S on the Right
7. Click File > Run > Command File to create element sets to identify the open/closed status of
the elements at the end of the run.
Figure 368: Reviewing the Closed Gaps at the End of the Analysis
7. Repeat the steps in Reviewing the Internally Created CGAPC Elements for the component top and
the set ^MasterGrids_Contact_#1.
The model consists of two circular parts where the inner one is heated and the outer one cooled down,
leading to contact between the two. The effect of using several important contact settings such as
contact stabilization, clearance, adjust and smoothing on both the results and the convergence behavior
is considered.
The model consists of two circular parts where the inner one is heated and the outer one cooled down,
leading to contact between the two. The effect of using several important contact settings such as
contact stabilization, clearance, adjust and smoothing on both the results and the convergence behavior
is considered.
6. In the Model Browser, select the interface cont_interf to assign the property to the interface.
7. In the Entity Editor, select Property Id as the property and change the PID to cont_prop.
Adding Clearance
Now you want to investigate the influence of clearance on the model.
1. In the Model Browser, select the cont_prop property.
2. In the Entity Editor, click on the field next to CLEARANCE and enter the value 0.1.
Clearance will internally set the gap between the surfaces to the real value chosen, independently
of the actual position of the grids, if grids are not moved to achieve this.
3. Repeat Submitting the Job, with the new file name Contact_Clearance.fem.
Figure 377: Selecting the Surface Smoothing Option on the CONTACT Card
10. In the Entity Editor, unselect the outer part of the structure.
Only the results on the contact surface will be visible.
11. Right-click in the window that shows the contour and select Apply Style > Current Page > All
selected to view the same results for both models.
12. A contour plot of normal contact traction shows for both runs.
The traction for the runs with clearance and adjust are more uniform than they are for the model
with stabilization only. The surface smoothing leads to a more uniform contour. In addition, the
peaks are much lower for these three models. The reason why is, the traction is much higher for
adjust than it is for the clearance, and the adjust run is that for adjust, the gap is closed initially,
which leaves less room for stress free thermal expansion as for the other runs.
Figure 379: Applying the Setup in One Window to the Rest of the Page
Figure 380: Normal Contact Traction Contour for the Four Different Runs
A comparison with linear analysis results is also provided to illustrate the requirement of conducting
a nonlinear large displacement analysis. This tutorial considers nonlinear geometric effects (large
displacements) and elastoplastic material.
For static analysis, the energy equation reduces to F=Ku, wherein we solve for the unknown
displacements (u). In Nonlinear Large Displacement analysis, the stiffness (K) may be a function of
material, geometry, and boundary conditions. Therefore, an incremental-iterative approach is utilized to
calculate the unknown displacements.
Therefore, it is possible to understand which conditions are considered in a linear analysis. First, the
material behavior is considered linear during the analysis, . Second, the geometry deformation should
be small enough that the initial shape is not changed significantly enough to affect the stiffness. Finally,
the boundary conditions should not vary during the analysis.
Figure 381:
The analysis considers both geometric and material nonlinearity. The geometric nonlinearity is
considered because of the large displacements observed in the geometry, . Besides, the resultant stress
exceeds the yield stress limit, which implies that material does not conform to a linear stress-strain
behavior and plastic effects begin to be observed.
Model Description
Figure 382 illustrates the structural model used for this tutorial: a long rectangular plate which is
supported at two ends and distributed load is applied on the top surface. The dimensions of the plate
and material parameters can be obtained, as shown below.
Units Length: mm
Time: s
Mass: ton
Force: N
Stress: MPa
Length 1000 mm
Width 200 mm
Thickness 4.0 mm
Initial Density
3
7.86e-9 kg/mm
Poisson coefficient
0.29
Yield stress
100.0 MPa
Tangent modulus
20000.0 MPa
Update Material
H is the plasticity modulus (work hardening slope) that defines the linear relation between strain
and stress in the plastic region. For a bilinear material curve, it is related to the Young’s modulus
by the tangent modulus ( ). Refer to MATS1 for more information.
Figure 383: Young’s and Tangent Modulus in the Stress-Strain Curve and Equation that Correlates Them
Figure 384:
Update Property
Figure 385:
1. In the Model Browser, right-click and select Create > Load Collector.
2. For Name, enter LC_SPC.
3. Click Color and select a color from the color palette.
4. For Card Image, select None.
5. From the Analysis page, select constraints, toggle create.
6. Switch entity selector to nodes and select the nodes.
Figure 386:
7. Select the degrees of freedom dof1 and dof3. Deselect all others.
Figure 387:
11. Select the degrees of freedom dof1, dof3 and dof3. Deselect all others. This constrains
translation movement in z direction.
12. For load types, select SPC.
13. Click create to create the boundary constraints.
14. Click return to go back to the main menu.
1. In the Model Browser, right-click and select Create > Load Collector.
2. For Name, enter LC_IMPLOAD.
3. Click Color and select a color from the color palette.
4. For Card Image, select None.
5. From the Analysis page, click pressures and toggle create.
6. Switch entity selector to elems and select all elements.
7. Click on the toggle next to magnitute= and switch pressure defintion method to constant
vector.
8. For magnitude, enter -0.02.
9. For load types, select PLOAD as the load type.
10. Click create > return.
1. In the Model Browser, right-click and select Create > Load Collector.
2. For Name, enter LC_NLPARM.
3. For Card Image, select NLPARM.
4. Select the CONV as UPW with an EPSUP and ESPS of 0.001, and EPSW of 1e-7, that are the
default values.
CONV flag selects the convergence criteria. In this case, UPW is a combination of displacement
(U), load (P) and work (W) criteria. EPSU, EPSP and EPSW are their respective error tolerances.
5. Input the values, as shown below. Refer to NLOUT for more information.
Figure 388:
1. In the Model Browser, right-click and select Create > Load Collector.
2. For Name, enter LC_NLOUT.
3. For Card Image, select NLOUT.
4. Check the box next to NINT and enter 10.
This parameter sets the number of intervals shown in output for intermediate results.
5. Input the values, as shown below. Refer to NLOUT for more information.
Figure 389:
1. In the Model Browser, right-click and select Create > Load Step.
2. For Name, enter nonlinear_lgdisp.
3. For Analysis type, select Nonlinear quasi-static.
4. For SPC, select Unspecified > Loadcol.
5. In the Select Loadcol dialog, select LC_SPC from the list of load collectors and click OK.
This sets the boundary condition created above.
6. For LOAD, select Unspecified > Loadcol.
7. In the Select Loadcol dialog, select LC_IMPLOAD from the list of load collectors and click OK.
This sets the imposed load created above.
8. For NLPARM, select Unspecified > Loadcol.
9. In the Select Loadcol dialog, select LC_NLPARM from the list of load collectors and click OK.
This sets the analysis parameters created above.
10. For NLOUT, select Unspecified > Loadcol.
11. In the Select Loadcol dialog, select LC_NLOUT from the list of load collectors and click OK.
This sets the output control parameters created above. The nonlinear analysis has been set.
12. In the Model Browser, right-click and select Create > Load Step.
13. For Name, enter linear.
14. For Analysis type, select Linear Static.
15. For SPC, select Unspecified > Loadcol.
16. In the Select Loadcol dialog, select LC_SPC from the list of load collectors and click OK.
17. For LOAD, select Unspecified > Loadcol.
18. In the Select Loadcol dialog, select LC_IMPLOAD from the list of load collectors and click OK.
The linear analysis has been set.
3. In the Save As dialog, specify location to write the OptiStruct model file and enter plate for
filename.
For OptiStruct input decks, .fem is the recommended extension.
4. Click Save.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to analysis.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to launch the OptiStruct job.
If the job is successful, new results files should be in the directory where the plate.fem was written.
The plate.out file is a good place to look for error messages that could help debug the input deck if
any errors are present.
The default files written to the directory are:
plate.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
plate.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
plate.h3d
HyperView binary results file.
plate.stat
Summary, providing CPU information for each step during analysis process.
In the output file (plate.out), it is possible to follow the convergence iterations that are calculated
according to criteria parameters chosen in Define Nonlinear Analysis Parameters. Also, the maximum
plastic strain is calculated for each step.
Figure 391:
You will see how the activation of Follower Loads leads to a significant difference in model behavior
and results, and how inaccurate results may be output if the follower load mechanism is not taken into
account. You will look at activation of Follower Loads that are concentrated forces (Beam model) and of
Follower Loads that are pressures (Rubber Disk model).
The name and location of the beam_fllwer.fem file displays in the input file field.
5. Set the export options toggle to all.
6. Set the run options toggle to analysis.
7. Set the memory options toggle to memory default.
8. Click OptiStruct. This launches the OptiStruct job.
If the job is successful, the new results files should be in the directory from which
beam_fllwer.fem was selected. The beam_fllwer.out file is a good place to look for error
messages that could help debug the input deck if any errors are present.
Figure 397:
Figure 398:
Figure 399:
Note: This parameter has no control over the adaptive load size selection
during the incremental-iterative solution process. It only specifies the number of
intervals when results are saved for output during the solution process.
Figure 400:
Compare the displacement results between models without Follower Load activation.
1. Launch HyperView.
2. Click to split the page into two windows.
3. Load the result files by clicking and navigating to your working directory.
Note: Since you have requested results for intermediate iterations via NLOUT, you will
see results for all intermediate iterations.
5. In the Results Browser, click Load Factor and select the final increment Load Factor =
1.000000E+00.
Figure 402:
The Displacement contour results display. You can see that the activation of follower forces has modified
the displacement profile significantly.
Figure 403:
In this disk model, the loads are pressure loads which may depend on the area of the element faces
to whom they are applied. Additionally, you have multiple subcases to showcase the effect of different
FLLWER options. In the FLLWER Bulk Data Entry in the OptiStruct help, you will see the OPT parameter
which contains the following options for the calculation of Follower Loads:
= -1, 0 Follower force calculation is not activated.
1. In the Model Browser, right-click and select Create > Load Collector.
A default load collector template displays in the Entity Editor.
2. For Name, enter FLLWER_1.
3. Set Card Image to FLLWER.
4. Set OPT to 1.
Figure 404:
Figure 405:
Note: This parameter has no control over the adaptive load size selection
during the incremental-iterative solution process. It only specifies the number of
intervals when results are saved for output during the solution process.
Figure 406:
Figure 407:
3. Select the directory where you would like to write the OptiStruct model file and enter the name for
the model, disk_fllwer.fem, in the File name field.
For OptiStruct input decks, .fem is the recommended extension.
4. Click Save.
The name and location of the disk_fllwer.fem file displays in the input file field.
5. Set the export options toggle to all.
6. Set the run options toggle to analysis.
7. Set the memory options toggle to memory default.
8. Click OptiStruct. This launches the OptiStruct job.
If the job is successful, the new results files should be in the directory from which
disk_fllwer.fem was selected. The disk_fllwer_ON.out file is a good place to look for error
messages that could help debug the input deck if any errors are present.
Compare the displacement results between models with and without Follower Load activation.
1. Launch HyperView.
2. Click to split the page into two windows.
Figure 409:
b) Activate the third window and load the disk_fllwer_ON.h3d result file. In the Results
Browser, select Subcase 2 (fllwer_3).
c) Activate the fourth window and load the disk_fllwer_ON.h3d result file. In the Results
Browser, select Subcase 2 (NO_fllwer).
5. Setup contouring for each window.
a) Click the window to activate it, then click on the toolbar.
Note: Since you have requested results for intermediate iterations via NLOUT, you will
see results for all intermediate iterations.
The Displacement contour results display. You can see that the activation of follower forces has modified
the displacement profile significantly. Additionally, you can see that since subcase 3 (OPT=3) updates
the load direction but not the area, the force (Pressure*Area) distribution at the grid points is low for
Subcase 3 and the Displacement results reflect this when compared to OPT=1 and 2.
Figure 410:
This tutorial helps you to define finite sliding contact between the circular gear and rack. The gear is
held fixed at the center in all dof while the rack is given displacement in x dof but constrained in all
other dof. All constraints and enforced displacements have already been defined in model. Contact
surfaces to define the slave and master surfaces are also pre-defined in the model. Contact stabilization
has been defined for the contact to help stabilize any rigid body motion before contact gets established.
A very tiny end-of-subcase stabilization also has been specified to overcome any temporary instabilities
that may sometimes occur at end-of-analysis.
Figure 412:
Tip: You can review, in a similar manner, the remaining pre-defined data entries, like
properties and load collectors. The procedure for load collector review is not as straight
forward as shown above in some cases; however, this has been thoroughly illustrated in
various other tutorials for your benefit.
1. In the panel area, go to the Analysis page and click contactsurfs to review the already created
contact surfaces.
2. Go to the solid faces subpanel.
3. Review the contact surface for rack.
a) Click name.
b) Select rack.
c) Click review.
h) Click update.
7. To review the interface, click review.
Note: CONTF gives contact output results, like contact pressure, gap penetration,
sliding distance, and so on.
If the job is successful, new results files should be in the directory where the rack_pinion.fem was
written. The rack_pinion.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
4. Under Result type, from the first drop-down menu, select Element Stresses (2D & 3D)(t).
6. Similarly, you can change the load factor and observe the changes in stresses on the rack and
gear.
7. Optional: Animate the results using the Set Transient Animation Mode in HyperView.
Figure 422:
8. Optional: Select other result types in the Contour panel and click Apply.
• OS-T: 1600 Fluid-Structure Interaction Analysis of Piezoelectric Harvester Assembly (p. 437)
• OS-T: 1610 Thermal Fluid-Structure Interaction Analysis on a Manifold (p. 449)
OptiStruct Tutorials
Fluid-Structure Interaction Analysis p.437
In this tutorial, you will explore the possibility of using piezoelectric based fluid flow energy harvesters.
These harvesters are self-excited and self-sustained in the sense that they can be used in steady
uniform flows. The configuration consists of a piezoelectric cantilever beam with a cylindrical tip body
(which is the structure model) which promotes sustainable, aero-elastic structural vibrations induced
by vortex shedding and galloping. The structural and aerodynamic properties of the harvester alter the
vibration amplitude and frequency of the piezoelectric beam and the fluid flow. As you may know, the
Piezoelectric energy harvesting using fluid flow involves the mutual interaction of three distinct dynamic
systems, namely the fluid, the structure and the associated electrical circuit.
Note: This tutorial is limited to study only fluid and the structure domain.
Figure 424 illustrates the fluid structural model used for this tutorial: the dimensions of the beam are
shown in Figure 423 and Figure 424.
The AcuSolve fluid model (slab_dcfsi.inp) and the OptiStruct structural beam model (Slab.fem) are
located in the fsi_models.zip file. Refer to Accessing the Model Files.
5. Click Open.
6. Click Import, then click Close to close the Import tab.
Figure 426:
Figure 427:
Figure 428:
Figure 429:
Figure 430:
Figure 431:
If the job is successful, new results files should be in the directory where the Slab.fem was written.
The Slab.out file is a good place to look for error messages that could help debug the input deck if any
errors are present.
Initiating a Run
1. Launch the HyperWorks Solver Run Manager and select the Slab.fem file.
2. Click Run.
Figure 433:
Figure 434:
3. Open the AcuSolve Cmd Prompt application and enter the command: acuRun-pb slab_dcfsi -np
8.
Figure 435:
If the job is successful, you will see new results files in the directory where HyperMeshwas invoked.
The Slab.out file is where you will find error messages that will help you debug your input deck, if any
errors are present.
The default files that will be written to your directory are:
cci.txt Contains information pertaining to model progression. Logs
regarding connection establishment, initial external code
handshake and subsequent time step data in conjunction with
exchange/stagger.
Slab.out ASCII based output file of the model check run before the
simulation begins and gives some basic information on the results
of the run.
Figure 436:
This example is an engine exhaust manifold with conjugate heat transfer and structural deformation.
The structure is gray cast iron, initially at 300 K. The manifold outer surface has a convective heat
2
transfer coefficient of h = 6 W/m K at 300 K. The four inlets to the manifold are held at 500 K with air
as the fluid at 5 m/s. AcuSolve passes heat fluxes to OptiStruct. OptiStruct passes the temperatures to
AcuSolve.
Note: This tutorial is limited to study fluid and thermal domain only.
The AcuSolve Fluid model (FSI_AS_MANIFOLD.inp) and OptiStruct Structural beam model
(FSI_OS_MANIFOLD.fem) files are in the tfsi_models.zip file. Refer to Accessing the Model Files.
Tip: To pick all the elements in the internal face, use the brake angle of 30 degrees.
Figure 438:
Figure 439:
Figure 440:
If the job is successful, new results files should be in the directory where the FSI_OS_MANIFOLD.fem
was written. The FSI_OS_MANIFOLD.out file is a good place to look for error messages that could help
debug the input deck if any errors are present.
Initiating a Run
1. Launch the HyperWorks Solver Run Manager and select the FSI_OS_MANIFOLD.fem file.
2. Click Run.
Figure 442:
Figure 443:
3. Open the AcuSolve Cmd Prompt application and enter the command: acuRun-pb
FSI_AS_MANIFOLD -np 8.
Figure 444:
If the job is successful, you will see new results files in the directory where HyperMeshwas invoked. The
FSI_OS_MANIFOLD.out file is where you will find error messages that will help you debug your input
deck, if any errors are present.
The default files that will be written to your directory are:
cci.txt Contains information pertaining to model progression. Logs
regarding connection establishment, initial external code
handshake and subsequent time step data in conjunction with
exchange/stagger.
FSI_OS_MANIFOLD.out ASCII based output file of the model check run before the
simulation begins and gives some basic information on the results
of the run.
Figure 445:
This exercise includes the creation of PRBODY (rigid body definition), JOINT and boundary conditions in
HyperMesh. An existing finite element model is used in this tutorial problem.
2. Select the 3bodies_dynamics.hm file you saved to your working directory from the
optistruct.zip file. Refer to Accessing the Model Files.
3. Click Open.
The 3bodies_dynamics.hm database is loaded into the current HyperMesh session, replacing any
existing data. The database only contains geometric data. The model has three components and a
few free nodes that will be used to create bodies and joints for the MBD model.
Creating PRBodies
PRBODY is the Rigid Body Definition for Multibody Simulation. PRBODY defines a rigid body out of a list
of finite element properties, elements and grid points.
1. From the Analysis page, click the bodies panel.
2. Select the create subpanel.
3. Define PRBODY for the body1 component.
a) In the body= field, enter blue.
b) Click type= and select PRBODY.
c) Using the props selector, select body1.
d) Click create.
4. Define PROBDY for the body2 component.
a) In the body= field, enter lime.
b) Click type= and select PRBODY.
c) Using the props selector, select body2.
d) Click create.
5. Define PROBDY for the body3 component.
a) In the body= field, enter orange.
b) Click type= and select PRBODY.
c) Using the props selector, select body3.
d) Click create.
6. Click return.
Creating Joints
You will create two revolute joints, one ball joint, and one universal joint to constrain the degrees of
freedom, such that the remaining degree of freedom will be just 1.
Revolute 3 2 5
Universal 3 1 4
Ball (Spherical) 3 0 3
Tip: Nodes 12319 and 13158 are coincident. Use coincident node picking in the
options panel > graphics subpanel to help you select these coincident nodes in
the modeling window.
d) Click create.
The vectors 12319 to 12910 define the axis of rotation of the revolute joint.
Figure 448:
Figure 449:
Figure 450:
1. In the Model Browser, right-click and select Create > Load Collector from the context menu.
A default load collector displays in the Entity Editor.
2. For Name, enter gravity.
3. Click Color and select a color from the color palette.
4. Set Card Image to GRAV.
5. Input the values as illustrated below.
Figure 452:
Figure 453:
If the job is successful, new results files should be in the directory where the
3bodies_dynamics_complete.fem was written. The 3bodies_dynamics_complete.out file is a good
place to look for error messages that could help debug the input deck if any errors are present.
HyperView is a complete post-processing and visualization environment for finite element analysis
(FEA), multi-body system simulation, video and engineering data.
The model and results are loaded in the current HyperView window.
2. Click to open the Contour panel.
Figure 455:
Figure 456:
This tutorial includes the creation of PRBODY (rigid body definition), PFBODY (flexible body definition),
and JOINT in HyperMesh.
Figure 457:
2. Select the slider_crank.hm file you saved to your working directory from the optistruct.zip
file. Refer to Accessing the Model Files.
3. Click Open.
The slider_crank.hm database is loaded into the current HyperMesh session, replacing any
existing data. The database only contains geometric data.
Creating PRBodies
PRBODY is the Rigid Body Definition for Multibody Simulation. PRBODY defines a rigid body out of a list
of finite element properties, elements and grid points.
1. From the Analysis page, click the bodies panel.
2. Select the create subpanel.
3. Define PRBODY for the support component.
a) In the body= field, enter support.
b) Click type= and select PRBODY.
c) Using the props selector, select support.
d) Click create.
4. Define PROBDY for the crank component.
a) In the body= field, enter crank.
b) Click type= and select PRBODY.
c) Using the props selector, select crank.
d) Using the nodes selector, select the node (ID 25231) at the center of RBE2 spider between
connecting rod and crank.
Figure 458:
e) Click create.
5. Define PROBDY for the block component.
a) In the body= field, enter block.
b) Click type= and select PRBODY.
c) Using the props selector, select block.
d) Using the nodes selector, select the node (ID 25232) at the center of RBE2 spider between
connecting rod and block.
Figure 459:
e) Click create.
6. Click return.
Tip: You could also use 'elems by id' and input the IDs 18795 and 18796 to select the
two RBE2 elements.
Figure 460:
Figure 461:
9. Click create.
10. Click return.
Creating Joints
You will create three revolute joints, one fixed joint, and one translational joint are created to constrain
the degrees of freedom.
Revolute 3 2 5
Fixed 3 3 6
Translational 2 3 5
Figure 462:
Tip: Nodes 25313 and 25543 are coincident. Use coincident node picking in the
options panel > graphics subpanel to help you select these coincident nodes in
the modeling window.
c) Click create.
Figure 463:
Figure 464:
5. Create the revolute joint between the crank and connecting rod.
a) Set joint type to revolute.
b) Select node ID 25229 as first terminal and select node ID 25231 as second terminal.
c) Set first orientation to coordinates, then enter x= 0.0, y= 0.0, z= 1.0.
The z-axis will be the axis of rotation of revolute joint.
d) Click create.
Figure 465:
6. Create the revolute joint between the connecting rod and sliding block.
a) Set joint type to revolute.
b) Select node ID 25230 as first terminal and select node ID 25232 as second terminal.
c) Set first orientation to coordinates, then enter x= 0.0, y= 0.0, z= 1.0.
The z-axis will be the axis of rotation of revolute joint.
d) Click create.
Figure 466:
7. Create the translational joint between the sliding block and ground.
a) Set joint type to translational.
b) Select node ID 14519 as first terminal and select node ID 25228 as second terminal.
c) Set first orientation to coordinates, then enter x= 1.0, y= 0.0, z= 0.0.
The x-axis will be the direction of translation.
d) Click create.
Figure 467:
8. Click return.
Figure 468:
1. In the Model Browser, right-click and select Create > Load Collector from the context menu.
Figure 469:
Figure 470:
If the job is successful, new results files should be in the directory where the
slider_crank_complete.fem was written. The slider_crank_complete.out file is a good place to look
for error messages that could help debug the input deck if any errors are present.
Also, the following files will be output and which are specific to the random response analysis.
slider_crank_complete_mbd.abf
Binary plotting file.
slider_crank_complete_mbd.h3d
Binary results file (Modal results).
slider_crank_complete_mbd.log
Log file from OS-Motion containing the information on the joints and markers, simulation etc.,
which are specific to MBD analysis.
slider_crank_complete_mbd.mrf
Binary results file for plotting.
slider_crank_complete_mbd.xml
Model file in .xml format – solver intermediate input deck.
HyperView is a complete post-processing and visualization environment for finite element analysis
(FEA), multibody system simulation, video and engineering data.
The model and results are loaded in the current HyperView window.
2. Click the Contour panel toolbar icon .
Figure 472:
Figure 473:
6. In the Contour panel, under Results type, select Element Stresses [2D & 3D].
Figure 474:
Using HyperMesh, you will import an existing finite element model of a cantilever beam and setup
the model (creation of joint, loading, and so on). You will use HyperView to post-process the large
displacement results of the cantilever beam model.
Figure 475:
In this tutorial, you learn how to create a JOINT, a PFBODY, an MBMNTC and a multi-body dynamics
subcase.
The beam model consists of 10 different flexible bodies (PFBODY) and each body is to be connected
through a fixed joint and rigid element (RBE2).
There are two RBE2's defined at the boundary of each body (one for each body at this boundary). The
fixed joint will be created using coincident nodes which are independent nodes of each of the RBE2s.
Creating Joints
In this step you will define all of the necessary joints required for this model. Only fixed joints for
this model are needed. The fix joint at the left corner of body_1 will be created to represent clamped
boundary condition. This fixed joint will be created using coincident nodes, so that coincident nodes
need to be created first at the left corner of body_1.
1. Create the component, joints.
a) In the Model Browser, right-click and select Create > Component from the context menu.
A default component template displays in the Entity Editor.
b) For Name, enter joints.
2. Create coincident nodes.
a) From menu bar, click Geometry > Create > Nodes > XYZ to open the Create Nodes panel.
b) In the modeling window, on the upper left corner of body_1, click three times.
The nodal coordinates (x=, y=, z=) of that node will be populated.
c) Click create.
d) Create another coincident node on the lower left corner of body_1.
e) Click return.
3. From the menu bar, click Mesh > Create > 1D Elements > Joints.
The Joints panel opens.
4. Create a fixed joint at the left corner of body_1.
a) Set joint type to fixed.
b) Select the coincident node in the upper, left corner as the first terminal and select the other
coincident node at the same location as the second terminal.
Tip: Use coincident node picking in the options panel > graphics subpanel to help
you select these coincident nodes in the modeling window.
c) Click create.
Creating PFBodies
PFBODY is the Flexible Body Definition for Multibody Simulation. PFBODY defines a flexible body out of a
list of finite element properties, elements, and grid points.
You will have ten bodies apart from the ground body in your model.
Make sure that all PFBODY have a damping of 10.0 defined in parameters subpanel. For pfbody_4,
enter a value of 7 in the nmodes= field.
13. Click return.
Figure 480:
a) In the Model Browser, right-click and select Create > Load Collector from the context
menu.
A default load collector displays in the Entity Editor.
b) For Name, enter mbmoment.
c) Set the Card Image to None.
2. Create the sim load collector.
a) In the Model Browser, right-click and select Create > Load Collector from the context
menu.
A default load collector displays in the Entity Editor.
b) For Name, enter sim.
c) Set the Card Image to MBSIM.
d) Set TTYPE to END.
e) For TIME, enter 0.5.
f) Set STYPE to DELTA.
g) For DELTA, enter 2.0e-04.
h) Set ITYPE to VSTIFF.
Creating an MBMNTC
1. Change the load type for moment to MBMNTC.
a) From the Analysis page, select load types.
b) Click moment= and select MBMNTC.
c) Click return.
MBMNTC is the moment based on the curve.
2. Create a curve.
a) From the menu bar, click XYPlots > Curve Editor to open the Curve editor window.
b) Click New.
c) For name =, enter mycurve.
d) Click proceed.
e) From the Curve List, select my curve.
f) Populate the X Y table, as shown in Figure 481.
Figure 481:
g) Click Update.
h) Click Close.
3. In the Model Browser, Load Collectors folder, right-click on mbmoment and select Make Current
from the context menu.
4. Create moments.
a) From the Analysis page, click moments.
b) Using the nodes selector, select the 2 nodes at right tip of a beam.
If the job is successful, new results files should be in the directory where the
cantilever_beam_MBD.fem was written. The cantilever_beam_MBD.out file is a good place to look for
error messages that could help debug the input deck if any errors are present.
HyperView is a complete post-processing and visualization environment for finite element analysis
(FEA), multibody system simulation, video and engineering data.
The model and results are loaded in the current HyperView window.
2. Click the Contour panel toolbar icon .
Figure 484:
Figure 485:
6. In the Contour panel, under Results type, select Element Stresses [2D & 3D].
7. Click Apply.
8. Click the Start/Pause Animation icon to start the animation.
Figure 486:
Figure 487:
Figure 488:
b) Using the nodes selector, select the nodes that sit in the middle of the multi-node rigid on the
primary attachment point of the control arm to the chassis.
c) Click create.
4. Create the second constraint.
a) Select the degrees of freedom, dof2 and dof3.
b) Using the nodes selector, select the node and the last attachment point of the control arm..
c) Click create.
5. Create the third constraint.
a) Select the degree of freedom, dof3.
b) Using the nodes selector, select the top node in the rigid which would fasten the bottom of
the shock assembly to the control arm.
c) Click create.
6. Create the fourth constraint.
a) Select the degrees of freedom, dof1, dof2, and dof3.
b) Using the nodes selector, select the top node in the rigid on the boss to the right.
c) Click create.
Creating Subcase
1. From the , click Setup > Create > Control Cards to open the Control Cards panel.
2. Click GLOBAL_CASE_CONTROL.
3. Enable CMSMETH.
4. Click CMSMETH and select the CMS load collector.
5. Click return to return to the Control Cards panel.
Tip: To check the material properties of your model, go to the Model Browser,
Materials folder and click MAT1_1. In the Entity Editor, view the Elastic modulus
(2.1e+05), Poisson's Ratio (0.3) and the Density of the material (7.9e-09). For
this model, the material used is Steel. Since the values of the material properties
provided are consistent with Megagram, Newton, Millimeter, Second, the MGG N
MM S sequence is selected for this control card.
b) The values of the material properties provided are consistent with Megagram, Newton,
Millimeter, Second, therefore select the MGG N MM S sequence.
c) Click return.
3. Define the analysis type.
a) Click GLOBAL_OUTPUT_REQUEST.
b) Select STRESS.
c) Select the options shown below.
Figure 490:
d) Click return.
4. Create the output control for the component mode synthesis.
a) Click OUTPUT.
b) Select the options shown below.
Figure 491:
c) Click return.
5. Create a title.
a) Click TITLE.
b) Enter a title for the analysis.
c) Click return twice.
susp_sla.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
susp_sla.h3d
HyperView binary results file.
susp_sla.res
HyperMesh binary results file.
susp_sla.stat
Summary, providing CPU information for each step during analysis process.
The Curved Pentagon Positive Return Cam system is used to define the contacts. In this system the
curved pentagon rolls inside the circle and translates the slider.
3. Click Open.
The for_contact_tutorial.hm database is loaded into the current HyperMesh session, replacing
any existing data. The database only contains geometric data.
There will be five bodies apart from the ground body in our model via: the stand, the slider, the driver,
the pentagon and the circle. Pre-defined free nodes will be used to define the bodies and joints.
9. Click return.
Creating Joints
In this step you will create all of joints needed for the model. The first joint is the fixed joint between
the stand and ground body. The second joint is a revolute joint between the stand and driver, the third
joint is the translational joint that connects the slider to the stand, the fourth joint is the revolute joint
between the driver and the pentagon, and the fifth joint is the fixed joint between the slider and the
circle.
Revolute 3 2 5
Fixed 3 3 6
Translational 2 3 5
Motion (rev) 3 2 1
Tip: The first and second terminals are corresponding to the bodies that are
connected by the joint. Nodes 19401 and 19402 are coincident. Use coincident
node picking in the options panel > graphics subpanel to help you select these
coincident nodes in the modeling window.
c) Click create.
4. Create a fixed joint between the slider and the circle.
a) Set joint type to fixed.
b) Select node ID 19399 as the first terminal and node ID 19400 as the second terminal.
c) Click create.
5. Create a revolute joint between the stand and driver.
a) Set joint type to revolute.
b) Select node ID 19391 as the first terminal and node ID 19392 as the second terminal.
c) Set the first orientation selector to vector, then select y-axis.
d) Click create.
6. Create a revolute joint between the driver and pentagon body.
a) Set joint type to revolute.
b) Select node ID 19395 as the first terminal and node ID 19396 as the second terminal.
c) Set the first orientation selector to vector, then select y-axis.
d) Click create.
7. Create a translational joint between the slider and stand.
a) Set joint type to translational.
b) Select node ID 2 as the first terminal and node ID 4 as the second terminal.
c) Set the first orientation selector to vector, then select x-axis.
d) Click create.
8. Click return to exit the panel.
Defining a Contact
In this step you will use pre-defined element sets to add a contact to the model. The element sets are
defined from the Analysis page, entity sets by choosing a set of elements. The set of elements on the
face of the pentagon body is named master and the sets elements on the face of the circle body is
named slave.
1. Create a contact.
a) From the Analysis page, click the interfaces panel.
b) Select the create subpanel.
c) In the name= field, enter Contact.
d) Click type= and select MBCNTR.
e) Click create.
Figure 495:
Figure 497:
e) Click return.
4. Click return to exit the Interface panel.
A new load collector (auto1) has been added to the model. The motion is assigned to this load collector
and will be used as reference in the OptiStruct subcase.
1. In the Model Browser, right-click and select Create > Load Collector from the context menu.
A default load collector displays in the Entity Editor.
2. For Name, enter gravity.
3. Click Color and select a color from the color palette.
4. Set Card Image to GRAV.
5. Input the values as illustrated below.
Figure 499:
Figure 500:
for_contact_tutorial.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
for_contact_tutorial.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
for_contact_tutorial.h3d
HyperView binary results file.
for_contact_tutorial.res
HyperMesh binary results file.
for_contact_tutorial.stat
Summary, providing CPU information for each step during analysis process.
There are a few more files written to the directory with the name for_contact_tutorial_mbd.
HyperView is a complete post-processing and visualization environment for finite element analysis
(FEA), multibody system simulation, video and engineering data.
The model and results are loaded in the current HyperView window.
2. Click the Contour panel toolbar icon .
Figure 502:
In this tutorial, a Curved Pentagon Positive Return Cam system is modeled with the help of a CVCV
constraint.
There will be five bodies apart from the ground body in our model via: the stand, the slider, the driver,
the pentagon and the circle. Pre-defined free nodes will be used to define the bodies and joints.
9. Click return.
Creating Joints
In this step you will create all of joints needed for the model. The first joint is the fixed joint between
the stand and ground body. The second joint is a revolute joint between the stand and driver, the third
joint is the translational joint that connects the slider to the stand, the fourth joint is the revolute joint
between the driver and the pentagon, and the fifth joint is the fixed joint between the slider and the
circle. You will also create a CVCV joint.
Revolute 3 2 5
Fixed 3 3 6
Translational 2 3 5
Motion (rev) 3 2 1
b) Select node ID 19401 as the first terminal and node ID 19402 as the second terminal.
Tip: The first and second terminals are corresponding to the bodies that are
connected by the joint. Nodes 19401 and 19402 are coincident. Use coincident
node picking in the options panel > graphics subpanel to help you select these
coincident nodes in the modeling window.
c) Click create.
4. Create a fixed joint between the slider and the circle.
a) Set joint type to fixed.
b) Select node ID 19399 as the first terminal and node ID 19400 as the second terminal.
c) Click create.
5. Create a revolute joint between the stand and driver.
a) Set joint type to revolute.
b) Select node ID 19391 as the first terminal and node ID 19392 as the second terminal.
c) Set the first orientation selector to vector, then select y-axis.
d) Click create.
6. Create a revolute joint between the driver and pentagon body.
a) Set joint type to revolute.
b) Select node ID 19395 as the first terminal and node ID 19396 as the second terminal.
c) Set the first orientation selector to vector, then select y-axis.
d) Click create.
7. Create a translational joint between the slider and stand.
a) Set joint type to translational.
b) Select node ID 2 as the first terminal and node ID 4 as the second terminal.
c) Set the first orientation selector to vector, then select x-axis.
d) Click create.
8. Create a CVCV joint.
Pre-defined curves will be used in order to add a CVCV joint. These curves are defined from the
Analysis page, entity sets by choosing a set of nodes. The curve on the pentagon body is named
master and the curve on the circle body is named slave.
a) Set joint type to cvcv.
b) Select 4246 as the first terminal and 414 as the second terminal.
c) For the first curve, click set= and select master.
d) For second curve, click set= and select slave.
e) Click create.
9. Click return to exit the panel.
A new load collector (auto1) has been added to the model. The motion is assigned to this load collector
and will be used as reference in the OptiStruct subcase.
1. In the Model Browser, right-click and select Create > Load Collector from the context menu.
A default load collector displays in the Entity Editor.
2. For Name, enter gravity.
3. Click Color and select a color from the color palette.
4. Set Card Image to GRAV.
5. Input the values as illustrated below.
Figure 506:
Figure 507:
6. Define MOTION.
a) For MOTION, click Unspecified > Loadcol.
b) In the Select Loadcol dialog, select auto1 and click OK.
If the job is successful, new results files should be in the directory where the for_cvcv_tutorial.fem
was written. The for_cvcv_tutorial.out file is a good place to look for error messages that could help
debug the input deck if any errors are present.
The default files written to the directory are:
for_cvcv_tutorial.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
for_cvcv_tutorial.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
for_cvcv_tutorial.h3d
HyperView binary results file.
for_cvcv_tutorial.res
HyperMesh binary results file.
for_cvcv_tutorial.stat
Summary, providing CPU information for each step during analysis process.
HyperView is a complete post-processing and visualization environment for finite element analysis
(FEA), multibody system simulation, video and engineering data.
The model and results are loaded in the current HyperView window.
2. Click the Contour panel toolbar icon .
Figure 509:
An existing finite element model is imported into HyperMesh. The rest of the setup (creation of joint,
loading, etc.) is done in HyperMesh. HyperView is used to post-process the large deformations of the
flexible cable model.
You will learn how to create JOINTS (Fixed, PTDCV), a PFBODY, a PRBODY, a MBDCRV, and a multi-body
dynamics subcase.
The flexible cable consists of 50 different CBAR elements (PFBODY) and the end of this flexible body is
connected to ground (GROUND) using fixed joints.
The Hook (PRBODY) is an external graphic and is connected to the flexible cable by the PTDCV joint.
Figure 512:
Note: The selection of a property is not required when defining a ground body.
Figure 513:
Creating Joints
You will create all the necessary joints including the PTDCV joint. Three joints for the model are needed.
Two fixed joints between the Cable ends to the Ground, and one PTDCRV between the Hook and the
Cable.
1. Create the component, joints.
a) In the Model Browser, right-click and select Create > Component from the context menu.
A default component template displays in the Entity Editor.
b) For Name, enter joints.
2. From the menu bar, click Mesh > Create > 1D Elements > Joints.
The Joints panel opens.
3. Create a fixed joint between one end of the Cable and Ground.
a) Set joint type to fixed.
b) Select node ID 1 as first terminal and select node ID 14397 as second terminal.
Tip: Nodes 1 and 14397 are coincident. Use coincident node picking in the
options panel > graphics subpanel to help you select these coincident nodes in
the modeling window.
c) Click create.
4. Create the fixed joint between the other end of the Cable and Ground.
a) Set joint type to fixed.
b) Select node ID 2 as first terminal and select node ID 14398 as second terminal.
c) Click create.
5. Create the PTDCV joint.
a) Set joint type to ptdcv.
b) Select node ID 14399 as first terminal.
c) Click set= and select deform_curve.
The deform_curve entity set is defined as MBDCRV.
d) Click create.
Figure 514:
6. Click return.
1. In the Model Browser, right-click and select Create > Load Collector from the context menu.
A default load collector displays in the Entity Editor.
2. For Name, enter gravity.
3. Click Color and select a color from the color palette.
4. Set Card Image to GRAV.
5. Input the values as illustrated below.
Figure 515:
Figure 516:
If the job is successful, new results files should be in the directory where the flex_cable.fem was
written. The flex_cable.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
The default files written to the directory are:
flex_cable.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
flex_cable.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
flex_cable.h3d
HyperView binary results file.
flex_cable.res
HyperMesh binary results file.
flex_cable.stat
Summary, providing CPU information for each step during analysis process.
HyperView is a complete post-processing and visualization environment for finite element analysis
(FEA), multibody system simulation, video and engineering data.
The model and results are loaded in the current HyperView window.
2. Click the Contour panel toolbar icon .
Figure 518:
The topology optimization technique yields a new design and optimal material distribution. Topology
optimization allows designers to start with a design that already has the advantage of optimal material
distribution and is ready for design fine tuning with shape or size optimization.
1. In the Model Browser, right-click and select Create > Material from the context menu.
A default material displays in the Entity Editor.
2. For Name, enter steel.
3. Set Card Image to MAT1.
4. Enter the material values next to the corresponding fields.
a) For E (Young's Modulus), enter 2.1E5.
b) For NU, (Poisson's Ratio), enter 0.3.
c) For RHO (Mass Density),
A new material, steel, has been created. The material uses OptiStruct's linear isotropic material model,
MAT1.
A new property, prop_shell, has been created as a 2D PSHELL. Material information is also linked to this
property.
Creating Constraints
In this step you will create SPC constraints and assign them to the Constraints load collector.
1. From the Model Browser, Load Collectors folder, right-click on Constraints and select Make
Current from the context menu.
2. From the Analysis page, click constraints.
3. Create the first constraint.
a) Using the nodes selector, select the node indicated in Figure 519.
b) Select the degree of freedom, dof3; unselect all others.
c) Click create.
Figure 519:
Figure 520:
Figure 521:
6. Click return.
Creating Forces
In this step, you will load the structure with two opposing forces of 100.0 N at the opposite tips of the
opening of the c-clip.
1. From the Model Browser, Load Collectors folder, right-click on Forces and select Make Current
from the context menu.
2. From the Analysis page, click forces.
3. Create a force at the top of the opening of the c-clip.
a) Using the nodes selector, select the node at the top of the opening of the clip.
b) In the magnitude= field, enter 100.
c) Set the vector selector to y-axis.
d) Click create.
Figure 522:
Figure 523:
5. To provide a separation between the arrows, enter 7 in the uniform size= field.
Figure 524:
If the job is successful, new results files should be in the directory where the cclip_complete.fem was
written. The cclip_complete.out file is a good place to look for error messages that could help debug
the input deck if any errors are present.
Figure 527:
HyperView closes.
7. Click return to exit the panel.
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 where the maximum displacement is likely to occur. In this tutorial,
you will apply a displacement constraint on the nodes so that they would not displace more than 0.07 in
the y-axis.
d) Click create.
Figure 528:
5. Create another displacement response, named lowerdis. Using the nodes selector, select the node
labeled B, on the lower opening of the c-clip.
Figure 529:
The default files that get written to your run directory include:
cclip_complete.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and
constraint for each iteration.
cclip_complete.HM.comp.tcl
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.
cclip_complete.oss
OSSmooth file with a default density threshold of 0.3. You may edit the parameters in the file to
obtain the desired results.
cclip_complete.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the cclip_complete.fem file.
cclip_complete.res
HyperMesh binary results file.
cclip_complete.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. This file may be used to restart a run.
cclip_complete.stat
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, and so on.
cclip_complete_hist.mvw
Contains the iteration history of the objective, constraints, and the design variables. It can be
used to plot curves in HyperGraph, HyperView, and MotionView.
cclip_complete.h3d
HyperView binary results file.
Figure 530:
4. On the Standard Views toolbar, click XY Top Plane View to set the correct view.
5. From the menu bar, click Results > Plot > Iso.
6. In the panel area, set Result type to Element Densities.
7. Click Apply.
8. In the Current value field, enter 0.3.
9. Under Current value, move the slider to change the density threshold.
Use this tool to get a better look at the material layout and the load paths from OptiStruct.
The iso value in the modeling window update interactively when you scroll to a new value.
Figure 532:
16. Under Result type, select Element Stresses (2D & 3D) (t).
17. Set Averaging method to Simple.
18. Click Apply.
19. In the first window, right-click and select Apply Style > Current Page > Contour from the
context menu.
Figure 533:
Only use these stress results as a reference to help you understand how far from the limits the design
is. Remember that topologic optimization will show you a concept shape. The stress results should be
validated during the next design phases.
Performing topology optimizations early in the conceptual design stage results in the generation of a
good baseline design and contributes to a shorter design cycle. One challenge with post-processing
topology optimization results is that the results may have several intermediate density elements or
checkerboard patterns which can be interpreted either as solid members or as a void. If these semi-
dense elements are interpreted as thin members, the final design is harder to manufacture.
OptiStruct offers the minimum member size control method which provides some control over member
size in the final topology designs by defining the least dimension required in the final design. It helps
achieve a discrete solution by eliminating the intermediate density elements and checkerboard density
pattern, resulting in a discrete and better-reinforced structure, which is easier to interpret and also
easier to manufacture.
Note: It is recommended that the MINDIM value be three times larger than this
average element size unless the element's mesh is aligned; in which case it can be two
times larger.
9. Click Close.
The result files load automatically into HyperMesh and HyperView on completion of the run, so you can
proceed directly to the post-processing step.
Figure 534:
4. On the Standard Views toolbar, click XY Top Plane View to set the correct view.
5. From the menu bar, click Results > Plot > Iso.
6. In the panel area, set Result type to Element Densities.
7. Click Apply.
8. In the Current value field, enter 0.3.
9. Compare the results to the one you achieved in the previous optimization without the application
of minimum member size control, OS-T: 2000 Design Concept for a Structural C-Clip.
The iso value plot displayed is similar to the one previously achieved. The smaller members in
the original iso surface plot are replaced by a more discrete rib pattern. This design is easier to
manufacture.
The finite element mesh contains designable and non-designable regions. Part specifications constrain
the resultant displacement of the point where loading is applied for three load cases to 0.05mm,
0.02mm, and 0.04mm, respectively. The optimal design would use as little material as possible.
Figure 536: Finite Element Mesh Containing Designable (blue) and Non-Designable (yellow) Material
A finite element model representing the designable and non-designable material is imported into
HyperMesh. Appropriate properties, boundary conditions, loads, and optimization parameters are
defined and the OptiStruct software determines 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. Iso surfaces are also used to view the density results. Areas that need reinforcement will
tend towards a density of 1.0.
1. In the Model Browser, right-click and select Create > Material from the context menu.
A default material displays in the Entity Editor.
2. For Name, enter Steel.
3. Set Card Image to MAT1.
4. Enter the material values next to the corresponding fields.
a) For E (Young's Modulus), enter 2.0E5.
b) For NU, (Poisson's Ratio), enter 0.3.
c) For RHO (Mass Density),
A new material, Steel, has been created. The material uses OptiStruct's linear isotropic material model,
MAT1.
1. In the Model Browser, right-click and select Create > Property from the context menu.
A default property displays in the Entity Editor.
Applying Constraints
In this step you will create SPC constraints and assign them to the SPC load collector.
1. From the Model Browser, Load Collectors folder, right-click on SPC and select Make Current from
the context menu.
2. From the Analysis page, click constraints.
3. Set the Load type to SPC.
4. Create the first constraint.
a) Using the nodes selector, select the node at one end of the bushing.
b) Select the degrees of freedom, dof1-dof3; unselect all others.
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.
c) Click create.
A constraint is created. A constraint symbol (triangle) appears at the selected node. The number
123 is displayed beside the constraint symbol, indicating that dof1, dof2 and dof3 are constrained.
Figure 537: Constraining dof1, dof2 and dof3 at One End of the Bushing
Figure 538: Constraining dof2 and dof3 at the Other End of the Bushing
7. Click return.
Tip: For better visualization of the forces, in the uniform size= field, enter 100.
Figure 540: Forces Applied to the Brake, Corner and Pothole Loadcases
For better visualization of the forces, the design component is turned off using the Display panel.
a) For the Corner load step, set SPC to SPC and LOAD to Corner.
b) For the Pothole load step, set SPC to SPC and LOAD to Pothole.
f) Click create.
5. Click return to go back to the Optimization panel.
When the processing is complete, view the file carm_complete.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 the different sections of this file for possible warnings and errors.
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.
9. Click Close.
The default files that get written to your run directory include:
carm_complete.res
HyperMesh binary results file.
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.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the carm_complete.fem file.
carm_complete.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. This file may be used to restart a run.
carm_complete.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and
constraint for each iteration.
carm_complete.oss
OSSmooth file with a default density threshold of 0.3. You may edit the parameters in the file to
obtain the desired results.
carm_complete.stat
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, and so on.
carm_complete.his_data
The OptiStruct history file containing iteration number, objective function values and percent of
constraint violation for each iteration.
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.
The second page has the results from the carm_complete_s1.h3d file. The name of the page is
displayed as Subcase 1 - Brake to indicate that the results correspond to subcase 1.
3. From the Animation toolbar, set the animation mode to linear ( ).
b) Under Deformed shape, set Result type to Displacement (v), set Scale to Model units, set
Type to Uniform, and enter 10 in the Value field.
Specifying a Value of 10 indicates that the maximum displacement will be 10 Model units and
all other displacements will be proportional.
c) Under Undeformed shape, set Show to Wireframe.
d) Click Apply.
A deformed plot of your model with displacement contour should be visible, overlaid on the
original undeformed mesh.
6. From the Animation toolbar, click (Start/Pause) to animate the model.
Figure 541:
9. In the top, right of the application click to move to the third page.
The third page has results loaded from carm_complete_s2.h3d file. The name of the page is
displayed as Subcase 2 - corner to indicate that the results correspond to subcase 2.
10. Repeat the above steps to display the displacement contours and deformed shape of the model for
the second subcase.
Analyze the following:
• 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?
11. Similarly, review the displacements and deformation for subcase 3 (pothole).
Notice: The Result type is set to Element Densities (s) and Density. This should
be the only result type in the carm_complete_des.h3d file.
The density contour displays. The contour is all blue because your results are on the first design
step or Iteration 0.
3. In the Results browser, select Iteration 18.
Each element of the model is assigned a legend color, indicating the density of each element for
the selected iteration.
The Iso value in the modeling window updates interactively when you enter a new value or move
the slider. This feature is useful when you want to get a better look at the material layout and the
load paths from OptiStruct.
Figure 542:
Creating Constraints
In this step you will create constraints at bolt locations.
1. From the Model Browser, Load Collectors folder, right-click on Constraints and select Make
Current from the context menu.
2. From the Analysis page, click constraints.
3. Select the Create subpanel.
4. Double-click nodes and select by id, then enter 1075, 1076 in the id= field.
5. Constrain all dofs.
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.
6. Click create.
7. Click return to go to the main menu.
Two constraints are now created. Constraint symbols (triangles) appear at the selected nodes. The
number 123456 is displayed beside the constraint symbol, indicating that all dofs are constrained.
If the job is successful, new results files should be in the directory where the sshield_analysis.fem
was written. The sshield_analysis.out file is a good place to look for error messages that could help
debug the input deck if any errors are present.
The default files written to the directory are:
sshield_analysis.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
sshield_analysis.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
sshield_analysis.h3d
HyperView binary results file.
sshield_analysis.res
HyperMesh binary results file.
sshield_analysis.stat
Summary, providing CPU information for each step during analysis process.
sshield_analysis.mvw
HyperView session file.
sshield_analysis_frames.html
HTML file used to post-process the .h3d with HyperView Player using a browser. It is linked with
the _menu.html file.
sshield_analysis_menu.html
HTML file to post-process the .h3d with HyperView Player using a browser.
Figure 545:
b) Move the Max Frame Rate slider between 60 and 1 to increase or decrease the animation
speed.
Tip: You can also change the default values for Angular Increment to refine your
animation.
6. On the Page Control toolbar, click the Page Delete icon to delete the HyperView page.
Figure 546:
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 0.300 (the original shell thickness). You
will change this to 1.0 so that the ribs of a maximum height of 0.7 units can be obtained by the
topology optimization.
9. Click return.
10. Edit the thickness of the design property.
a) In the Model Browser, Properties folder, click design.
Defining Constraints
A response defined as the objective cannot be constrained. In this case, you cannot constrain the
response freq1. An upper bound constraint needs to be defined for the response volfrac.
1. Click dconstraints.
2. In the constraint= field, enter volume_constr.
3. Check the box next to upper bound, then enter 0.40.
4. Click response = and select volfrac.
5. Click create.
A constraint is defined on the response volfrac. The constraint is an upper bound with a value of 0.40.
The constraint applies to all subcases as the volumefrac response is a global response. In this step you
are allowing the topology optimization to use additional volume with which it can come with ribsvconstr.
OptiStruct also reports error messages if any exist. The file sshield_optimization.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.
9. Click Close.
The default files that get written to your run directory include:
sshield_optimization.mvw
HyperView session file.
sshield_optimization.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.
sshield_optimization.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the sshield_optimization.fem file.
sshield_optimization.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. This file may be used to restart a run.
sshield_optimization.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and
constraint for each iteration.
sshield_optimization.oss
OSSmooth file with a default density threshold of 0.3. You may edit the parameters in the file to
obtain the desired results.
sshield_optimization.stat
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, and so on.
sshield_optimization.his_data
The OptiStruct history file containing iteration number, objective function values and percent of
constraint violation for each iteration.
sshield_optimization.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.
sshield_optimization.html
HTML report of the optimization, giving a summary of the problem formulation and the results
from the final iteration.
sshield_optimization_frame.html
HTML file used to post-process the .h3d with HyperView Player using a browser. It is linked with
the _menu.html file.
sshield_optimization_menu.html
HTML file used to post-process the .h3d with HyperView Player using a browser.
sshield_optimization_des.H3D
HyperView binary results file that contains: Density results from topology optimizations, Shape
results from topography or shape optimizations and Thickness results from size and topology
optimizations.
sshield_optimization_s1.H3D
HyperView binary results file that contains: Displacement results from linear static analysis,
Element strain energy results from normal mode analysis and Stress results from linear static
analysis, etc.
Figure 547:
Each element of the model is assigned a legend color, indicating the thickness of each element for
the selected iteration.
6. On the Page Control toolbar, click the Page Delete icon to delete the HyperView page.
Figure 549:
Deleting the current model clears the current HyperMesh database. Information stored in .hm files
on your disk is not affected.
If the job is successful, new results files should be in the directory where the sshield_newdesign.fem
was written. The sshield_newdesign.out file is a good place to look for error messages that could help
debug the input deck if any errors are present.
The default files written to the directory are:
sshield_newdesign.html
HTML report of the analysis, providing a summary of the problem formulation and the analysis
results.
sshield_newdesign.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
sshield_newdesign.h3d
HyperView binary results file.
sshield_newdesign.res
HyperMesh binary results file.
sshield_newdesign.stat
Summary, providing CPU information for each step during analysis process.
sshield_newdesign.mvw
HyperView session file.
sshield_newdesign_frames.html
HTML file used to post-process the .h3d with HyperView Player using a browser. It is linked with
the _menu.html file.
sshield_newdesign_menu.html
HTML file to post-process the .h3d with HyperView Player using a browser.
Type Uniform
Value 10
6. Click Apply.
7. Click to start the animation.
An animation of the mode shape should be seen for the first frequency.
8. Click again to stop the animation.
Comparing Results
What is the percentage increase in frequency for your first mode (sshield_analysis.fem vs.
sshield_newdesign)?
You have seen that the frequency of the structure for the first mode has increased from 43.63 Hz to
84.88 Hz.
How much mass has been added to the part (check the mass of your ribs in the mass calc panel in the
Tool page)?
The finite element mesh contains designable (brown) and non-designable regions (blue) is shown in
Figure 551.
3. Click Open.
The controlarm.hm database is loaded into the current HyperMesh session, replacing any existing
data. The database only contains geometric data.
2. Click Responses.
3. Create the volume fraction response.
a) In the responses= field, enter Volfrac.
b) Below response type, select volumefrac.
c) Set regional selection to by entity and no regionid.
d) Click create.
4. Create the weighted component response.
a) In the responses= field, enter Comp1.
b) Below response type, select weighted comp.
c) Click loadsteps, then select all loadsteps.
d) Click return.
e) Click create.
5. Click return to go back to the Optimization panel.
4. Click Save.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to optimization.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to run the optimization.
The following message appears in the window at the completion of the job:
OPTIMIZATION HAS CONVERGED.
FEASIBLE DESIGN (ALL CONSTRAINTS SATISFIED).
OptiStruct also reports error messages if any exist. The file controlarm_opt.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.
9. Click Close.
The default files that get written to your run directory include:
controlarm_opt.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and
constraint for each iteration.
controlarm_opt.hist
The OptiStruct iteration history file containing the iteration history of the objective function and of
the most violated constraint. Can be used for a xy plot of the iteration history.
controlarm_opt.HM.comp.tcl
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.
controlarm_opt.HM.ent.tcl
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.
controlarm_opt.html
HTML report of the optimization, giving a summary of the problem formulation and the results
from the final iteration.
controlarm_opt.mvw
HyperView session file.
controlarm_opt.oss
OSSmooth file with a default density threshold of 0.3. You may edit the parameters in the file to
obtain the desired results.
controlarm_opt.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the controlarm_opt.fem file.
controlarm_opt.res
HyperMesh binary results file.
controlarm_opt.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. This file may be used to restart a run.
controlarm_opt.stat
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, and so on.
controlarm_opt_des.h3d
HyperView binary results file that contain optimization results.
controlarm_opt_frame.html
HTML file used to post-process the .h3d with HyperView Player using a browser. It is linked with
the _menu.html file.
controlarm_opt_hist.mvw
Contains the iteration history of the objective, constraints, and the design variables. It can be
used to plot curves in HyperGraph, HyperView, and MotionView.
controlarm_opt_menu.html
HTML file used to post-process the .h3d with HyperView Player using a browser.
controlarm_opt_s#.h3d
HyperView binary results file that contains from linear static analysis, and so on.
The resulting contours represent the displacement field resulting from the applied loads and boundary
conditions.
In this model, refining the mesh should provide a more discrete solution; however, for the sake of this
tutorial, the current mesh and results are sufficient.
Figure 552:
A displacement plot for the last iteration displays. The stress results are also available for the
respective iterations.
Figure 555: Displacement Contour for the First Loadstep at the Last Iteration
Figure 556: Displacement Contour for the Second Loadstep at the Last Iteration
The objective of this tutorial is to minimize the weighted compliance through all three load cases. The
volume fraction of the weld component is limited to 0.3. The design space is the spot weld component.
Figure 557:
3. Click Open.
The hut.hm database is loaded into the current HyperMesh session, replacing any existing data.
The database only contains geometric data.
The objective of this tutorial is to minimize the compliance for the single subcase. The volume fraction
of the design space is limited to 0.3. The design spaces are the three plates.
Figure 559:
5. Click Apply.
6. Change the density threshold.
• In the Current value field, enter 0.4.
• Under Current value, move the slider.
7. Set Show values to Above.
8. Under Clipped geometry, select Features and Transparent.
An isosurface plot is displayed. The elements with a density greater than the value of 0.4 are
shown in color, the rest are transparent.
Figure 560:
9. On the Page Controls toolbar, click the Delete Page icon to delete the HyperView page.
Figure 561:
Figure 562:
You have identified the first DTPL card with ID 1 (on the first component) as the master, and the DTPL's
of ID 2 (second component) and ID 3 (third component) as the slaves, which are dependent on the
DTPL of ID1. The second component is scaled 0.6 in both the x- and y-axis, while the third component
is scaled 0.3 in both the x- and y-axis with respect to the first component.
9. Click Close.
5. Click Apply.
6. Change the density threshold.
• In the Current value field, enter 0.38.
• Under Current value, move the slider.
7. Set Show values to Above.
8. Under Clipped geometry, select Features and Transparent.
An isosurface plot is displayed. The elements with a density greater than the value of 0.38 are
shown in color, the rest are transparent.
Figure 564:
9. On the Page Controls toolbar, click the Delete Page icon to delete the HyperView page.
Figure 565:
This tutorial uses the same optimization problem considered in OS-T: 2010 Design Concept for an
Automotive Control Arm, except that a refined mesh will be used in order to better capture the effect of
applying symmetric and draw manufacturing constraints simultaneously. The finite element mesh of the
structural model containing the designable (blue) and the non-designable (red) regions, along with the
loads and constraints applied.
Figure 566:
Figure 567:
Figure 568:
OptiStruct also reports error messages if any exist. The file carm_draw_symm_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.
9. Click Close.
2. In the top, right of the application, click to return to the Design History page, indicating that
the results correspond to optimization iterations.
3. From the Results toolbar, click to open the Contour panel.
4. Verify that the Result type is set to Element Densities[s] and Density.
This should be the only result type in the carm_draw_symm_complete_des.h3d file.
5. Set the Averaging method to Simple.
6. Click Apply to display the density contour.
The contour is all blue because the results are on the first design step or Iteration 0.
7. In the Results Browser, select the last iteration listed.
Each element of the model is assigned a legend color, indicating the density of each element for
the selected iteration.
Figure 569:
3. Click Apply.
An Iso Plot displays.
4. Change the density threshold.
• In the Current value field, enter 0.2.
• Under Current value, move the slider.
When you update the density threshold, the Iso value displayed in the modeling window updates
interactively. Use this tool to get a better look at the material layout and the load paths from
OptiStruct.
The parts of the model with densities greater than the specified value of 0.2 display.
Review questions:
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).
Has the volume been minimized for the given constraints?
Design Variables The density for each element in the design space.
Figure 572: Topology Optimization Results for the Full Cantilever Beam Model
The part to be reduced out of the model through the static reduction model reduction technique is
referred to as a superelement. In OptiStruct, ASET or ASET1 Bulk Data Entries are required to indicate
the boundary degrees of freedom of a superelement, meaning the set of degrees-of-freedom where
the component (being replaced by direct matrix input) connects to the modeled structure. Both the
accuracy and the cost of static reduction increase as the number of ASET entries is increased. For
example, by using static reduction, the size of the matrix to solve will become smaller, but if the
reduced matrix (DMIG) is very dense, then the solution time will become larger than the solution
time for the full model where the matrix may be sparse. Hence, the selection of ASET entries is very
important in performing an efficient analysis using DMIG.
In order to prevent the reduced matrix from being too dense, ASET entries are chosen carefully (see the
next figure) instead of creating ASET entries for all of the boundary nodes between the design and non
design spaces. Due to the small size of the problem used for this tutorial, the selection of ASET entries
may not affect the solution time.
Generating a Superelement
Figure 574:
Figure 575:
If the job is successful, new results files should be in the directory where the cantilever_dmig.fem
was written. The cantilever_dmig.out file is a good place to look for error messages that could help
debug the input deck if any errors are present.
The default files written to the directory are:
cantilever_dmig.out
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 of the optimization iterations, and compute time information. Review this file
for warnings and errors.
cantilever_dmig.stat
Summary of analysis process, providing CPU information for each step during analysis process.
cantilever_dmig_AX.pch
Reduced matrices (DMIG) file.
The matrices are written to the .pch file with the same format as the DMIG bulk data entry. They are
defined by a single header entry and one or more column entries. By default, the name of the stiffness
matrix is KAAX, the mass is MAAX, and the load is PAX. Since mass matrix is not used in this tutorial, it
is not written to .pch file.
The I/O Option Entry, DMIGNAME, provides you with control over the name of the matrices.
Figure 577:
2. In the Save As dialog, enter cantilever_opti.hm for the file name and save it to your working
directory.
The default files that get written to your run directory include:
cantilever_opti.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and
constraint for each iteration.
cantilever_opti.HM.comp.tcl
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.
cantilever_opti.HM.ent.tcl
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.
cantilever_opti.html
HTML report of the optimization, giving a summary of the problem formulation and the results
from the final iteration.
cantilever_opti.oss
OSSmooth file with a default density threshold of 0.3. You may edit the parameters in the file to
obtain the desired results.
cantilever_opti.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the cantilever_opti.fem file.
cantilever_opti.res
HyperMesh binary results file.
cantilever_opti.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. This file may be used to restart a run.
cantilever_opti.stat
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, and so on.
cantilever_opti_des.h3d
HyperView binary results file that contain optimization results.
cantilever_opti_s#.h3d
HyperView binary results file that contains from linear static analysis, and so on.
The resulting contours represent the element densities field resulting from the applied loads and
boundary conditions.
Figure 578:
When you update the density threshold, the Iso value displayed in the modeling window updates
interactively. Use this tool to get a better look at the material layout and the load paths from
OptiStruct.
Figure 579:
The structural model is loaded into HyperMesh Desktop. The constraints, loads, subcases and material
properties are already defined in the model. The topology design variables and the optimization problem
setup will be defined using HyperMesh, and OptiStruct is used to determine the optimal material layout.
The results can then be reviewed in HyperView.
2. Click topology.
3. Select the create subpanel.
4. In the desvar= field, enter shells.
5. Set type: to PSHELL.
6. Using the props selector, select Design and Base.
7. Click create.
8. Update the design variable's parameters.
a) Select the parameters subpanel.
b) Toggle minmemb off to mindim=, then enter 1.0.
c) Under stress constraint, toggle none to stress= and enter 1000.
d) Click update.
9. Click return.
Applying Constraints
There is no need for additional constraints, since setting a stress target in the design variable serves as
a constraint that limits the amount of material used in the optimized model.
d) In the Results Browser, select Design and Iteration 26 (or your final iteration number).
Figure 581:
Figure 582:
d) Click Apply.
e) In the Current value field, change the value to see the results with varying density values.
When you update the density threshold, the Iso value displayed in the modeling window
updates interactively. Use this tool to get a better look at the material layout and the load
paths from OptiStruct.
You will 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.
Note: There might still be high local stress regions which can be improved more effectively
with local shape and size optimization.
This tutorial show the steps involved in defining topology optimization over a curved beam, simulating a
rail, over which a vehicle is moving. Both ends of the beam are supported. A point load is applied over
the length of the rail in seven independent load cases, simulating the movement of the vehicle. The
rail should be manufactured through extrusion. The steps taken to define the topology design space,
the extrusion-manufacturing constraints and the optimization parameters (responses, objective and
constraints) using HyperMesh are shown.
The DTPL (Design Variable for Topology Optimization) card is used for this optimization.
In this tutorial, you will perform topology optimization on a curved beam so that the extruded rail will
be stiffer and have less material.
Figure 585: Finite Element Mesh of the Curved Beam with Loads and Boundary Conditions
b) Click nodes > by id, then enter 71559,70001 in the id= field.
c) Select display.
d) Click on.
e) Click return.
2. Define extrusion path.
a) In the topology subpanel, select the extrusion subpanel..
b) Double-click desvar = and select design_solid.
c) Switch from none to no twist.
Extrusion constraints can be applied to domains characterized by non-twisted cross-sections
or twisted cross-sections by using the NOTWIST or TWIST parameters, respectively.
d) Click node list > by path, then select node 71559 first and node 70001 second.
e) Click update.
A line of nodes starting from 71559 and ending with node 70001 should be highlighted, indicating
the extrusion path.
It is not required to select as many nodes to define the curve. This is an exercise to show that the
nodes by path option can also be used.
The curve between these grids is then interpolated using parametric splines. The minimum
amount of grids depends on the complexity of the extrusion path. Only two grids are required for
a linear path, but it is recommended that at least 5-10 grids be used for more complex curves.
OptiStruct also reports error messages if any exist. The file rail_complete_extrusion.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.
9. Click Close.
Figure 587:
3. From the Results toolbar, click to open the Iso Value panel.
The result with manufacturing extrusion constraints permits a constant cross section for the entire
length of the model.
The result with manufacturing extrusion constraints shows constant cross section through the length of
the model.
Initially, an existing finite element (FE) model of a flat plate is retrieved and modal frequency response
analysis is performed to derive the peak magnitude. A dynamic response optimization is then performed
on the same plate to obtain a new design.
The new design gives an optimized material layout with a minimized peak response. Post-processing
tools will be used in HyperView to visualize iso-plots, magnitude, and phase of the complex
displacement results.
Design Variables The density for each element in the design space.
Figure 591:
a) In the Model Browser, right-click and select Create > Load Collector from the context
menu.
A default load collector displays in the Entity Editor.
b) For Name, enter unit-load.
c) Click Color and select a color from the color palette.
d) Set Card Image to None.
Creating Constraints
1. From the Model Browser, Load Collectors folder, right-click on spc and select Make Current from
the context menu.
Figure 592:
b) Click nodes > by id, and enter 1,2,3,4 in the id= field.
c) Click on.
d) Click return.
3. From the Analysis page, click the constraints panel.
4. Select the create subpanel.
5. Apply constraints to the nodes with IDs 1 and 2.
a) Using the nodes selector, select the nodes with IDs 1 and 2.
b) Select dof1 - dof6.
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.
c) Click create.
6. Apply a constraint to the node with ID 4.
a) Using the nodes selector, select the node with ID 4.
b) Uncheck all dofs except dof3.
c) Click create.
7. Creating a unit load at a point on the flat plate.
a) From the Model Browser, Load Collectors folder, right-click on unit-load and select Make
Current from the context menu.
b) In the Constraints panel, use the nodes selector to select the node with ID 3.
c) Uncheck all dofs except dof3.
d) In the dof3= field, enter 20.
e) Click load types= and select DAREA.
f) Click create.
8. Click return to go to the main menu.
Figure 594:
A frequency range of 0.0 to 1000.0 with a constant load over this range is created.
Figure 595:
Figure 596:
A set of frequencies is defined for the modal method of frequency response analysis by specification of a
frequency range and fractions of the natural frequencies within that range.
Figure 597:
An OptiStruct subcase has been created which references the constraints in the load collector spc, the
unit load in the load collector rload2; with a set of frequencies defined in load collector freq5 and modal
method defined in the load collector eigrl.
It is recommended to do a modal analysis before any FRF simulation. Here, this step is suppressed to
focus on Frequency Response Analysis setup.
With FRF simulation, the amount of data generated can easily create big results files. It is a good
practice to work with sets where you can specify only the points of interest. This reduces the CPU time
and the amount of data to be saved.
Figure 598:
If the job is successful, new results files should be in the directory where the
frf_response_analysis.fem was written. The frf_response_analysis.out file is a good place to look
for error messages that could help debug the input deck if any errors are present.
Figure 600:
4. From the Curves toolbar, click to open the Define Curves panel.
8. Click the Symbol Attributes tab, and select the square symbol.
Figure 601:
Figure 602:
11. Click the Scale and Tics (Magnitude) tab, and select Logarithmic.
12. In the Min field, enter 5.
13. In the Max field, enter 200000.
14. Click the Scale and Tics (Phase) tab, and change the Tics per axis to 7.
15. Set the Axis to Horizontal.
Figure 603:
18. From the Curves toolbar, click to open the Coordinate Info panel.
Figure 605:
20. Click the maximum button to see the maximum Y-magnitude ~ 15055 in the table. The peak
displacement of the baseline model.
Figure 606:
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 0.15 (the original shell thickness). You will
change this to a higher value to create a design space where the material can be removed.
9. Update the design variable's parameters.
a) Select the parameters subpanel.
b) Toggle minmemb off to mindim=, then enter 2.0.
c) Toggle maxmemb off to maxdim=, then enter 6.0.
d) Click update.
10. Click return.
11. Edit the thickness of the design property.
a) In the Model Browser, Properties folder, click design.
b) In the Entity Editor, T field, enter 1.000.
4. Click Save.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to optimization.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to run the optimization.
The following message appears in the window at the completion of the job:
OPTIMIZATION HAS CONVERGED.
FEASIBLE DESIGN (ALL CONSTRAINTS SATISFIED).
OptiStruct also reports error messages if any exist. The file frf_response_optimization.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.
9. Click Close.
The default files that get written to your run directory include:
frf_response_optimization.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and
constraint for each iteration.
frf_response_optimization.HM.comp.tcl
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.
frf_response_optimization.HM.ent.tcl
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.
frf_response_optimization.html
HTML report of the optimization, giving a summary of the problem formulation and the results
from the final iteration.
frf_response_optimization.oss
OSSmooth file with a default density threshold of 0.3. You may edit the parameters in the file to
obtain the desired results.
frf_response_optimization.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the frf_response_optimization.fem file.
frf_response_optimization.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. This file may be used to restart a run.
frf_response_optimization.stat
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, and so on.
frf_response_optimization_des.h3d
HyperView binary results file that contain optimization results.
frf_response_optimization_s#.h3d
HyperView binary results file that contains from linear static analysis, and so on.
frf_response_optimization.his_data
The OptiStruct history file containing iteration number, objective function values and percent of
constraint violation for each iteration.
Figure 607:
Figure 609:
Figure 610: Original and Final Design Results for the Plate
You will setup the model in HyperMesh, and run the Topology optimization job with OptiStruct.
The Objective of the optimization is to maximize the stiffness of the Lower arm of an excavator model,
while keeping the mass to less than an allowable value. The model units are kg, N, m and s.
Design Variables Element density of elements in the lower arm (flexible body)
component.
If the job is successful, new results files should be in the directory where the
excavator_MBD_analysis.fem was written. The excavator_MBD_analysis.out file is a good place to
look for error messages that could help debug the input deck if any errors are present.
4. On the Page Controls toolbar, click to delete the page, close HyperView, and return to
HyperMesh.
7. Click update.
A message appears in the lower left corner to indicate that the body has been update to a new
type.
8. Click return.
A constraint is defined on the response Volfrac. The constraint will force the volume fraction used in the
design space to be less than 0.5.
Figure 614:
4. From the Results toolbar, click to open the Iso Value panel.
Figure 615:
Figure 616:
You will use a finite element model of the design space with loads and constraints in this tutorial. It
is assumed that the part is to be formed using a stamping process. The objective is to minimize the
displacement of the node where the force is applied in the positive z-direction. Only the shape of the
plate can be changed to achieve the objective, not the thickness.
Figure 617: Finite Element Model of the Design Space with Loads and Constraints
A finite element model 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 determines 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.
A topography design space definition, topo, has been created. All elements organized into the
design component collector(s) are now included in the design space.
4. Create a bead definition for the design space topo.
a) Select the bead params subpanel.
b) Verify the desvar = field is set to topo, which is the name of the newly created design space.
c) In the minimum width= field, enter 5.0.
This parameter controls the width of the beads in the model. The recommended value is
between 1.5 and 2.5 times the average element width.
d) In the draw angle= field, enter 60.0 (this is the default).
This parameter controls the angle of the sides of the beads. The recommended value is
between 60 and 75 degrees.
e) In the draw height=, enter 4.0.
This parameter sets the maximum height of the beads to be drawn.
f) Select buffer zone.
This parameter establishes a buffer zone between elements in the design domain and
elements outside the design domain.
g) Toggle draw direction to normal to elements.
This parameter defines the direction in which the shape variables are created.
h) Set boundary skip to load and spc.
This tells OptiStruct to leave nodes at which loads or constraints are applied out of the design
space.
i) 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.
5. Update the bounds of the design variable.
a) Select the bounds subpanel.
b) Verify the desvar = field is set to topo, which is the name of the design space.
c) In the Upper Bound= field, enter 1.0.
Upper bound on variables controlling grid movement (Real > LB, default = 1.0). This sets the
upper bound on grid movement equal to UB*HGT.
d) In the Lower Bound= field, enter 0.0.
e) 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.
6. Click return to go to the Optimization panel.
2. Click Responses.
3. Create the displacement response.
a) In the response= field, enter displace.
b) Below response type, select static displacement.
c) Click nodes > by id, then enter 2500 in the id= field.
d) Set the displacement type to dof3.
e) Click create.
4. Click return to go back to the Optimization panel.
The following message appears in the window at the completion of the job:
OPTIMIZATION HAS CONVERGED.
FEASIBLE DESIGN (ALL CONSTRAINTS SATISFIED).
OptiStruct also reports error messages if any exist. The file torsion_plate.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.
9. Click Close.
The default files that get written to your run directory include:
torsion_plate.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and
constraint for each iteration.
torsion_plate.hist
The OptiStruct iteration history file containing the iteration history of the objective function and of
the most violated constraint. Can be used for a xy plot of the iteration history.
torsion_plate.html
HTML report of the optimization, giving a summary of the problem formulation and the results
from the final iteration.
torsion_plate.oss
OSSmooth file with a default density threshold of 0.3. You may edit the parameters in the file to
obtain the desired results.
torsion_plate.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the torsion_plate.fem file.
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. This file may be used to restart a run.
torsion_plate.stat
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, and so on.
torsion_plate_des.h3d
HyperView binary results file that contain optimization results.
torsion_plate_s#.h3d
HyperView binary results file that contains from linear static analysis, and so on.
torsion_plate.grid
An OptiStruct file where the perturbed grid data is written.
Figure 618:
4. On the Animation toolbar, click to choose the last iteration from the Simulation list.
A deformed plate appears.
5. Click Apply.
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.
Figure 620:
4. With the animation running, use the slider bar, below Max Frame Rate, to adjust the speed of the
animation.
5. Click to pause the animation.
This page has the subcase information from the torsion_plate_s1.h3d file.
2. On the Animation toolbar, set the animation mode to Linear Static.
Tip: For a better visual of what it happening with this model, turn on mesh lines and
contour the results.
Figure 621:
9. With the animation running, use the slider bar, below Max Frame Rate, to adjust the speed of the
animation.
A deformation animation of the original model is shown.
Does the deformed shape look correct for the boundary conditions you applied to the mesh?
10. Click to stop the animation.
11. On the Page Controls toolbar, click to delete the HyperView page.
The configuration obtained in the previous example (see the contour plot showing the reinforcement
pattern at the 17th iteration) might be difficult to manufacture. It does give an idea of what kinds of
patterns are likely to optimize the structure (in this case -- to minimize the displacement at the selected
node).
A possible pattern, suggested by the static contour plot obtained in the previous exercise, is to use
channels parallel to a diagonal. In this example, you choose the diagonal emerging from the node
where the load is applied.
9. Click update.
10. Click return twice to go to the main menu.
OptiStruct also reports error messages if any exist. The file torsion_pattern.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.
9. Click Close.
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?
The bracket is modeled with shell elements. The objective is to maximize the frequency of the first
mode by introducing beads or swages to the bracket. This can be achieved by using topography
optimization. The regions around the holes are specified as non-designable, while the bulk of the
bracket is available for developing stiffening beads.
In this step, the values of a bead width of 15mm, a bead height of 5mm, and draw angle of 85 degrees
will be used. Symmetry of the bead pattern should be forced along the symmetry line of the design
space.
b) Verify the desvar = field is set to topo, which is the name of the newly created design space.
c) In the minimum width= field, enter 15.0.
This parameter controls the width of the beads in the model. The recommended value is
between 1.5 and 2.5 times the average element width.
d) In the draw angle= field, enter 85.0 (this is the default).
This parameter controls the angle of the sides of the beads. The recommended value is
between 60 and 75 degrees.
e) In the draw height=, enter 5.0.
This parameter sets the maximum height of the beads to be drawn.
f) Select buffer zone.
This parameter establishes a buffer zone between elements in the design domain and
elements outside the design domain.
g) Toggle draw direction to normal to elements.
This parameter defines the direction in which the shape variables are created.
h) Set boundary skip to load and spc.
This tells OptiStruct to leave nodes at which loads or constraints are applied out of the design
space.
i) 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.
5. Adding pattern grouping constraints.
a) Select the pattern grouping subpanel.
b) Click desvar = and select topo.
c) Set the pattern type to 1-pln sym.
d) Click anchor node, and enter 337 in the id= field.
e) Click first node, and enter 613 in the id= field.
f) Click update.
6. Update the bounds of the design variable.
a) Select the bounds subpanel.
b) Verify the desvar = field is set to topo, which is the name of the design space.
c) In the Upper Bound= field, enter 1.0.
Upper bound on variables controlling grid movement (Real > LB, default = 1.0). This sets the
upper bound on grid movement equal to UB*HGT.
d) In the Lower Bound= field, enter 0.0.
e) 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.
7. Click return to go to the Optimization panel.
The default files that get written to your run directory include:
Lbkttopog.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and
constraint for each iteration.
Lbkttopog.hist
The OptiStruct iteration history file containing the iteration history of the objective function and of
the most violated constraint. Can be used for a xy plot of the iteration history.
Lbkttopog.html
HTML report of the optimization, giving a summary of the problem formulation and the results
from the final iteration.
Lbkttopog.oss
OSSmooth file with a default density threshold of 0.3. You may edit the parameters in the file to
obtain the desired results.
Lbkttopog.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the Lbkttopog.fem file.
Lbkttopog.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. This file may be used to restart a run.
Lbkttopog.stat
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, and so on.
Lbkttopog_des.h3d
HyperView binary results file that contain optimization results.
Lbkttopog_s#.h3d
HyperView binary results file that contains from linear static analysis, and so on.
Lbkttopog.grid
An OptiStruct file where the perturbed grid data is written.
Figure 625:
5. Move the Max Frame Rate slider to adjust the animation speed.
The frequencies of all of the modes requested from the analysis are shown in the Subcase drop-down.
Look at the frequency values for the last iteration. Upon observation, the frequency for the first mode
has changed from around 48 Hz to around 93 Hz for first and last iterations, respectively.
2. On the Animation toolbar, click to set the Current time to the last step.
The objective of autobead is to offer automation of bead interpretation so that a prototype-like design
could be created automatically.
Figure 630:
3. In the Results Browser, from the list of load cases, toggle between Iteration 0 and Iteration 12.
Figure 631:
The topography optimization yields an almost 100% increase in the frequency of the first mode by
reviewing the Mode 1-F value in the Simulation list.
4. Click to animate the model.
Tip: 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.
Figure 632:
2. In the file: field, select the OptiStruct base input file from which to extract the final geometry.
3. In the output: field, select the IGES output format of the final geometry.
• The default output format is STL. Other format options are: Mview, Nastran, IGES, and H3D.
• If you select IGES as the output format, select the output unit type. The default is mm
(millimeters).
4. Select load geom to load the new geometry into the current HyperMesh session.
5. Select autobead, and enter 0.3 for the bead threshold.
6. Leave the rest of the options at their default settings.
7. Click OSSmooth.
8. Click Yes to overwrite.
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.
9. Click FE > Surf to generate new geometry from the optimization results.
10. Click Save and Exit to continue.
11. In the Mask browser, click Isolate for Geometry and click Hide for Load Collectors.
Figure 633:
12. In the Model Browser, uncheck geometry display for the original components design and fixed.
Figure 634:
Figure 635:
In this step, the design space is composed of the shell elements with the property PSHELL_5. A
minimum bead width of 0.4, a bead height of 1, and draw angle of 60 degrees is used in the bead
definition. A 2-plane symmetrical pattern grouping constraint is defined to generate a symmetrical bead
design.
Figure 637:
e) Click update.
6. Update the bounds of the design variable.
a) Select the bounds subpanel.
b) Verify the desvar = field is set to plate, which is the name of the design space.
c) In the Upper Bound= field, enter 1.0.
Upper bound on variables controlling grid movement (Real > LB, default = 1.0). This sets the
upper bound on grid movement equal to UB*HGT.
d) In the Lower Bound= field, enter -1.0.
e) 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.
7. Click return to go to the Optimization panel.
How much was the peak value of the PSD acceleration reduced?
Figure 639: PSD Acceleration Plots of the Original and the Optimized Designs
• OS-T: 3100 Combined Topology and Topography Optimization of a Slider Suspension (p. 692)
• OS-T: 3200 Design of a Composite Aircraft Underbelly Fairing (p. 700)
• OS-T: 3300 Lattice Optimization Process (p. 726)
• OS-T: 3400 Design an Open Hole Tension (OHT) (p. 741)
OptiStruct Tutorials
Combination Optimization p.692
The objective of this tutorial is to increase the stiffness of the slider suspension and make it lighter at
the same time. This requires the use of both topology and topography optimization.
The finite element model of the slider suspension contains force and boundary conditions. The structure
is made of quad elements and has both linear statics and normal modes subcases (loadsteps). Steps
are described to define topology and topography design space, responses, constraints, and objective
function. The optimized structure will be stiffer for both linear statics and normal modes subcases and
will have beads and less material.
Problem Statement
Perform combined topology and topography optimization on a disk drive slider suspension to maximize
the stiffness and weighted mode. The lower bound constraint on the seventh mode is 12 cycles/ms.
Objective Function Minimize the combined weighted compliance and the weighted
modes.
th
Constraints 7 Mode > 12 cycles/ms.
Mode Weight
1 1.0
2 2.0
3 1.0
Mode Weight
4 1.0
5 1.0
6 1.0
f) Click create.
5. Click return to go back to the Optimization panel.
An iso-surface plot is displayed. Those parts of the model with a density greater than the value of 0.3
are shown in with density contour, the rest are removed from the display.
Figure 642:
Phase 2: Design Fine Tuning Design fine tuning Size optimization identifies the optimal
(Size Optimization) thicknesses of each ply bundle.
Phase 3: Ply Stacking Sequence Ply stacking sequence optimization Shuffling optimization obtains
Optimization an optimal stacking sequence.
The process expands upon three important and advanced optimization techniques; free-size
optimization, size optimization and ply stacking sequence optimization. By stringing these three
techniques together, OptiStruct offers a unique and comprehensive process for the design and
optimization of composite laminates. The process is automated and integrated in HyperWorks by
generating the input data for a subsequent phase automatically from the previous design phase.
Model Definition
The finite element model of the underbelly fairing was generated in HyperMesh. Material properties for
carbon-fiber were considered and represented using an orthotropic material (MAT8) for two dimensional
elements. The fairing was modeled with four ply orientations (0°, 90°, 45° and -45°) of uniform
thickness. The SMEAR option is applied in the PCOMP card to eliminate stack biasing.
Two load cases were defined to represent the operating conditions - an internal uniform pressure
loading of 0.02MPa and an external gravity loading of 6.75g. The fairing was considered to be riveted
along its edges to the surrounding structure. Two equipment masses, weighing 2Kg and 3Kg each, were
mounted to the fairing through RBE3 elements. The fairing has been designed considering two major
performance criteria: the first natural frequency is at least 20Hz, and the maximum strain is less than
1000 micro-strain.
Figure 643:
The following optimization setup is defined in the concept design phase to identify the stiffest design
for the given fraction of the material. To obtain more meaningful results, manufacturing constraints are
incorporated and carried through all design phases automatically.
Objective Minimize the weighted compliance of the two load cases.
Manufacturing Constraints Ply percentage for the 0s no more than 80% exist.
This loads the 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 for
OptiStruct.
h) Select BALANCE.
i) In the DSIZE_NUMBER_OF_BALANCE= field, 1.
A BALANCE continuation line is added to the DSIZE data entry.
j) Define the PLYPCT, BALANCE and PLYMAN constraints as shown in Figure 644.
Figure 645: Requesting CSTRAIN and CSTRESS results output to the .h3d file
a) Click OUTPUT.
b) In the number_of_outputs field, enter 1.
c) Set KEYWORD to FSTOSZ.
d) Set FREQ to YES.
e) Click return.
OptiStruct automatically generates a sizing model after free-size optimization.
Figure 646: Requesting the free-size to size (FSTOSZ) optimization output file for Phase 2
The default files that get written to your run directory include:
fairing_freesize.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the fairing_freesize.fem file.
fairing_freesize_des.h3d
HyperView binary results file that contain optimization results.
fairing_freesize_s#.h3d
HyperView binary results file that contains from linear static analysis, and so on.
fairing_freesize_sizing.*.fem
A ply-based sizing optimization input file generated during free-sizing phase. This resulting deck
contains PCOMPP, STACK, PLY, and SET cards describing the ply-based composite model, as well as
DCOMP, DESVAR, and DVPREL cards defining the optimization data. The * sign represents the final
iteration number.
fairing_freesize_sizing.*.inc
An ASCII include file contains the same ply-based modeling and optimization data as in the input
deck. The * sign represents the final iteration number.
5. Click Apply.
6. On the Standard Views toolbar, click to view the results in the X-Y plane.
The element thickness results from the free-size optimization are shown in the following image. The
regions indicated in red or in colors tending towards red (from the legend) can be interpreted as thicker
regions, while those in blue or tending towards blue are thinner regions. The contour plot indicated
above is the total thickness distribution that includes contributions from each ply orientation, i.e. a
thickness contribution from the 0s, +/-45s and the 90s. It also indicates the shape and layout of plies
per orientation as can be seen in the ply thickness plot.
5. Create the ply thickness contours for super-ply 2 (45°), 3 (-45°), and 4 (90°) by selecting Layers
2, 3 and 4, respectively in the Contour panel.
Due to the balance constraint applied, the thickness distribution of the +45° and the -45° super
ply are the same.
Tip: You can review ply bundles in the Model Browser, Plies folder. Click any ply to
view it's corresponding card data in the Entity Editor.
Figure 653: Element set 5 representing ply bundle 1 of the +45 degree super ply
Figure 654: Element set 6 representing ply bundle 2 of the +45 degree super ply
Figure 655: Element set 7 representing ply bundle 3 of the +45 degree super ply
Figure 656: Element set 8 representing ply bundle 4 of the +45 degree super ply
The shapes of the plies as indicated through the element set can be used as-is in design Phase 2:
Design Fine Tuning (Size Optimization), or modified easily by updating the element sets in HyperMesh
to improve the manufacturability. In this case, the element sets are used as-is.
Manufacturing constraints are preserved and transferred to the DCOMP card. A minimum manufacturable
ply thickness of 0.1, defined in Phase 1: Reference Design Synthesis (Free-Size Optimization), is
transferred to the PLY card. It allows for the optimal ply bundle thicknesses to be a multiple of the
minimum ply thickness value, and helps in calculating the total number of plies required per fiber
orientation.
Figure 657:
The responses defined in free-sizing phase are deleted. The constraint and objective function defined
based on them are automatically removed.
Creating Constraints
The responses of frequency and composite strain are defined as the optimization constraints.
1. From the Optimization panel, click the dconstraint panel.
2. Create the constraint, freq1.
a) In the constraint= field, enter freq1.
b) Click response= and select freq1.
c) Check the box next to lower bound, then enter 0.02.
d) Using the loadsteps select, select norm_modes.
e) Click create.
3. Repeat step 2 to create the constraints freq2, freq3, freq4, and freq5 respectively with the same
lower bound of 0.02.
4. Create the constraint, cstrain.
a) In the constraint= field, enter cstrain.
b) Click response= and select cstrain.
c) Check the box next to upper bound, then enter 0.001.
d) Using the loadsteps select, select gravity and pressure.
e) Click create.
5. Click return to go back to the Optimization panel.
Figure 659:
The default files that get written to your run directory include:
fairing_size.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the fairing_size.fem file.
fairing_size_des.h3d
HyperView binary results file that contain optimization results.
fairing_size_s#.h3d
HyperView binary results file that contains from linear static analysis, and so on.
fairing_size_shuffling.*.fem
A ply stacking optimization input deck. The DESVAR and DVPREL cards from the previous stage
are removed, and a bare DSHUFFLE card is introduced. The * sign represents the final iteration
number.
fairing_size_shuffling.*.inc
An ASCII include file containing ply stacking optimization data.
Figure 660:
5. In the Contour panel, set the Result type to Orientation Thicknesses (s).
The thickness contour for each ply orientation displays.
6. Set the Result type to Ply Thicknesses (s).
The thickness contour for each ply bundle displays.
After the free-size and size optimizations, a weight reduction of ~65% of the original design was
achieved without violating any of the prescribed design constraints. The optimum ply shape and patch
locations in Phase 1: Reference Design Synthesis (Free-Size Optimization), and subsequently optimized
ply bundle thicknesses in Phase 2: Design Fine Tuning (Size Optimization), have been established, and
allow us to determine the required number of plies. In the third and final phase of the design process
you will try to identify a proposal for the optimal stacking sequence of the plies.
It is important that design performances are preserved. Hence, the optimization problem is retained as
previously formulated in the size optimization phase. Two manufacturing constraints are applied:
• The maximum successive number of plies of a particular orientation does not exceed 4 plies.
• The + 45s and - 45s are reversed paired.
Figure 661:
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to optimization.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to run the optimization.
The following message appears in the window at the completion of the job:
OPTIMIZATION HAS CONVERGED.
FEASIBLE DESIGN (ALL CONSTRAINTS SATISFIED).
OptiStruct also reports error messages if any exist. The file fairing_shuffling.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.
9. Click Close.
The history of the shuffling optimization displays. The columns represent the global trend of the ply
stacking sequence at a particular iteration, with the last column being the final solution. The plies are
color coded based on their fiber orientations. The weight of the fairing has not been changed during the
shuffling design phase.
This light weight design therefore meets all of the performance requirements, is feasible and
manufacturable.
Lattice Optimization in OptiStruct is a two-phase process to create blended Solid and Lattice structures
from concept to the detailed final design. The first phase performs a concept-level topology optimization
to optimally partition solid, void, and intermediate space and create the lattice elements. The second
phase optimizes the size of each lattice element to determine the final optimized structure. The
completed model can then be manually reinterpreted to fit a number of different manufacturing
operations, including, but not limited to, 3D printing.
Figure 663:
Problem Statement
Geometry Control Arm, sectioned into non-design and designable
components.
Figure 664:
The Model Browser shows that there is already an optimization set up.
Figure 665:
Lattice optimization differs from topology as a concept-level optimization in that elements with
intermediate densities will be mathematically interpreted as solid, lattice, or void, depending on your
settings in the setup phase. You will add continuation cards and parameters in a text editor to change
this from standard topology to lattice optimization.
Figure 666:
Figure 667:
Field Descriptions
Field Descriptions
1 Sets the lattice type (LT) according to the solid element type
that it is replacing. 1 is the default or enter 2 as an option.
Element Types
0.1 The lower bound (LB) for lattice structure. Any elements with
a topology density below this value is considered void (empty)
at the end of Phase I.
0.7 The upper bound (UB) for lattice structure. Anything above
this element density in the optimization is considered fully
solid. Elements where element density is between the lower
and upper bound are considered porous and is replaced by
lattice elements at the end of Phase I.
200. Sets a stress constraint target for optimization for the second
phase of lattice optimization (LATSTR). That means for Phase
II, OptiStruct will automatically create a stress constraint
(refer to Lattice Structure Optimization in the User Guide).
The stress target for Phase I (via the STRESS continuation card
which was already present in this deck and set to 200), is not
automatically "copied" to Phase II.
5. Save controlarm.fem.
DOPTPRM,POROSITY,MED
DOPTPRM,LATLB,CHECK
DOPTPRM indicates that optimization parameters to control the optimization are being added.
DOPTPRM, POROSITY determines the penalty factor applied to all designable elements throughout
the optimization. In regular topology optimization, a penalty is applied to avoid medium dense
elements by significantly reducing their stiffness. In Lattice optimization, medium dense elements
can be accepted as they can be manufactured as a lattice structure. You can apply a smaller
penalty or nothing, which controls the number of medium dense elements and consequently
lattice type elements. This parameter has three options:
LOW: Sets the penalty factor to 1.8. This setting accurately represents the structural
relationship between intermediate dense solid elements and lattice type elements, which
result in a model that has few lattice elements, as medium dense elements are widely
removed, due to the penalty.
MED: Sets the penalty factor to 1.25. This penalizes intermediate dense elements to some
extent and results in a moderate presence of lattice zones.
HIGH: Sets the penalty factor to 1, negating any penalty to the Young's Modulus and density
relationship. This usually leads to a high number of lattice elements, but also produces a
mathematical over-estimation of stiffness for structures known to be porous, which leads to a
larger discrepancy between the structural performance of Phases I and II.
In some cases a certain value for LB can lead to important parts of the structure being interpreted
as void. For instance, for a high number, such as 0.5 or where important parts of the structure
have low densities. In those cases, the removal of the void elements can lead to a non-functioning
structure. DOPTPRM, LATLB aims at preventing such scenarios. It will force OptiStruct to check
the structure for large differences in compliance between the final iteration of Phase I and the one
where the elements with density below LB are removed. If the structure is found to be too 'soft',
the lower bound for lattice zones can be adjusted downward during the optimization to create a
more continuous or stiff structure that more closely represents the original mesh. This parameter
has the following options:
CHECK: Requests that OptiStruct check the lattice optimized representation of the model for
differences in compliance.
AUTO: Allows OptiStruct to automatically adjust the lower bound of the lattice-optimized
model downward to increase the model continuity.
NONE: No check for performance loss is made.
Figure 668:
2. Save controlarm.fem.
Figure 669:
4. When the optimization has completed, open the controlarm.fem file in a text editor.
5. Check how the optimization progressed. Make sure that the optimization is fully converged and
that the constraint is satisfied.
OptiStruct provides a summary of the lattice optimization and its effects on the model, at the end of the
output file.
Figure 670:
Since DOPTPRM, LATLB, CHECK was applied, OptiStruct checked the drop-in compliance, due to the
removal of elements with density below LB. The drop is relatively small and this LB can be considered a
good choice.
Figure 671:
b) OptiStruct has inserted the CBAR elements, which represent the new lattice material, below
the GRID cards, which provides details about the model nodes.
Figure 672:
c) Each CBAR element has its own PBAR property definition, listed later in the deck, which
indicates each element can be individually optimized.
Figure 673:
d) Each joint between multiple CBAR elements has a design variable created for it.
Figure 674:
e) At the end of the file are the design variable property relationships (DVPREL1), which relate
properties to their associated design variable for the size optimization in the second phase.
These are followed by the responses, the constraints, and the objective.
Note: The volume fraction response in the original model has been replaced by
total volume in the size optimization phase, which will now be minimized and
a new response has been added to constrain the von Mises stress in the lattice
region to 200. This was created from the value in the last field of the LATTICE
continuation card in the first phase.
Figure 675:
Figure 676:
4. When the optimization has completed, open the controlarm_lattice.fem file in a text editor to
review critical information about the optimization run.
5. Verify that the optimization is fully converged and that the constraint is satisfied.
Figure 677:
The difference in lattice penalty (lower than 1.8, set by the optimization parameters) causes the
compliance of the final Phase I model to differ from the initial Phase II model. This compliance
difference is also affected by solid elements retained in the Phase II model, which recover their
full density/stiffness. For this reason, post-processing a lattice optimization requires that you
analyze changes to the model compliance between the Phase I final optimization compliance and
the Phase II initial compliance calculation and again at the end of Phase II.
6. Open the HyperWorks Solver Run Manager.
7. Open the controlarm_lattice_optimized.fem file.
8. Click Run for verification purposes.
Since the optimization removes CBAR elements of small radius after the last
optimization, the compliance for the last optimized run should be confirmed against the
controlarm_lattice_optimized.fem file, an analysis of the optimized structure provided by
OptiStruct.
Figure 678:
Figure 682: Front View of the Optimized Lattice/Solid Model Showing the Variation in CBAR Radius
Figure 683:
Phase 2: Design Fine Tuning Design fine tuning Size optimization identifies the optimal
(Size Optimization) thicknesses of each ply bundle.
Phase 3: Ply Stacking Sequence Ply stacking sequence optimization Shuffling optimization obtains
Optimization an optimal stacking sequence.
The process expands upon three important and advanced optimization techniques; free-size
optimization, size optimization and ply stacking sequence optimization. By stringing these three
techniques together, OptiStruct offers a unique and comprehensive process for the design and
optimization of composite laminates. The process is automated and integrated in HyperWorks by
generating the input data for a subsequent phase automatically from the previous design phase.
Together with these steps, an initial and final analysis will be utilized to determine the baseline and final
characteristics of the designed part.
Model Definition
The composite design optimization methodology presented within this tutorial was developed to solve
very complex composite design optimization problems. The methodology breaks down the complex
composite design optimization problem, which is not solvable by itself, into several simpler composite
design optimization problems, which are solvable by themselves. The cumulative solution to each of the
simpler composite design optimization problems provides a solution to the complex design optimization
problem. This process of breaking down complex problems into several simpler problems is consistent
with the engineering method.
Figure 687:
Figure 688:
Creating Laminate
1. In the Model Browser, right-click and select Create > Laminate from the context menu.
The Create Laminate dialog opens.
Figure 689:
Figure 690:
If the job is successful, new results files should be in the directory where the oht_analysis.fem was
written. The oht_analysis.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
Figure 692:
In free-size optimization, the thickness of each designable element is defined as a design variable.
Applying this concept to the design of composites implies that the design variables are the thickness of
each 'Super-ply' (total designable thickness of a ply orientation) per element.
To obtain more meaningful results, manufacturing constraints are incorporated and carried through all
design phases automatically.
Objective Minimize the compliance of the load case.
Manufacturing Constraints Ply percentage for the 0s no more than 80% exist.
Figure 694: DSIZE Data Entry Fields for the PLYPCT Cards
8. Define BALANCE.
a) Select BALANCE.
b) Set Balance Constraints Options to BYANG.
c) In the DSIZE_NUMBER_OF_BALANCE= field, enter 1.
A BALANCE continuation line is added to the DSIZE Data Entry.
d) In the BALANCE row, enter 45 for BANGLE1 and -45 for BANGLE2.
Figure 695: DSIZE Data Entry Fields for the BALANCE Card
9. Define PLYDRP.
a) Select PLYDRP.
Figure 696: DSIZE Data Entry Fields for the PLYDRP Card Using the PLYSLP Method
Figure 697: Requesting the free-size to size (FSTOSZ) optimization output file for Phase 2
The default files that get written to your run directory include:
oht_opti_ph1.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the oht_opti_ph1.fem file.
oht_opti_ph1_des.h3d
HyperView binary results file that contain optimization results.
oht_opti_ph1_s#.h3d
HyperView binary results file that contains from linear static analysis, and so on.
oht_opti_ph1_sizing.*.fem
A ply-based sizing optimization input file generated during free-sizing phase. This resulting deck
contains PCOMPP, STACK, PLY, and SET cards describing the ply-based composite model, as well as
DCOMP, DESVAR, and DVPREL cards defining the optimization data. The * sign represents the final
iteration number.
oht_opti_ph1_sizing.*.inc
An ASCII include file contains the same ply-based modeling and optimization data as in the input
deck. The * sign represents the final iteration number.
Note: If opening these files from standalone HyperMesh, the page numbers will be
decremented.
6. Click Apply.
7. On the Standard Views toolbar, click to view the results in the X-Y plane.
The element thickness results from the free-size optimization are shown in the image below. The
regions indicated in red or in colors tending towards red (from the legend) can be interpreted as thicker
regions, while those in blue or tending towards blue are thinner regions. The contour plot indicated
above is the total thickness distribution that includes contributions from each ply orientation, i.e. a
thickness contribution from the 0s, +/-45s and the 90s. It also indicates the shape and layout of plies
per orientation as can be seen in the ply thickness plot.
5. Create the ply thickness contours for super-ply 2 (45°), ply 3 (-45°), and ply 4 (90°) by selecting
Layers 2, 3 and 4, respectively in the Contour panel.
Due to the balance constraint applied, the thickness distribution of the +45° and the -45° super
ply are the same.
Figure 703: Ply Thickness Contour Plot of the -45/+45 Degree Super-ply
Figure 705: Model Browser View Showing Ply 11300 Selected (Laminate 1, Ply 1, Shape 3)
Figure 706: Graphics Area View of Ply 11300 (Laminate 1, Ply 1, Shape 3)
The shapes of the plies as indicated through the element set can be used as-is in design Phase 2, or
modified easily by updating the element sets in HyperMesh or using ply smoothing to improve the
manufacturability. Ply smoothing operations are shown in the next section.
Figure 707: View of Ply 11300 after Smoothing Operations (Laminate 1, Ply 1, Shape 3)
To ensure that the optimization design meets the design requirements, additional performance criteria
on may be incorporated into the problem formulation. These new criteria will be fiber strain, matrix
strain, and mass.
Manufacturing constraints previously applied are preserved and transferred to the DCOMP card.
Note: The DESVARs have the same ID numbers as the design variable property
relationship (DVPREL) that they relate to. These ID numbers also refer to the plies
created in the previous optimization - in this way, they can easily be cross-referenced.
Figure 708:
The laminate option defines the laminate behavior. In this case SMEAR theory is used to define the
laminate behavior; that is the A-matrix is calculated exactly since it is stacking sequence independent,
the D-matrix is calculated as AT2/12, and finally the B-matrix is set to zero. Adding the Symmetric
option to the SMEAR theory just assures a symmetric laminate will be output by adding/removing 2
plies at a time vs. 1 ply at a time.
When responses are deleted in HyperMesh, all constraints and objectives which depend on those
responses are deleted.
6. Click create.
7. Create constraint matrix_e on response matrix_e for loadstep nx_step with an upper bound of
0.007.
8. Click return to go back to the Optimization panel.
The default files that get written to your run directory include:
oht_opti_ph2.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the oht_opti_ph2.fem file.
oht_opti_ph2_des.h3d
HyperView binary results file that contain optimization results.
oht_opti_ph2_s#.h3d
HyperView binary results file that contains from linear static analysis, and so on.
oht_opti_ph2_shuffling.*.fem
A ply stacking optimization input deck. The DESVAR and DVPREL cards from the previous stage
are removed, and a bare DSHUFFLE card is introduced. The * sign represents the final iteration
number.
oht_opti_ph2_shuffling.*.inc
An ASCII include file containing ply stacking optimization data.
An element thickness contour plot (final iteration) after phase-2 size optimization displays.
Figure 712:
Each ply bundle is divided into multiple PLYs whose thickness is equal to the manufacturable thickness
(0.01 in this case), and the STACK card is updated accordingly. In this design phase, composite plies
are shuffled to determine the optimal stacking sequence.
It is important that design performances are preserved. Hence, the optimization problem is retained as
previously formulated in the size optimization phase. Two manufacturing constraints are applied:
• The maximum successive number of plies of a particular orientation does not exceed 4 plies.
• The outermost four layers of the layup must be -45, 0, 45, 90.
The default files that get written to your run directory include:
oht_opti_ph3.prop
OptiStruct property output file containing all updated property data from the last iteration for size
optimization.
oht_opti_ph3.shuf.html
An HTML file contains the history of the shuffling optimization and the view of the ply stacking
sequence.
Post-processing Results
In an Internet browser, open the oht_opti_ph3.shuf.html file.
The plies are color coded based on their fiber orientations. The columns represent the global trend of
the ply stacking sequence at a particular iteration, with the last column being the final solution.
The weight of the part has not been changed during the shuffling design phase, rather the plies were
reordered to obtain the maximum performance.
This light weight design therefore meets all of the performance requirements, is feasible and
manufacturable.
The properties of the model are updated with the optimized parameters.
Figure 714: Model Thickness with Half of the Model's Elements Masked
If the job is successful, new results files should be in the directory where the oht_final.fem was
written. The oht_final.out file is a good place to look for error messages that could help debug the
input deck if any errors are present.
3. Set the Result type to Composites Strains(Mech) (s) and the subtype to Normal X Strain.
This corresponds to the fiber strain in the model.
4. To view the individual strain contributions from any one ply, select the appropriate ply name in the
Layers drop-down. Confirm that no ply exceeds 9000 microstrain (9e-3).
5. Set the Result type to Composites Strains(Mech) (s) and the subtype to Normal Y Strain.
This corresponds to the matrix strain value.
6. To view the individual strain contributions from any one ply, select the appropriate ply name in the
Layers drop-down. Confirm that no ply exceeds 7000 microstrain (9e-3) for the matrix.
A structural model with loads and constraints is used in this tutorial. The deflection at the end of the
tubular cross-member should be limited. The optimal solution would be to use as little material as
possible.
You will load the structural model into HyperMesh. The constraints, loads, material properties,
and subcases (loadsteps) are already defined in the model. Size design variables and optimization
parameters are defined, and OptiStruct determines the optimal gauges for the components. The results
are then reviewed in HyperView.
Constraints A given maximum nodal displacement at the loading grid point for
two loading conditions.
e) Select tube.
f) Click return.
g) Click create.
A design variable property relationship, tube_th, has been created relating the design variable
tube to the thickness entry on the PSHELL card for the property tube2.
8. Create a design variable property relationship, rail_th.
a) In the name = field, enter rail_th.
b) Using the prop selector, select tube1.
c) Under the props selector, select Thickness T.
d) Click designvars.
e) Select rail.
f) Click return.
g) Click create.
A design variable property relationship, rail_th, has been created relating the design variable rail
to the thickness entry on the PSHELL card for the property tube1.
9. Click return to go to the Optimization panel.
Creating Responses
1. Click the responses panel.
2. Create the response, volume.
a) In the response= field, enter volume.
b) Set the response type to volume.
c) Set the regional selection to total.
d) Click create.
The response, volume, is defined for the total volume of the model.
3. Create the response, X_Disp.
a) In the response= field, enter X_Disp.
b) Set the response type to static displacement.
c) Click nodes > by id, then enter 3143 in the id= field.
This is the node at center of rigid spider at loading point.
d) Select dof1.
e) Click create.
The response, X_Disp, is defined for the x-displacement of the node 3143.
4. Create the response, Z_Disp.
a) In the response= field, enter Z_Disp.
Creating Constraints
A response defined as the objective cannot be constrained. In this case, you cannot constrain the
response volume.
Upper bound constraints are to be defined for the responses X_Disp and Z_Disp.
The default files that get written to your run directory include:
joint_sizeOPT.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and
constraint for each iteration.
joint_sizeOPT.prop
OptiStruct property output file containing all updated property data from the last iteration for size
optimization.
joint_sizeOPT.hist
The OptiStruct iteration history file containing the iteration history of the objective function and of
the most violated constraint. Can be used for a xy plot of the iteration history.
joint_sizeOPT.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the joint_sizeOPT.fem file.
joint_sizeOPT.res
HyperMesh binary results file.
joint_sizeOPT.stat
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, and so on.
joint_sizeOPT_des.h3d
HyperView binary results file that contain optimization results.
joint_sizeOPT_s#.h3d
HyperView binary results file that contains from linear static analysis, and so on.
joint_sizeOPT_des.h3d
Contains the element thickness for all five iterations.
joint_sizeOPT_s1.h3d
Contains displacement and stress results for the linear static analysis for iteration 0 and iteration
4 of subcase with ID 1 (subcase Force_X).
joint_sizeOPT_s2.h3d
Contains displacement and stress results for the linear static analysis for iteration 0 and iteration
4 of subcase with ID 2 (subcase Force_Z).
joint_sizeOPT.out
Contains gauge and volume information for all iterations.
The results contained in the HyperView binary results file will be examined first. Then the gauge history
in the joint_sizeOPT.out file will be reviewed.
A contoured image representing shell thickness should be visible. Each element in the model is assigned
a legend color, indicating the thickness value for that element for the current iteration.
The third page, which has results loaded from the file joint_sizeOPT_s1.h3d, is displayed. The
name of the page is displayed as Subcase 1 - FORCE_X to indicate that the results correspond to
subcase 1.
2. From the Animation toolbar, set the animation mode to Linear Static.
3. On the Results toolbar, click to open Contour panel.
The x-displacement value for 3143 (center of rigid spider, where loading is applied) displays. The
x-displacement is larger than the upper bound constraint, which was defined earlier, of 0.9.
Figure 719: Displacement on X-direction for the X-force loadcase at the first iteration
Figure 720: Displacement on X-direction for the X-force loadcase at the last iteration
The fourth page shows the results loaded from the joint_sizeOPT_s2.h3d file. The name of the
page is displayed as Subcase 2 - Force_Z to indicate that the results correspond to subcase 2.
9. On the Results toolbar, click to open the Contour panel.
Figure 721:
What are the resulting gauges for the rail and tube?
You will load the structural model into HyperMesh. The constraints, loads, material properties,
and subcases (loadsteps) are already defined in the model. Size design variables and optimization
parameters are defined and the OptiStruct software determines the optimal gauges. The results are
then reviewed in HyperMesh.
Constraints Maximum von Mises Stress of the brackets < 100 Mpa.
f) Click return.
g) Click create.
A design variable property relationship, part1_th, has been created relating the design variable
part1 to the thickness entry on the PSHELL card for the property part1.
8. Create a design variable property relationship, part2_th.
a) In the name = field, enter part2_th.
b) Using the prop selector, select part2.
c) Under the props selector, select Thickness T.
d) Click designvars.
e) Select part2.
f) Click return.
g) Click create.
A design variable property relationship, part2_th, has been created relating the design variable
part2 to the thickness entry on the PSHELL card for the property part2.
9. Click return to go to the Optimization panel.
5. Click return.
The design variable part2 is now linearly dependent on the design variable part1.
Creating Constraints
A response defined as the objective cannot be constrained. In this case, you cannot constrain the
response volume.
Upper bound constraints are to be defined for the responses stress1 and stress2.
The constraint is an upper bound with a value of 100. The constraint applies to the subcase STEP.
3. Define a constraint on the response stress2.
a) In the constraints= field, enter stress2.
b) Check the box next to upper bound, then enter 100.
c) Click response = and select stress2.
d) Using the loadsteps selector, select STEP.
e) Click create.
The constraint is an upper bound with a value of 100. The constraint applies to the subcase STEP.
4. Click return to go to the Optimization panel.
The default files that get written to your run directory include:
bracket_size.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and
constraint for each iteration.
bracket_size.prop
OptiStruct property output file containing all updated property data from the last iteration for size
optimization.
bracket_size.hist_dat
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.
bracket_size.html
HTML report of the optimization, giving a summary of the problem formulation and the results
from the final iteration.
bracket_size.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the bracket_size.fem file.
bracket_size.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. This file may be used to restart a run.
bracket_size.stat
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, and so on.
bracket_size.h3d
HyperView binary results file.
The third page has the results loaded from the bracket_size_s1.h3d file. The name of the page
is displayed as Subcase 1 - STEP to indicate that the results correspond to subcase 1.
3. On the Results toolbar, click to open the Contour panel.
4. Set the Result type to Element Stresses [2D & 3D] (t) and vonMises.
5. Set the Averaging method to None.
6. Click Apply.
A contoured image representing von Mises stresses should be visible. Each element in the model
is assigned a legend color, indicating the von Mises stress value for that element resulting from
the applied loads and boundary conditions. If you did not change the Iteration step, you should
contour the stress of the initial step. To contour the final step, set the last iteration of that
loadcase using the Model Browser.
7. In the Results Browser, select the last iteration from the simulation list.
Only two iterations are displayed; the First and Last (FL) is the default setting for optimization
runs. To change this setting, add an OUTPUT control card with a frequency setting of ALL.
Figure 723:
This will now contour your final iteration of that loadcase. Review the stress to see that it is under the
proper constraints.
1. In the top, right of the application, click to go back to the previous page.
Alternatively, you can also open the bracket_size.prop file in a text editor to view the final gauge
thicknesses of the two parts.
Creating Loads
1. In the Model Browser, Load Collectors folder, right-click on crank and select Make Current from
the context menu.
2. Create a force.
a) From the Analysis page, click the forces panel.
b) Select the create subpanel.
c) Set the entity selector to nodes, then select the node at the center of the rigid spider.
d) Set the coordinate system toggle to global system.
e) In the magnitude = field, enter -100.0.
f) Set the direction definition to z-axis.
g) Click create.
h) Click return.
A point force is created at the pedal location.
3. Create a moment.
a) From the Analysis page, click the moments panel.
Note: This is a simplified loading regime that represents the transformed loads from a
person's foot on the pedal.20.
Creating Constrains
1. In the Model Browser, Load Collectors folder, right-click on spcs and select Make Current from
the context menu.
2. From the Analysis page, click the constraints panel.
3. Select the create subpanel.
4. Set the entity selector to nodes, then select the nodes to constrain the structure by clicking on
the center of the rigid spiders.
Figure 727: SPCs Applied to Upper and Lower Portion of Head Tube
Dofs with a check are to 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.
6. Click create.
7. Click return.
Tip: Quickly create identical design variables by right-clicking on thk1 and selecting
Duplicate from the context menu.
4. Examine the PCOMP branch to see all of the PCOMPs in the model.
Figure 728:
c) Using the nodes selector, select the node at the bottom of the bracket where the loads were
applied.
d) Set the displacement type to total disp.
e) Click create.
5. Click return to go back to the Optimization panel.
A constraint is defined on the response disp. It states that any solution (min. volume) needs to have a
displacement lower than 1.8 mm to be feasible.
3. In the Save As dialog, specify location to write the OptiStruct model file and enter
bicycle_frameOPT for filename.
For OptiStruct input decks, .fem is the recommended extension.
4. Click Save.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to optimization.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to run the optimization.
The following message appears in the window at the completion of the job:
OPTIMIZATION HAS CONVERGED.
FEASIBLE DESIGN (ALL CONSTRAINTS SATISFIED).
OptiStruct also reports error messages if any exist. The file bicycle_frameOPT.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.
9. Click Close.
2. From the menu bar, click File > Open > Session.
3. In the Open Session File dialog, navigate to your working directory and open the
bicycle_frameOPT_hist.mvw file.
This file contains plots of the objective, constraints, and design variables against iteration history.
Figure 730: Maximum constraint violation (% [disp > 1.8 mm]) for each iteration
The next pages show the design variables (DVs) which are grouped together making it
possible to compare the behavior of the different plies. This plot can be created by opening the
bicycle_frameOPT.hgdata file.
A structural model with loads and constraints is used in this tutorial. The objective is to minimize the
amount of material used in the model subject to certain stress specifications.
Figure 732:
You will load the structural model into HyperMesh. The constraints, loads, material properties,
and subcases (loadsteps) are already defined in the model. Size design variables and optimization
parameters are defined, and OptiStruct determines the optimal gauges. The results are then reviewed
in HyperView.
Constraints Maximum von Mises stress of the brackets < 120 MPa.
f) Click return.
g) Click create.
A design variable property relationship, part1_th, has been created relating the design variable
part1 to the thickness entry on the PSHELL card for the property part1.
8. Create a design variable property relationship, part2_th.
a) In the name = field, enter part2_th.
b) Using the prop selector, select part2.
c) Under the props selector, select Thickness T.
d) Click designvars.
e) Select part2.
f) Click return.
g) Click create.
A design variable property relationship, part2_th, has been created relating the design variable
part2 to the thickness entry on the PSHELL card for the property part2.
9. Click return to go to the Optimization panel.
Creating Constraints
A response defined as the objective cannot be constrained. In this case, you cannot constrain the
response volume.
Upper bound constraints are to be defined for the responses stress1 and stress2.
The third page has the results loaded from the discrete_bracket_size_s1.h3d file. The name of
the page is displayed as Subcase 1 - STEP to indicate that the results correspond to subcase 1.
3. On the Results toolbar, click to open the Contour panel.
4. Set the Result type to Element Stresses [2D & 3D] (t) and vonMises.
5. Set the Averaging method to None.
6. Click Apply.
A contoured image representing von Mises stresses should be visible. Each element in the model
is assigned a legend color, indicating the von Mises stress value for that element resulting from
the applied loads and boundary conditions. If you did not change the Iteration step you should be
contouring the stress of the initial step.
7. On the Animation toolbar, click to set the last iteration of that loadcase and contour the final
step.
Only two iterations are displayed; the First and Last (FL) is the default setting for optimization
runs. To change this setting, add an OUTPUT control card with a frequency setting of ALL.
This will now contour your final iteration of that loadcase. Review the stress to see that it is under
the proper constraints.
Figure 734:
Review
The .out file contains a summary of the optimization process. From the information in the.out
file, you can see how the objective, constraints, and design variables are changing from one
iteration to the next.
Has the volume been minimized for the given constraints?
Have the stress constraints been met?
What are the resulting gauges for the two parts?
Hints
Go to the des.h3d page, clear the contour if one was applied, set to the last simulation step and
apply the Element Thickness contour.
Append discrete_bracket_size.mvw to review objective, constraints, and other information.
Size optimizations involve the changing of the properties of either 1D or 2D elements. These properties
include area, moments of inertia of the 1D elements, and the thickness of 2D elements. Size
optimization is performed when it is not necessary to remove materials, generate beads or change the
shape of the structure.
With size optimization, the cross-sectional properties of the elements are changed to meet the
necessary objective. Properties are linked with design variables (DESVAR) using DVPREL cards.
This tutorial outlines using OptiStruct macros under an OptiStruct user profile to setup the optimization
problem.
Design Variables Beam width, beam thickness, beam depth, and shell thickness.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to analysis.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to launch the OptiStruct job.
If the job is successful, new results files should be in the directory where the shredder_analysis.fem
was written. The shredder_analysis.out file is a good place to look for error messages that could help
debug the input deck if any errors are present.
Using a scale factor higher than 1.0, amplifies the deformations while a scale factor smaller than
1.0 would reduce them. In this case, you are accentuating displacements in all directions.
5. Define undefomed shape settings.
a) Set Show to Edges.
b) Set Color to Mesh.
6. Click Apply.
7. In the Results Browser, from the list of simulations, select Mode 1.
Figure 737:
9. Click Apply.
Figure 738:
Figure 739:
14. Click the first window, then click Edit > Copy > Window from the menu bar.
15. Click the second window, then click Edit > Paste > Window from the menu bar.
16. Copy the first window into the third and fourth windows.
17. Change the mode assigned to the windows by clicking a window to make it active, then selecting a
mode in the Results Browser.
• Set the second window to Mode 2.
• Set the third window to Mode 3.
• Set the fourth window to Mode 4.
Figure 741:
18. On the Animation toolbar, click to start the animation. Click again to stop the animation.
The third and fourth mode (~ 3.9 and 4.8 Hz) has a transversal shape that can reduce the
performance of the shredder when it gets excited. The objective, then, is to get the minimum
mass to greater than 7Hz.
19. From the menu bar, click File > Save As > Report Template.
20. In the Save Report As dialog, navigate to your working directory and save the file as
report.tpl.
Figure 743:
21. In the top, right of the application, click and to navigate back to the HyperMesh client on
the first page.
Beamwide 50 30 90
Beamthck1 10 5 15
Beamthck2 20 15 30
Figure 744:
Defining Constraints
1. Click the dconstraints panel.
2. Create the constraint, c_f3.
a) In the constraint= field, enter c_f3.
b) Check the box next to lower bound, then enter 6.0.
c) Click response = and select f3.
d) Using the loadsteps selector, select ld1.
e) Click create.
3. Create the constraint, c_f4.
a) In the constraint= field, enter c_f4.
b) Check the box next to lower bound, then enter 6.0.
c) Click response = and select f4.
d) Using the loadsteps selector, select ld1.
e) Click create.
4. Click return to exit the panel.
Figure 745:
Figure 746:
It is assumed that the tail is cantilevered about its inboard section. Three loading scenarios are
considered; one where the tail experiences pressure loads of 0.25 psi on the bottom skin, a second
where the tail experiences a tip load of 400 lbs, and a third where the tail experiences both the
pressure load and tip load simultaneously. The applied loading is represented below.
The optimum design should be as light as possible without failing or buckling under the given loading
conditions.
G12 800ksi (800000 psi) 3ksi (3000 psi) Rho 0.1 lb/in3
G1,Z 800ksi (800000 psi) 4ksi (4000 psi) Yield 50ksi (50000 psi)
Rib thicknesses.
This loads the 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 for
OptiStruct.
1. In the Model Browser, right-click and select Create > Material from the context menu.
A default material displays in the Entity Editor.
2. For Name, enter al2024-t3.
3. Set Card Image to MAT1.
4. Enter the material values next to the corresponding fields.
These values are taken from the table Aluminum 2024-T3 at the beginning of the tutorial.
a) For E (Young's Modulus), enter 10.6e6.
b) For NU, (Poisson's Ratio), enter 0.33.
c) For RHO (Mass Density), enter 0.1
A new material, al2024-t3, has been created. The material uses OptiStruct's linear isotropic material
model, MAT1.
A new property, Ribs, has been created as a 2D PSHELL. Material information is also linked to this
property.
A property collector named Ribs has been created. It has a PSHELL definition with a thickness of 1.0. It
also references the Aluminum 2024-T3 material definition and the component name Ribs.
Figure 749:
NU12 0.1
d) Click Apply.
An orthotropic material definition for Glass_fabric is complete.
3. Create the material definition, core.
a) In the Laminate Browser, right-click on MAT8 and select New from the context menu.
A new material definition is created and appears in the Laminate browser under MAT8.
b) Under the Define, Edit material section, enter Core in the Material field.
c) Edit the following fields:
NU12 0.3
Xt 500 psi
Xc 500 psi
Yt 500 psi
Yc 500 psi
S 150 psi
d) Click Apply.
Two new orthotropic material definitions have been created on the MAT8 branch of the Laminate
Browser.
Figure 750:
10. In the Laminate Browser, right-click Inboard_section_top and select Duplicate from the
context menu.
11. Under the Laminate definition section, edit laminate information.
a) In the Name field, enter Inboard_section_btm.
b) Click the color box and select a new color for the laminate.
12. Click Update Laminate.
13. Update the ply angles on the laminates Outboard_section_btm, Outboard_section_top,
Midspan_section_btm, and Midspan_section_top to be the same as Inboard_section_top, then
click Update Laminate.
14. From the menu bar, click File > Exit.
HyperLaminate closes, and the laminate information is exported back to HyperMesh.
Six laminate definitions have been created using the PCOMP keyword.
Figure 753:
6. In the Model Browser, Components folder, right-click on Tail and select Isolate Only from the
context menu.
Only the elements forming the ribs which are in the tail collector display.
7. Organize the elements forming the ribs in the Ribs component collector.
a) In the Organize panel, click elems > displayed.
Orienting Elements
1. From Tool page, click the normals panel.
2. Select the elements subpanel.
3. Set the entity selector to elems, then click elems > by collector.
4. Select Ribs.
5. Click comps > reverse.
6. Click select.
7. Click display.
Verify the element normals are not all in the same direction.
8. If element normals are not all in the same direction, adjust element normals.
a) Under orientation, set the selector to elem and select an element whose normal is pointing
inward.
b) Click adjust.
All skin normals should now point inwards. These skin normals are the local z-axes for each
element.
9. Click return to return to the main menu.
10. From the 2D page, click the composites panel.
11. Select the material orientation subpanel.
12. Use the comps selector to select the components that contain all of the elements belonging to the
skin.
The local x-axis of each of the selected elements is oriented to be the projection of the global z-axis.
This is indicated by the small white arrows that appear on each element.
Having defined the local x and z axes of the elements belonging to the component collectors
Inboard_section_top, Inboard_section_btm, Midspan_section_top, Midspan_section_btm,
Outboard_section_top, and Outboard_section_btm, you have fully established the local orientation for
each element referencing a composite laminate.
In previous steps, a load collector containing the pressure loads and another containing the tip load
were created, but a load collector containing both together is still needed. Next is to create a load
collector which is a combination of the load collectors pressure and tip_load.
A combination load collector, combining 1.0 times the loads in the pressure load-collector with 1.0 times
the loads in the tip_load collector, is created.
e) In the Number_of_Plies= dialog, set SOUT for all plies to YES and click Close.
This requests stress and strain results to be output for all plies.
2. Repeat step 1 for the other composite laminates.
3. Edit the GLOBAL_CASE_REQUEST control card.
a) From the Analysis page, click the control cards panel.
b) In the Card Image dialog, click GLOBAL_CASE_REQUEST.
c) Verify CSTRAIN and CSTRESS is selected.
d) Click return twice to exit the dialog.
Stress, strain, and failure results will now be output for the composite laminates.
If the job is successful, new results files should be in the directory where the
tail_baseline_complete.fem was written. The tail_baseline_complete.out file is a good place to
look for error messages that could help debug the input deck if any errors are present.
The Volume, Mass, and Buckling Modes for the baseline model are given in the analysis results section.
ANALYSIS RESULTS :
------------------
ITERATION 0
Subcase Compliance
1 5.455666E+02
3 2.486638E+01
5 7.735856E+02
4 4 8.466939E+01
4 5 8.541136E+01
4 6 8.618942E+01
4 7 8.695226E+01
4 8 8.765920E+01
4 9 8.834313E+01
4 10 8.907416E+01
6 1 1.329775E+01
6 2 1.351079E+01
6 3 1.372538E+01
6 4 1.394187E+01
6 5 1.416444E+01
6 6 1.417737E+01
6 7 1.439755E+01
6 8 1.445274E+01
6 9 1.464175E+01
6 10 1.466889E+01
The displacement contour displays for the 1st subcase [pressure only]. You could also view the same for
other subcases.
6. Set the Result type to Element Stresses (2D & 3D) [t] and von Mises.
7. Click Apply.
A contour plot of the von Mises stresses for the metallic ribs displays.
Figure 756:
9. Click Flip.
The Ribs component is now hidden and the composite laminate components are displayed.
10. On the Results toolbar, click to open the Contour panel.
11. Set the Result type to Composite Stresses (s) and Ply Failure.
12. Set Layers to 1.
13. Click Apply.
A contour plot of the composite failure indices from the composite skins results is displayed for the
first layer.
Figure 757: Failure index for the first layer for the pressure only loadstep
After calculating the failure indices for individual plies, OptiStruct calculates the potential failure
index for the composite shell element. This is based on the premise that failure of a single layer
qualifies as failure of the composite. Thus, a failure index for composite elements is calculated as
a maximum of all computed ply and bonding failure indices.
Note: Only plies with requested stress output are taken into account here.
Figure 758: Max failure index found on all layers for pressure only loadstep
Repeat this process to have the maximum failure index for all loadsteps.
Return to HyperMesh Desktop by deleting the HyperView page or navigating back to the HyperMesh
client.
• To delete the HyperView page and return to the HyperMesh client, click on the Page Controls
toolbar.
• To keep the page open but return to the HyperMesh client page, click / in the top, right of the
application until the HyperMesh client returns.
Figure 759: Gauge Panel Settings for Rib Thickness Design Variable
6. Review the other ten design variables in HyperLaminate and verify their bounds match the
information in Table 4.
Table 4:
Twelve total composite design variables now exist, one for the thickness of the glass fabric for each
composite laminate component, and the other for the thickness of the core for each composite laminate
component. As the laminates are symmetric, the glass fabric will reference the same design variables
on either side of the core.
Creating Constraints
In this step you will define constraints. You will attempt to minimize the total mass of the structure,
while keeping the von Mises stress in the metallic ribs below yield, the composite failure index of the
composite skins below 1.0, and the buckling modes of the structure above 1.0.
1. Click the dconstraints panel.
2. Create the constraint, cnst1.
a) In the constraints= field, enter cnst1.
b) Click response= and select vm_strs.
c) Check the box next to upper bound, then enter 50,000.
d) Using the loadsteps selector, select pressure_only, tip_load_only, and combo.
e) Click create.
A constraint is defined on the von Mises stress of the metallic ribs to be less than 50ksi for all of
the static subcases.
3. Create the constraint, cnst2.
a) In the constraints= field, enter cnst2.
b) Click response= and select hl_ist.
c) Check the box next to upper bound, then enter 1.0.
d) Using the loadsteps selector, select pressure_only, tip_load_only, and combo.
e) Click create.
A constraint is defined on the hill failure criteria for the Inboard_section_toplaminate to be less
than 1.0. for all of the static subcases.
4. Create the cnst3 through cnst7 constraints by repeating step 3.
5. Create the constraint, cnst8.
a) In the constraints= field, enter cnst8.
b) Click response= and select buckle.
c) Uncheck the box next to upper bound.
Together, these two options ensure that up to 10 modes are considered in the buckling constraint.
The value of the objective, the retained constraints, and the design variables are provided for all
iterations in the optimization iteration history section.
The final iteration provides information on the mass of the optimized structure, the values of the design
variables for the optimized structure and the values of the objective and retained constraints for the
optimized structure.
1. From the Page Controls toolbar, click to create a new page with the HyperView client.
2. From the menu bar, click File > Open > Session. The Open Session File window appears.
3. In the Open Session File dialog, navigate to the directory where you ran the OptiStruct
optimization and open the tail_opt_hist.mvw file.
This is a HyperView session which creates plots of the objective, constraints, and design variables
against iteration number using information from the tail_opt.hist file.
The Figure 760 shows page 1 of the session, which is the plot of the objective against iteration. It
shows how the mass decreased through the optimization process and how convergence is achieved
when the change in mass levels out.
Similar plots are available for the design variables and the constraints. There is also a plot showing the
maximum constraint violation for a given iteration against iteration. When this value is zero, it indicates
that there is no constraint violation.
Figure 760:
Figure 761:
7. In the Load Model File dialog, navigate to the directory where you ran the OptiStruct baseline
analysis and open the Tail_baseline_complete.h3d file.
The path and file name for Tail_baseline_complete.h3d appears in the fields to the right of
Load model and Load results. This is good because the Hyper3D format contains both model and
results data.
8. Click Apply.
The model and results are loaded in the current HyperViewwindow.
9. Click the second window to active it.
10. From the Standard toolbar, click to load a new model file.
11. In the Load Model File dialog, navigate to the directory where you ran the OptiStruct
optimization and open the tail_opt_s1.h3d file.
For the optimization, analysis results are written to files named *_s#.h3d (static analysis results,
where # is the subcase ID) and *_m#.h3d (eigenvalue analysis results, where # is the subcase
number), while the density, thickness and shape results are written to the file *_des.h3d.
12. Activate the first window.
13. On the Results toolbar, click to open the Contour panel.
Figure 762:
The optimized displacement results are greater than the baseline because you were optimizing for
mass without displacement constraints.
Figure 763:
21. On the Animation toolbar, set the animation mode to (Linear static).
22. Click to animate the deformation. Click again to stop the animation.
Similar steps can be followed to compare stress and composite failure plots before and after the
optimization.
Notice how the maximum value for the composite failure index is almost at the design limit of 1.0.
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.
Design Variables for Free Thickness of each shell element in the design space.
Sizing Optimization
Design Variables for Topology Element density of each element in the design domain.
Optimization
4. Click create.
5. Click return twice to exit the Optimization panel.
The default files that get written to your run directory include:
rib_freesize.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and
constraint for each iteration.
rib_freesize.hist
The OptiStruct iteration history file containing the iteration history of the objective function and of
the most violated constraint. Can be used for a xy plot of the iteration history.
rib_freesize.HM.comp.tcl
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.
rib_freesize.HM.ent.tcl
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.
rib_freesize.html
HTML report of the optimization, giving a summary of the problem formulation and the results
from the final iteration.
rib_freesize.mvw
HyperView session file.
rib_freesize.oss
OSSmooth file with a default density threshold of 0.3. You may edit the parameters in the file to
obtain the desired results.
rib_freesize.out
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 all optimization iterations, and compute time information. Review this file for
warnings and errors that are flagged from processing the rib_freesize.fem file.
rib_freesize.res
HyperMesh binary results file.
rib_freesize.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. This file may be used to restart a run.
rib_freesize.stat
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, and so on.
rib_freesize_des.h3d
HyperView binary results file that contain optimization results.
rib_freesize_frame.html
HTML file used to post-process the .h3d with HyperView Player using a browser. It is linked with
the _menu.html file.
rib_freesize_hist.mvw
Contains the iteration history of the objective, constraints, and the design variables. It can be
used to plot curves in HyperGraph, HyperView, and MotionView.
rib_freesize_menu.html
HTML file used to post-process the .h3d with HyperView Player using a browser.
rib_freesize_s#.h3d
HyperView binary results file that contains from linear static analysis, and so on.
rib_freesize.fsthick
The element definitions for those elements that were part of a free size design space. The
optimized thickness of these elements is provided as nodal thickness values (Ti).
3. Select Auto appy mode: Display Off, then select the Web component.
All of the components are undisplayed except Web.
4. Click the Mesh shaded mesh option .
Figure 765:
9. On the Standard Views toolbar, click to show the top view of the Web.
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.
10. On the Page Controls toolbar, click to close the HyperView client pages until the HyperMesh
client displays.
The web component has now been defined as the design component for topology optimization.
4. Click update.
5. Click return twice.
3. Select Auto appy mode: Display Off, then select the Web component.
All of the components are undisplayed except Web.
4. Click the Mesh shaded mesh option .
9. On the Standard Views toolbar, click to show the top view of the Web.
10. Click Apply to show the contour of element density on the Web component.
The results from topology optimization show very discrete results as expected.
Angular velocity at the revolute joint defined left end of the bar is 10*SIN(2*TIME) rad/sec. The
objective is to minimize the maximum stress of the structure subject to certain mass specifications. The
bar consists of five bar elements with a solid circle cross section (each element has its own PBARL with
ROD cross section). The design variables are the radius of each bar property.
Figure 769:
4. Create constraints.
Only 6 dof per flexible body should be fixed to remove 6 rigid body motion of each flexible body.
a) From the Analysis page, click the constraints panel.
b) Click the left end of the model.
Two node numbers display.
c) Select node number 1.
Figure 770:
d) Select all dofs (dof1 to dof6), and verify that their values are set to 0.0.
e) Click create.
f) Click return.
Figure 771:
4. Click OK.
5. Click return.
6. Define MOTION.
a) For MOTION, click Unspecified > Loadcol.
b) In the Select Loadcol dialog, select MBSIM1 and click OK.
f) Click return.
g) Click create.
A design variable to property relationship, bar1_rad1, has been created relating the design
variable rad1 to the radius entry on the PBARL card for property PBARL_1.
8. Create the design variable to property relationship bar2_rad2, bar3_rad3, bar4_rad4, and
bar5_rad5 relating the design variables to the radius entry on the PBARL cards for the property
PBARL_2, PBARL_3, PBARL_4, and PBARL_5.
9. Click return to go to the optimization panel.
Figure 772:
If the optimization was successful, no error messages are reported to the shell. The optimization is
complete when the message Processing completed successfully appears in the shell.
If the job was successful, the new results file can be seen in the directory where the input
file was saved. In addition to ordinary output files, you can see a text file with the name
rotating_bar_design.eslout. This file is a good source to see the process of the ESL optimization.
After ~ 7 interations, the model should converge to the descending values shown in Figure 773.
Figure 773:
One of the advantages with composite materials is that the structural performance can be controlled
precisely by choosing the appropriate ply thickness, ply orientation, stacking sequence, ply materials,
and so on. The ability to vary many different parameters provides greater flexibility, but at the same
time it is tougher to optimize the part as the number of design variables increases many fold. OptiStruct
has the ability to directly or indirectly optimize the ply thickness, ply orientation and stacking sequence
for composite structures.
Free-size optimization handles the thickness of each ply in each element as a design variable and
optimizes the structure by determining the optimal thickness distribution for each ply in the laminate.
For several reasons, every composite manufacturer has their own manufacturability standards for
the laminated composites. These additional manufacturing constraints are to be included with free-
size optimization to achieve an acceptable manufacturing solution. OptiStruct supports different
manufacturability constraints that can be defined with free-size optimization. This tutorial helps explain
the procedure used to define the manufacturing constraints in the free-size optimization of composite
structures.
Design Variables Thickness of each ply of each element in the design space.
In this step you will use HyperLaminate to define, review, and edit ply lay-up information. Size design
variables can also be set up in this panel for performing size optimization.
In this step you will define the minimum member size control to be 5.0. Member size control gives you
some control over the member size in the final free-size design and the resulting structure will have
discrete members that are easy to interpret during post-processing.
1. Select the parameters subpanel.
2. Click desvars= and select Skins.
3. Toggle minmemboff to mindim =, and enter 5.0.
4. Click update.
In this step you will define the percentage following manufacturing constraints.
• Minimum laminate thickness of 0.2.
• A Minimum of 10% and a maximum of 60% thickness (of total laminate thickness) constraints
defined for all the plies. This means that for each element, none of the plies will have thickness less
than 10% or greater than 60% of the totals laminate thickness.
• The thickness of ply with ply angle of 45 degree to be same as the thickness of ply with ply angle of
-45 degree.
Figure 776:
9. In the first COMP PLYPCT row, edit the PANGLE, PPMIN, PPMAX, and PTMAN constraints.
a) For PANGLE, enter 0.
This define that ply percentage constraints are defined for the ply with ply angle of 0 degree.
b) For PPMIN, enter 0.1.
c) For PPMAX, enter 0.6.
d) Leave the PTMAN field blank.
This defines that for each element, the thickness of the ply with ply angle 0, should be no less
than 10% or more than 60% of the total thickness.
10. In the second COMP PLYPCT row, edit the PANGLE, PPMIN, PPMAX, and PTMAN constraints.
a) For PANGLE, enter 45.
b) For PPMIN, enter 0.1.
c) For PPMAX, enter 0.6.
d) Leave the PTMAN field blank.
11. In the third COMP PLYPCT row, edit the PANGLE, PPMIN, PPMAX, and PTMAN constraints.
a) For PANGLE, enter -45.
b) For PPMIN, enter 0.1.
c) For PPMAX, enter 0.6.
d) Leave the PTMAN field blank.
12. In the second COMP PLYPCT row, edit the PANGLE, PPMIN, PPMAX, and PTMAN constraints.
a) For PANGLE, enter 90.
b) For PPMIN, enter 0.1.
c) For PPMAX, enter 0.6.
d) Leave the PTMAN field blank.
13. Select BALANCE.
The BALANCE constraint ensures that two plies will always be of equal thickness.
BALANCE BALANCE flag indicating that a balancing constraint is applied.
14. In the BALANCE row, edit the BANGLE1 and BANGLE2 constraints.
a) For BANGLE1, enter 45.
b) For BANGLE2, enter -45.
This defines that the plies with ply angle of 45 and -45 will always have the same thickness.
15. Click return to return from the panel.
16. Click update to update the above defined manufacturing constraints to the free-size design
variable.
17. Click return to return from the free size panel.
e) Click create.
5. Click return to go back to the Optimization panel.
Figure 777:
The contoured thickness is the optimal laminate thickness distribution for the current design.
2. Click Apply.
The isometric view of the model displays.
3. In the Results Browser, click to activate the Component view.
Figure 778:
4. From the view controls in the Results Browser, click (Isolate Shown) and click the
BottomSkin and TopSkin components.
The two components are isolated.
5. On the Visualization toolbar, click to open the Exploded View panel.
Verify if all the manufacturing constraints (ply percentage, balance and minimum laminate thickness)
are satisfied. Additionally, open the Wing_FreeSize_with_PLYPCT.out file in a text editor and verify
that the displacement constraints are satisfied in the last iteration.
Since HyperMath is an interpreter, you can build custom responses without having to compile your
HyperMath script.
You will load the structural model into HyperMesh. The materials, shell properties, loads and boundary
conditions are already defined in this model. The thicknesses of the three components are identified
as design variables. The von Mises stress of element numbers 58 and 59 (elements located on the
circumference of the hole) are defined as responses, and a total volume response is defined as well.
The von Mises stress of elements 58 and 59 are passed as inputs to the HyperMath script which in turn,
returns two values: the sum of the two von Mises stresses, and the average value of the two elemental
von Mises stresses.
Constraints Constraints on the sum of the von Mises stresses and the average
von Mises stress.
Figure 781:
Launching HyperMath
1. Launch HyperMath.
2. From the menu bar, click File > Open.
3. In the Open File dialog, open the dresp3_simple_h.hml file you saved to your working directory
from the optistruct.zip file. Refer to Accessing the Model Files.
4. Examine the HyperMath script to calculate external responses.
The HyperMath script identified with the function MYSUM takes two inputs, rparam[1] and
rparam[2], and returns two responses, rresp[1] - sum of the two inputs, and rresp[2] -
average value of the two inputs. The calculated responses rresp[1] and rresp[2] are sent back
to OptiStruct for use in the optimization. The script above will be linked to the DRESP3 related
cards in the OptiStruct input file, which will pass the two inputs to this script and then receive two
outputs from this script.
Note: In this script, it is possible to assign any name to the function, like MYSUM,
myresponses, sumandavg, etc. However, the argument names to the function such as
iparam, rresp, rparam, and so on. cannot be changed. External responses will now be
set up using DRESP3.
Figure 782:
This loads the 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 for
OptiStruct.
Note: There is a limited amount of space within the HyperMesh Desktop to enter the
file path and name. If the full file path with file name does not fit, exit the panel and
edit the rest manually.
4. Click return.
The design variables for the thicknesses of the three components are already defined. The responses for
the total volume and the von Mises stress of elements 58 and 59 have also been defined.
The DRESP3 bulk data entry is not supported in the current version of HyperMesh. Therefore, these
cards will be defined in the BULK_UNSUPPORTED_CARDS panel.
Note: A '$' symbol indicates a comment and the following data will not be read by the
solver.
1. Click BULK_UNSUPPORTED_CARDS.
2. In the Control Card dialog, enter in the following DRESP3 information:
Figure 783:
This defines two external responses: the sum of the von Mises stresses of elements 58 and 59 (SUMH)
and the average von Mises stress for elements 58 and 59 (AVGH).
The DRESP3 responses have different IDs from the DRESP1 responses and point to the library called
HLIB defined. Also, the function MYSUM is the same function name in the dresp3_simple_h.hml script.
This completes linking of the DRESP3 cards with the HyperMath Script.
Creating Constraints
In this step you should still be in the Control Card dialog.
Since the DRESP3 card is not supported in the current version of HyperMesh, the DCONSTR cards cannot
be assigned to the DRESP3 responses from the dconstraints panel either. The DCONSTR cards are
therefore also added using the BULK_UNSUPPORTED_CARDS panel.
1. In the Control Card dialog, enter the following constraint data (DCONSTR and DCONADD) following
the DRESP3 information:
Figure 784:
2. Click OK.
3. Click return.
The upper bound constraints of 50 and 25 on the SUMH response and the AVGH response are now
defined.
You will use a structural model with loads and constraints. The deflection at the lower right corner
should be limited to 3mm. The optimal design would use as little material as possible.
The structural model is loaded into HyperMesh and is used to generate and run a shape optimization of
the cantilever beam. Shape perturbation vectors are generated using HyperMorph, which is accessed,
through the HyperMesh interface. The OptiStruct software determines the optimal shape. The results
are then reviewed in HyperView.
Constraints Given maximum nodal displacement at the end of the beam < 3.0
mm.
This loads the 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 for
OptiStruct.
There are two types of handles: global handles, which are represented by larger red balls; and
local handles, which are represented by smaller yellow balls. Only local handles will be covered in
this tutorial.
4. Move handles.
a) Select the morph panel.
b) Select the move handles subpanel.
c) Switch interactive to move to node.
d) Using the handles selector, select the top right local handle (where the force is applied).
Figure 786:
e) Using the nodes selector, select the node in the middle of the right-hand side of the beam.
The beam changes shape, so that the handle you selected moved to the location of the node you
selected. Notice how the mesh adjusted to this change in shape.
Tip: To ensure that you select the top edge domain, hold down the left mouse
button and move the mouse over the top edge of the beam until the edge is
highlighted (white), then release the mouse button.
f) Using the nodes selector, select the node at the center of the top edge of the beam.
g) Click create.
h) Click return to return to the HyperMorph panel.
A new handle, 'aux1', is created at the center of the top edge of the beam.
Figure 788:
Notice: The mesh morphs interactively as the handle moves along the axis.
Tip: If you move the mouse upwards the number increases, if you move the
mouse downwards the number decreases.
f) Click update.
The curvature of the top edge has altered.
Two shape design variables are created using the shapes that were saved earlier.
e) Click create.
5. Click return to go back to the Optimization panel.
Figure 791:
Figure 792:
Figure 793:
Figure 794:
Figure 795:
In the schematic, the vertical deflection at point N should be limited to 2.0mm while minimizing the
amount of material required.
2. Select the Lbeamshape.hm file you saved to your working directory from the optistruct.zip file.
Refer to Accessing the Model Files.
3. Click Open.
The Lbeamshape.hm database is loaded into the current HyperMesh session, replacing any existing
data. The database only contains geometric data.
There are two types of handles; global handles, which are represented by larger red balls and
local handles, which are represented by smaller yellow balls. Only local handles are available in
this tutorial.
4. Move handles.
a) Click the morph panel.
b) Select the move handles subpanel.
c) Switch from interactive to translate.
d) Using the handles subpanel, select the local handle that is located at the node where the load
is applied.
Figure 797:
This shape is saved as shape1. Later, you can associate it to a design variable.
6. Click undo all.
The model returns to its original shape.
7. Repeat steps 4 and 5 for the local handles 3, 4 and 5.
a) Translate handles 3 and 4 by x=-10 and handle 5 by y=-10.
b) Save the shapes after morphing each handle as shape2, shape3 and shape4, respectively.
Four shape design variables are created using the shapes that were saved earlier.
A potential variation in shape of the vertical flange of the L-beam that could be achieved using the set
up described.
Figure 799:
e) Click create.
Figure 800:
2. In the top, right of the application, use the navigations buttons to navigate to the Design History
(page 2).
Figure 801:
Figure 802:
The seek slider and playback speed slider (top and bottom respectively) are located next to the
playback controls.
Figure 803:
3. Set the Result type: to Displacement (v) and Y (Y component of the Displacement, which is
what was constrained).
4. In the Results Browser, select the last iteration (iteration 6).
Figure 804:
5. Click Apply.
A plot of the displacements on your final shape displays. The maximum displacements for the last
Iteration #, is still below 2.0.
The essential idea of free-shape optimization, and where it differs from other shape optimization
techniques, is that the allowable movement of the outer boundary is automatically determined, thus
relieving users of the burden of defining shape perturbations.
Figure 805:
Constraints No Constraints.
5. Click create.
Figure 807:
Figure 808:
Figure 809:
Figure 810:
Figure 811:
The stress contour shows on top of the shape changes applied to the model.
Figure 812:
In practice, however, there will be some sort of constraints imposed upon the movement of grids due to
manufacturability. For this tutorial model, thickness must be unchanged to avoid any interference with
other parts.
In this step you will define constraints on DSHAPE grids such that the thickness of design space will
remain unchanged.
The constraints on free-shape design grids will be created separately for curved and flat parts of the
design space. The parts of the design space that are grouped as curved and those grouped as flat.
The constraints on the curved part will be created using a local rectangular coordinate system (the
other constraints on the flat part do not need a local coordinate system). Therefore, a local rectangular
coordinate system (z-axis will point to normal to DSHAPE surface) needs to be created first.
1. In the top, right of the application, click / to move back to Page 1 and the HyperMesh client.
f) Click add.
These nodes will move only on the specified plane.
c) Set the direction selector to local system, then click the local coordinate system you
created.
d) Set the vector definition switch to vector.
e) Set the direction definition, under vector, to z-axis.
f) Click add.
9. Click return twice to get back to the main menu.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to optimization.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to run the optimization.
The following message appears in the window at the completion of the job:
OPTIMIZATION HAS CONVERGED.
FEASIBLE DESIGN (ALL CONSTRAINTS SATISFIED).
OptiStruct also reports error messages if any exist. The file Free_Shape3D_const.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.
9. Click Close.
Figure 819:
Structures are said to "buckle" when a certain combination of loads cause them to be unstable and
deflection occurs. When a particular loading is reached, the structure continues to deflect without an
increase in the magnitude of the load. The critical load at which buckling occurs is the product of the
critical buckling factor and the applied reference load. The buckling factor is an eigenvalue and has no
dimension. Generally speaking, the lowest buckling load is usually of the most interest to engineers,
since a structure will fail prior to reaching any higher buckling loads.
When using OptiStruct to solve a linear buckling problem, apply a reference load to the structure and
calculate the buckling factors based on linear static and normal mode analysis. Use OptiStruct also
to perform size and/or shape optimizations on the structure to optimize for linear buckling. Neither
yielding of a structure nor change of force can occur during the optimization process.
Buckling optimization needs be performed to minimize the maximum von Mises stress among several
elements. This is done using the minimized maximum problem setup. Use MINMAX or MAXMIN statements
to define the objective function of a minimize maximum or maximize minimum problem. Many times
you will need to minimize or maximize several responses; minimizing the maximum von Mises stress
among several elements, for example. In such situations, using user-defined equations to minimize the
maximum von Mises stress will not achieve the expected result. Reducing the maximum stress in one
element often results in increased stress on another element.
This tutorial describes the steps involved in defining linear buckling and size optimization using the
gauge panel. Shape and size optimizations will both be applied to this structural optimization. The
shape optimization has been pre-defined in this model using HyperMorph, so you will not need to set
up the shapes and shape design variables. The size optimization is part of the exercise. A reference
value is given to the stress design objective, and the problem is formulated as a minmax optimization
problem. The resulting structure is thicker and wider to prevent buckling.
This problem will perform a size and shape optimization on a structural rail to prevent buckling in the
rail structure.
Objective Minimize maximum von Mises stress.
Figure 821:
8. Click animate.
9. Animate the shape, SHAPE - v1 (1).
a) Click simulation = and select SHAPE - v1 (1).
b) Set data type = and select Perturbation Vector.
c) Click linear.
d) Review the animation of the first shape.
10. Animate the shape, SHAPE - v2 (2).
11. Click return three times to go back to the Optimization panel.
Defining Constraints
1. From the optimization panel, click the dconstraints panel.
2. Create the constraint, BUCKLE.
a) In the constraint= field, enter BUCKLE.
b) Check the box next to lower bound, then enter 30.
c) Click response= and select Buckle.
d) Using the loadsteps selector, select Buckling.
e) Click create.
3. Create the constraint, Vol.
a) In the constraint= field, enter VOL.
b) Uncheck the box next to lower bound.
c) Check the box next to upper bound, then enter 800000.
d) Click response= and select Vol.
e) Click create.
4. Click return to go back to the Optimization panel.
3. In the Save As dialog, specify location to write the OptiStruct model file and enter
os_buckle_optimization for filename.
For OptiStruct input decks, .fem is the recommended extension.
4. Click Save.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to optimization.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to run the optimization.
The following message appears in the window at the completion of the job:
OPTIMIZATION HAS CONVERGED.
FEASIBLE DESIGN (ALL CONSTRAINTS SATISFIED).
OptiStruct also reports error messages if any exist. The file os_buckle_optimization.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.
9. Click Close.
Figure 822:
Figure 823:
b) With the animation running, use the slider bar to adjust the speed of the animation.
The seek slider and playback speed slider (top and bottom respectively) are located next to
the playback controls.
c) Click the Animation Controls icon next to the seek slider and activate the Bounce option to
review a back and forth animation of the impact.
d) Stop the animation and use the Current time: slider bar to manually control the animation.
Figure 824:
Figure 825:
Figure 826:
c) With the animation running, use the speed slider bar to adjust the animation.
Increase the scale to better see the buckling mode shape.
d) Activate the Bounce option to review animation of the impact.
e) The animation can also be manually controlled using the time slide to manually control the
animation.
Shape optimization requires you to have knowledge of the kind of shape you would like to change in
the structure. This may include finding the optimum shape to reduce stress concentrations to changing
the cross-sections to meet specific design requirements. Therefore, you need to define the shape
modifications and the nodal movements to reflect the shape changes. Shape optimization requires the
use of two cards DESVAR and DVGRID. They can be defined using HyperMorph. Then these cards are
included in the OptiStruct input file along with the objective function and constraints to run the shape
optimization.
Constraints Maximum von Mises stress of the joint < 200 MPa.
This loads the 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 for
OptiStruct.
If the job is successful, new results files should be in the directory where the
rail_joint_original.fem was written. The rail_joint_original.out file is a good place to look for
error messages that could help debug the input deck if any errors are present.
3. Set the Result type to Element Stresses [2D & 3D] (t) and von Mises.
4. Click Apply.
Take note of the Maximum von Mises Stress of the joint.
5. From the Page Controls toolbar, click to delete the page within the HyperView client.
You should now be on Page 1 in the HyperMesh client.
6. Click return to exit the panel.
Figure 831: Rail Domains After The Circular Edge Have Been Split
Creating Shapes
In this step, you will create shapes using the created domains and handles.
1. Click the morph panel.
2. Modify the curvatures of selected edge domains for the first shape.
a) Select the alter dimensions subpanel.
The alter dimensions subpanel can be used to modify the curvatures of selected edge
domains.
b) Set the first switch to curve ratio.
c) Set center calculation to by edges.
d) Under the edges only: domains selector, set the switch to hold ends.
Holding two ends of a selected edge domain allows a change of curvature of the selected
edge without altering its end points.
e) Leave the other settings with the defaults.
f) Using the domains selector, select the red edge-domains.
4. Click undo all to prepare for the generation of the next shape.
5. In the Model Browser, right-click on Shape and select Hide from the context menu.
6. Select the alter dimensions subpanel.
7.
Next to the domains selector, click to reset and remove any previous selections.
8. Modify the curvatures of selected edge domains for the first shape.
a) Using the domains selector, select the red edge curves.
b) Click morph.
A new curvature is applied to the selected eight edge domains.
9. Save the shape, sh2.
a) Select the save shape subpanel.
b) In the shape= field, enter sh2.
c) Toggle as handle perturbation to as node perturbation.
d) Click color and change the color of the shape vectors or leave the default color.
e) Click save.
10. Click undo all to prepare for the generation of the next shape.
11. In the Model Browser, right-click on Shape and select Hide from the context menu.
12. Create a new shape as a linear combination of existing shapes.
a) Select the apply shapes subpanel.
b) Using the shapes selector, select sh1 and sh2.
c) In the multiplier= field, enter 1.0.
d) Click apply.
13. Save the shape, sh3.
a) Select the save shape subpanel.
b) In the shape= field, enter sh3.
c) Toggle as node perturbation to as handle perturbation.
d) Click color and change the color of the shape vectors or leave the default color.
e) Click save.
The new shape, sh3, includes influences from both sh1 and sh2 shapes.
CAUTION: Do not click undo all at this moment, because one more shape based on this
third shape change will be created.
14. In the Model Browser, right-click on Shape and select Hide from the context menu.
15. In the Model Browser, Component folder, right-click PSHELL and click Hide from the context
menu.
The component is turned off for ease of visualization.
16. Modify the curvatures of selected edge domains for the first shape.
a) Select the alter dimensions subpanel.
b)
Next to the domains selector, click to reset and remove any previous selections.
c) Switch the top selector from curve ratio to distance.
This feature allows you to shorten the distance between selected domains.
d) Set end a to nodes and handles.
e) Using the node a and node b selectors, select the nodes indicated in Figure 839.
Figure 839:
Once nodes a and b are selected, the distance between node a and node b is measured
automatically and appears in distance = field. The distance between node a and node b is
about 43.
f) Under followers (end a), use the handles selector to select the eight handles shown by the
downward pointing arrows in Figure 839.
g) Under followers (end b), use the handles selector to select the eight handles near the
opposite face of the tube.
h) Set the bottom selector to hold middle.
These components are turned on for ease of visualization.
i) In the distance= field, enter 20.
j) Click morph.
A rectangular shape appears to the joint.
17. Save the shape, sh4.
a) Select the save shape subpanel.
b) In the shape= field, enter sh4.
c) Toggle as handle perturbation to as node perturbation.
d) Click color and change the color of the shape vectors or leave the default color.
e) Click save.
18. Click undo all to restore the mesh to the baseline configuration.
19. In the Model Browser, right-click on Shape and select Hide from the context menu.
20. Click return three times to go the main menu.
Four design variables are created with the same initial value, lower bound, and upper bound.
HyperMesh automatically links the design variables to each shape, respectively and assigns names
to each design variable the same as its associated shapes.
6. Animate the shapes.
a) Click animate.
b) Click simulation= and select SHAPE-sh1(1).
c) Set data type= to Perturbation vector.
d) Click modal.
e) Click next and then animate to see the next shape variable, and so forth.
7. Click return three times to go back to the Optimization panel.
Figure 841:
3. Set the Result type to Element Stresses [2D & 3D] [t] and von Mises.
4. In the Results Browser, select the last iteration.
5. Click Apply.
The stress contour shows on top of the shape changes applied to the model. Verify that this value is
around the constraint value specified.
Figure 843: von Mises Stress for the Last Iteration (Max < 200 MPa)
The mass of the system is to be minimized by controlling 12 shape design variables while the stress
should be less than an allowable value. Left link is a driving link whose angular velocity is 50 rad/sec.
Units (kg, N, cm, s).
Figure 845: Constant velocity (50 Rad/s) applied to the joint 66299
4. Click return.
3. In the Save As dialog, specify location to write the OptiStruct model file and enter
4bar_design_analysis for filename.
For OptiStruct input decks, .fem is the recommended extension.
4. Click Save.
The input file field displays the filename and location specified in the Save As dialog.
5. Set the export options toggle to all.
6. Set the run options toggle to analysis.
7. Set the memory options toggle to memory default.
8. Click OptiStruct to launch the OptiStruct job.
If the job is successful, new results files should be in the directory where the
4bar_design_analysis.fem was written. The 4bar_design_analysis.out file is a good place to look
for error messages that could help debug the input deck if any errors are present.
3. Set the Result type to Element Stresses (2D & 3D) (t).
4. Click Apply.
5. Click the Legend tab.
6. Click Edit Legend.
7. Set the Type to Dynamic scale.
Other properties can be changed here to created the desired legend.
8. On the Page Controls toolbar, set the page layout to , which create two vertical windows.
c) Click return.
3. Create constrains.
a) From the analysis page, click the constraints panel.
b) Select all dofs (1 through 6).
All of the dofs (1 through 6) should be fixed to remove the 6 rigid body motion of each
flexible body. Make sure that dof1 through dof6 are all checked in the constraints panel.
c) Click the center of the lower spider of the component Left. You should see two node numbers
at one location; choose node 288.
d) Click the center of the left spider of the component Middle and choose node 143.
e) Click the center of the lower spider of the component Right and choose node 441.
f) Set load type to SPC.
g) Click create.
Figure 849:
8. Click create.
9. Click return to go to the optimization panel.
A constraint is defined on the response Stress. The constraint will force the maximum stress on
2
SUBCASE1 to be less than 30000.0 N/cm .
2
Figure 850: von Mises stress contour (Max < 30000 N/cm )
2. On the Standard toolbar, click and open the last iteration (highest) number result file of
4bar_design_opt_des_0#.h3d from where the optimization was run.
3. Click Apply.
4. On the Results toolbar, click to open the Contour panel.
Open the file 4bar_design_opt.dsvar to see how OptiStruct changed the DVs during the optimization
process.
This will show that all DVs for the right and mid arms went to the limit of 1.2, showing that minimizing
the mass of these two arms are key to reducing the Stress.
Figure 852:
2. Select the freeshape3D_mfg.hm file you saved to your working directory from the
optistruct.zip file. Refer to Accessing the Model Files.
3. Click Open.
The freeshape3D_mfg.hm database is loaded into the current HyperMesh session, replacing any
existing data. The database only contains geometric data.
Figure 854:
The barrier should be constructed by shell elements with the smallest number of elements possible.
For this exercise, the mesh barrier was already created and the component name is barrier.
3. In the Results Browser, select Iteration 14, which is the final iteration result.
4. On the Results toolbar, click to open the Deformed panel.
2. Set the Result type to Element Stresses (2D & 3D) (t).
3. Set the stress type to von Mises.
4. Under selection, set the selector to Elements.
5. Click Elements > By set, then select stress.
6. Click Add and close.
7. Click Apply.
The torque control arm is loaded by brake force and vertical force. Two load time histories acquired for
279 seconds with 1HZ are applied. The material of the control arm is Steel, whose S - N curve.
Figure 862:
The control arm model is loaded. This model includes a whole definition of two static subcases,
elements sets, and material static properties, and so on.
3. Click Apply.
Figure 863:
4. Click Apply.
The current definitions are saved.
Figure 864:
Figure 865:
Figure 866:
In this step, one event consisting of two load time history is created, in other words, the linear
superposition of the stress caused by the two load time history is requested during analysis. Using this
event, one load sequence is constructed.
1. Add a loading definition.
a) In the panel area, click Add.
The Loading Definition dialog opens.
Figure 867:
Figure 868:
Figure 869:
If the job was successful, new results files can be seen in the directory where the OptiStruct model file
was written. The default files written to your directory are:
tarm_fatigue_opti.0.4.fat An ASCII format file which contains fatigue results of each fatigue
subcase in iteration step.
tarm_fatigue_opti_s4.h3d Hyper 3D binary results file, with both static analysis results and
fatigue free-shape optimization results.
tarm_fatigue_opti.out OptiStruct output file containing specific information on the file set
up, the set up of your fatigue problem, compute time information,
etc. Review this file for warnings and errors.
Figure 870:
HyperView opens and loads the tarm_fatigue_opti_s4.h3d results file for life results on top of
shape results.
2. In the Results Browser, select the last iteration (Iteration 11).
3. On the Animation toolbar, click to stop the animation.
6. In the Legend tab, click Edit Legend to edit the legend so that it is the same as Figure 871 and
Figure 872.
7. Click Exit to unload fatigue process manager.
A regular shape optimization has been defined in the model. The formulation of this optimization is
stated as:
Objective Minimize the maximum (minmax) displacement at the node where
the excitation load was applied.
1. In the Model Browser, review the model, loadstep, and optimization setup.
Figure 874:
4. Click animate.
One of the shapes should be displayed in the simulation= field.
5. Click linear.
The animation of that shape displays.
6. Review the other shapes by clicking next or prev.
7. Click return to go back to the optimization panel.
Both Subcase and Bulk Data Entries for global search are created with default parameters.
Figure 875:
Three shape design variables are created from the shapes created in the previous step.
The contour plot of grid temperature is applied on top of the optimized shape now.
Figure 878: Temperature distributions of the original design and the optimized design
B
basic small displacement fea tutorials 19
C
Combined Topology and Topography Tutorials 691
G
Gasket and Engine Block System Connected Using Head Bolts 357
L
Large Displacement FEA Tutorials 399
Large Displacement FEA Tutorials OptiStruct 399
M
multibody dynamics analysis tutorials 457
N
Nonlinear Adaptive Criteria and Nonlinear Intermediate Results 413
nonlinear implicit analysis 400
O
OptiStruct 19, 457
OS-0010: Running OptiStruct from HyperMesh 12
OS-T: 1000 Linear Static Analysis of a Plate with a Hole 20
OS-T: 1010 Thermal Stress Analysis of a Coffee Pot Lid 35
OS-T: 1020 Normal Modes Analysis of a Splash Shield 45
OS-T: 1030 3D Inertia Relief Analysis 55
OS-T: 1040 3D Buckling Analysis 64
OS-T: 1050 Connection of Dissimilar Meshes using CWELD Elements 73
OS-T: 1060 Analysis of a Composite Aircraft Structure using PCOMPG 83
OS-T: 1070 Analysis of an Axi-symmetric Structure 95
OS-T: 1080 Coupled Linear Heat Transfer/Structure Analysis 103
OS-T: 1085 Linear Steady State Heat Convection Analysis 116
OS-T: 1090 Linear Transient Heat Transfer Analysis of an Extended Surface Heat Transfer Fin 127
OS-T: 1100 Thermal Stress Analysis of a Printed Circuit Board with Anisotropic Material Properties 152
OS-T: 1110 Setting up a Modal Analysis 159
OS-T: 1300 Direct Frequency Response Analysis of a Flat Plate 166
995
OS-T: 1305 Modal Frequency Response Analysis of a Flat Plate 177
OS-T: 1310 Direct Transient Dynamic Analysis of a Bracket 189
OS-T: 1315 Modal Transient Dynamic Analysis of a Bracket 197
OS-T: 1320 Nonlinear Gap Analysis of an Airplane Wing Rib 206
OS-T: 1325 Random Response Analysis of a Flat Plate 219
OS-T: 1330 Acoustic Analysis of a Half Car Model 226
OS-T: 1340 Fatigue (Stress - Life) Method 239
OS-T: 1340 Fatigue Process Manager (FPM) using S-N (Stress - Life) Method 249
OS-T: 1340 Fatigue using S-N (Stress - Life) Method 239
OS-T: 1350 Fatigue (Strain - Life) Method 263
OS-T: 1350 Fatigue Process Manager (FPM) using E-N (Strain - Life) Method 273
OS-T: 1350 Fatigue using E-N (Strain - Life) Method 263
OS-T: 1360 NLSTAT Analysis of Gasket Materials in Contact 289
OS-T: 1365 NLSTAT Analysis of Solid Blocks in Contact 302
OS-T: 1370 Complex Eigenvalue Analysis of a Reduced Brake System 316
OS-T: 1371 Brake Squeal Analysis of Brake Assembly 321
OS-T: 1372 Rotor Dynamics of a Hollow Cylindrical Rotor 327
OS-T: 1375 Response Spectrum Analysis of a Structure 334
OS-T: 1380 Computation of Equivalent Radiated Power 344
OS-T: 1385 Heat Transfer Analysis on Piston Rings wth GAP Elements 349
OS-T: 1390: 1D and 3D Pretensioned Bolt Analysis of an IC Engine Cylinder Head 357
OS-T: 1392 Node-to-Surface versus Surface-to-Surface Contact 379
OS-T: 1393 Basics of Contact Properties and Debugging 390
OS-T: 1500: bending of plate 400
OS-T: 1510 Follower Loads 413
OS-T: 1520 Finite Sliding of Rack and Pinion Gear Model 428
OS-T: 1600 Fluid-Structure Interaction Analysis of Piezoelectric Harvester Assembly 437
OS-T: 1610 Thermal Fluid-Structure Interaction Analysis on a Manifold 449
OS-T: 1900 Dynamic Analysis of a Three-body Model 458
OS-T: 1910 Dynamic Analysis of a Slider Crank with a Flexible Connecting Rod 469
OS-T: 1920 Large Displacement Analysis of a Cantilever Beam 485
OS-T: 1930 Generating a Flexible Body for use in MotionSolve 495
OS-T: 1940 MBD Rigid Contact 501
OS-T: 1950 Curve to Curve Constraint 510
OS-T: 1960 Defining Point to Deformable 519
OS-T: 2000 Design Concept for a Structural C-Clip 529
OS-T: 2005 Design Concept for a Structural C-Clip with Minimum Member Size Control 545
OS-T: 2010 Design Concept for an Automotive Control Arm 549
OS-T: 2020 Increasing Natural Frequencies of an Automotive Splash Shield with Ribs 563
OS-T: 2030 Control Arm Topology Optimization with Draw Direction Constraints 577
OS-T: 2040 Spot Weld Reduction using CWELD and 1D 585
OS-T: 2050 Pattern Repetition using Topology Optimization 589
OS-T: 2060 Symmetry and Draw Direction Applied Simultaneously in Topology Optimization 598
OS-T: 2070 Topology Optimization of a Reduced Model using DMIG 605
OS-T: 2080 Topology Optimization of a Hook with Stress Constraints 618
OS-T: 2090 Extrusion Constraints 625
OS-T: 2095 Frequency Response Optimization of a Rectangular Plate 631
996
OS-T: 2098 Excavator Arm Model 651
OS-T: 3000 Topography Optimization of a Plate Under Torsion 659
OS-T: 3010 Topography Optimization of an L-bracket 670
OS-T: 3020 Automatic Recognition of Bead Results of an L-bracket 678
OS-T: 3030 Random Response Optimization 684
OS-T: 3100 Combined Topology and Topography Optimization of a Slider Suspension 692
OS-T: 3200 Optimization-driven Design of a Composite Aircraft Underbelly Fairing 700
OS-T: 3300 Using the Lattice Optimization Process 726
OS-T: 3400 Design an Open Hole Tension (OHT) 741
OS-T: 4000 3D Size Optimization of a Rail Joint 779
OS-T: 4010 Size Optimization of a Welded Bracket 788
OS-T: 4020 Composite Bike Frame Optimization 796
OS-T: 4030 Discrete Size Optimization of a Welded Bracket 806
OS-T: 4040 Size Optimization of a Shredder 814
OS-T: 4050 Optimization of a Horizontal Tail Plane 827
OS-T: 4070 Free-sizing Nonlinear Gap Optimization on an Airplane Wing Rib 856
OS-T: 4080 Minimization of the Maximum Stress of a Rotating Bar: A Size Optimization 865
OS-T: 4090 Manufacturing Constraints in a Free-size Optimization of a Composite Structure 872
OS-T: 4095 Size Optimization using External Responses (DRESP3) 883
OS-T: 5000 2D Shape Optimization of a Cantilever Beam 891
OS-T: 5010 Cantilever L-beam Shape Optimization 902
OS-T: 5020 3D Bracket Model using the Free-shape Method 910
OS-T: 5030 Buckling Optimization of a Structural Rail 923
OS-T: 5040 Rail Joint 933
OS-T: 5050 4 Bar Linkage 953
OS-T: 5060 3D Model using the Free-shape Method with Manufacturing Constraints 964
OS-T: 5070 Fatigue Optimization of a Torque Control Arm 972
OS-T: 5080 Global Search Optimization 983
OS-T: 5090 Thermal Optimization on Aluminum Fins 989
R
run OptiStruct at the command line 18
S
Shape Optimization Tutorials 890
Size Optimization Tutorials 778
T
Topography Optimization Tutorials 658
Topology Optimization Tutorials 528
tutorials implicit 289, 302
997