2011-26-0103
Process Improvements in Structural Optimization
and NVH
Rolf Fischer, Michael Klein and Christian Wulf
INTES GmbH, Stuttgart, Germany
ABSTRACT
Virtual development in the automotive industry like other
development processes is always under pressure to improve
the processes to save time and costs. In addition, the analyses
should include optimization techniques to get the best relation
between weight and stiffness. But it emerges that vibration
analysis must also be included in the optimization at the
same time. So, the situation in virtual development can
be characterized by severe time constraints and a need to
increase the complexity of the analysis and the processes.
One possible solution for these conflicting positions is to
improve the processes and methods for structural optimization
and the meshing for fluid structure analysis. The most
important key features for the improvement of the process
are:
 One tool with state of the art solvers,
 Several analysis options: static analysis, dynamic
(vibration) analysis, fluid-structure dynamic analysis,
 Combination of several analysis types in one optimization,
 Integrated optimization algorithms (efficiency),
 Graphical user interface for the definition of complex
analysis physics, including optimization,
 Graphical user interface for the automatic and semi
Automatic meshing of holes and cavities and
 Improvement for all time consuming, up to now manual,
processes.
One new approach will be presented for a guided definition
and checking of processes in a graphical user interface.
The combination of different analysis types in combination
with different optimization types like shape, size and bead
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Published on
19th-21st January
2011 SIAT, India
Copyright © 2011 SAE International and Copyright © 2011 SIAT, India
optimization will be demonstrated. A number of examples will
be presented to illustrate the achievements in the different
areas of analysis. For the improvement of manual processes
the wizard technique for cavity meshing (hole detection, hole
closing, meshing and coupling between fluid and structure)
as requirement for NVH analysis will be presented.
The combination of several improvements in the process
of optimization and NVH analysis leads to significant time
savings. All together lead to considerable better products in
a shorter time frame.
Keywords : NVH, FE Analysis, Fluid Structural Modelling
INTRODUCTION
Today the process for Finite Element (FE) analysis consists
of three major steps:
1. Pre-processing,
2. Computation and
3. Post-processing.
In many cases users want to apply one general pre- and
post-processor for creation of models for many analysis
disciplines like crash analysis (NVH, stress analysis, etc.).
Those solutions have all important general features available.
Beginning with CAD-import, followed by geometry repair
and geometry creation, complete variety of meshing tools
and solver specific model data specification are part of a
complete pre-processor. Those tools have a big advantage
in multi solver environments, with high productivity in all
features they can deliver.
But on the other hand those general tools fall behind for
complex solver specific functionality [1]. Typically there are a
Symposium on International Automotive Technology 2011
lot of model properties that are not completely supported. As
long as those properties are not complex and need no visual
feedback they can be added by a text file. Those inputs are
very error prone, but a possible solution. Left are the inputs
that need graphical interaction, those solver functionality,
mainly high advanced solutions, remain unused.
In that case, developer of FE solver has to think about a new
Graphical User Interface (GUI) which provides the missing
support for the solver functionality. The complete solver
input deck enhanced with the input lines of complex solver
functionality is the result of the GUI. No additional editor
input should be needed. The developer of the FE solver is
the correct instance which can make sure that this is fulfilled
and that all functionalities are up to date and developed in
conjunction with the solver.
Optimization and Fluid-Structure (FS) analysis are two typical
areas where very specific support is needed. In general,
structural optimization comprises the following methods [2].
 Topology optimization for concept studies
 Sizing optimization for best property entities of structural
members
 Shape optimization for geometry improvements
 Bead optimization as a special class of geometry
improvements
To get all advantages, the integration in the process by a GUI
and in addition the integration in the FE solver technology,
is highly desirable.
The user of FE analysis not only want to work in a single
environment with a consistent model description for structural
analysis and optimization, but they also still fear unacceptable
run times for their today’s model sizes and expect their
reduction from the software developers. Main goals to
achieve best results are:
 State of the art solver technology in all important FE
analysis disciplines as linear static analysis, contact
analysis, non-linear static analysis, dynamic analysis
(vibrations), fluid structure analysis and heat transfer
analysis
 Integration of optimization methods in FE analysis to
apply classical efficient solving tools for optimization,
too. Besides the mere speed of FE analysis solvers, the
efficient handling of large models makes it possible to
optimize such models. The availability of optimization
for large models is the key for final acceptance of
optimization in standard analysis workflows
 Integration of well-known condensation techniques in
optimization. FE analysis codes usually maintain a
number of condensation techniques like substructuring
in statics and dynamics. Besides other effects, the
reduction of problem size is the most important
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reason to apply condensation. The application of these
techniques in optimization has a large potential to fulfil
the requirements for reduction of run times
 Extension of all analysis features in FE analysis for use
in optimization and extension of optimization features to
fulfil the needs of all FE analysis. Hence, optimization
needs to have potential to handle:
 Coupled field problems like fluid-structure analysis
 Coupled field problems like heat-transfer-stress
analysis
 Non-linear analysis and
 Combination of analysis like statics and dynamics
(vibrations)
 Extension of post-processing for special optimization
needs. There are special results (like sensitivities or
element filling ratios) from optimization, which need
special treatment in post-processing.
In the following sections a few basic concepts are presented
which were developed. Integration of optimization features
in the FE analysis solver will be described. Process
improvements by combination of GUI and integration are
shown with examples.
THE PROCESS OF FE ANALYSIS
The usual process chain of a FE analysis process as shown
as ‘classic’ in Fig. 1 is characterized by an embedding of a
solver in the pre- and post-processing. So, a solver-oriented
modeling is used to amend the existing pre-processor and is
linked directly to the solver. In order to fit perfectly in the
process chain, the following requirements have to be fulfilled
for a model editing and visualization tool:
 Interfaces to import models from the pre-processor or
just meshes from CAD (‘direct’ process chain in Fig.1
FE analysis process chain in three varieties) or any
other meshing tool (‘multi’ process chain in Fig. 1 FE
analysis process chain in three varieties)
 Direct post-processing capabilities or interfaces to
support other post-processors
 Data consistency between the pre- and post-processor
and the model editor on the one hand and the model
editor and the solver on the other hand
 Intuitive operation of the tool in order to prevent
expensive training for the analysis engineer on another
software
Because the model editing tool is seen as an amendment of
the pre-processing step, there is an important issue regarding
the model reference. If the reference is the solver input, then
the model editor is the main tool to complete and check
all aspects of a model. But if the pre-processor model is
 Symposium on International Automotive Technology 2011

Figure 1. FE Analysis Process Chain in Three Varieties

the reference, then all model changes made by the model

editor have to be fed back to the pre-processor. In general, Figure 2. Common Data Structures for Solver and GUI
this is probably not possible for all features. So, this is an
open point and further experiences are needed to develop a
suitable concept to solve this problem. Such clear concepts also require a clear look and feel of
the GUI as shown in Fig. 3 where the basic screen provides
much space for the visualization of a model and the wizards
Basic Concepts are highlighted by the order as second scroll down menu,
In order to achieve data consistency it is seen as a crucial directly after the default ‘File’ scroll down menu.
point that the model editor and the solver use the same data
structures. Fig. 2 shows this concept where a programming
interface provides the model editor with all required model
data. This concept has the following advantages:

 Data consistency is a built-in feature,

 All interfaces of the solver can be used directly for

the model editor,

 Development of new optimized data structures can be

saved, or if needed used in both products,

 The solver data structures are already designed to

support large models in a very efficient way. This will
result in a highly effective work with the GUI.

In addition, advanced graphic concepts are used to support
specific solver functionalities:
 Visualization and handling of large models,
 Wizards to support ease of use, in cases:
 where modelling features are not frequently used,
 visual feedback is needed and
Figure 3. GUI with Wizards
Wizard Technique
One of the basic concepts of the model editing tool is the
wide use of application wizards which provide an easy-to-use
means for specific modelling features. This has the following
advantages:

 mistakes can be shown directly.
 Scripting support automation of modelling processes,
 Configurability to allow the adaption of the GUI to
modelling and post-processing standards.
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 A real application aid for the occasional user of such
features
 The user is guided through all necessary modelling steps
for the particular feature. So, this helps not to forget
important specifications
Symposium on International Automotive Technology 2011

 In addition, this guidance has an effect like a tutorial:

The user recognizes all necessary modelling steps
without any need to collect this information from
manuals

 At the end, a complete read-to-run model is achieved.

But, the formal completeness of the model is not a
guarantee, that all intended specifications are really made

In the following, a fluid-structure modelling example for the

application of a wizard is described in more detail.

Wizard for Fluid Structure Modelling

The completion of a model may include even mesh
generation. This is demonstrated by the wizard for acoustic Figure 5. List of Detected Holes and Visual Feedback
mesh generation. The wizard itself appears in an independent
window that can be placed at the best position on the screen.
In Fig. 4 the wizard window with several tabs is placed on
the left side next to the graphic window.

Figure 6. Automatic Meshing of Detected Holes

Figure 4. Basics Page FS Wizard

Starting from a structural mesh with several holes the wizard

supports:

 The detection of holes (Fig. 5) in general preprocessors

is a complete manual process without specific support.
By the automatic detection the process is less error
prone and much faster.

 The automatic and semi automatic closing of holes

(Fig.6) and automatic meshing of detected holes.

 The generation of an enclosed fluid mesh, and the

generation of interface (or coupling) elements which
couple the structural displacement degrees of freedom
with the fluid pressure degrees of freedom (Fig. 7).

Such a coupled model allows a fluid-structure acoustic

analysis where structure and fluid are seen as one vibrating
Figure 7. Enclosed Fluid Mesh and Coupling Elements
continuum.

4

In this sense, a wizard is not only a guidance through a
more or less complex model specification task, but a wizard
can also provide automated tools to support an easy-to-use
model set-up. In particular, the acoustic mesh generation by
a standard pre-processor and post-processor could be a very
time consuming task. So, the functionality contained in the
wizard is saving a lot of modelling time. If this functionality
is combined with scripting, the acoustic mesh generation can
be performed in a batch process for certain types of structures
saving additional modelling time.
THE PROCESS OF OPTIMIZATION IN
CONJUNCTION WITH FE ANALYSIS
The usual process chain of FE analysis is extended by the
optimization. Two major factors have the most influence of
the adapted process:
 Model extension to describe the optimization task as an
additional modelling task and
 The optimization loop around the FE analysis as
additional computation time.
One basic demand is that the same models should be used
to get the same results on the same accuracy level. Special
models are not applicable, because they may show different
behavior and the extra effort to evaluate the model to be
accepted as replacement for the usual model. Only integrated
optimization is able to perform this task in an acceptable time
frame, because the overhead for the integrated optimization
is the smallest that is possible.
Integrated Optimization
In each optimization constraints shall limit the value range for
design variables as well as for the response quantities like:
 Displacements, velocities, accelerations
 Contact pressure
 Element forces
 Reaction forces
 Stresses
 Compliance
 Weight
 Eigenfrequencies
 Sound radiation power density
 Temperatures
 Heat flux
 General constraints as combination or arbitrary function
of the above mentioned quantities. Such functions
include global criteria like max/min, absmax/absmin, or
RMS.
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Symposium on International Automotive Technology 2011
The objective function of an optimization may be the weight
or any other specified constraint.
The following solvers are available for optimization:
 Linear statics with/without contact
 Non-linear statics with/without contact
 Heat transfer
 Inertia relief
 Eigen value analysis
 Modal frequency response analysis
 Steady-state heat transfer analysis
 Combinations of the different solvers
For frequency response optimization amplitudes, phases, real,
and imaginary values of the above listed results are available
for constraint or objective definition. The limits for the
constraints can be made dependent on frequency. Different
solvers can be combined in one optimization task as well as
sizing, bead and shape parameters.
The optimization allows taking into account several loading
cases as well as different boundary conditions. In addition,
dynamic mode frequencies can also be optimized, where a
mode tracking during the structural changes is performed
automatically. If a small part of a structure is optimized,
substructuring can be used to reduce run time by separating
the design space in the top component. So, the reduction of
the unmodified parts has to be done only once.
The results of an optimization are the history of the objective
function and an overview on the validity of the design after
each iteration. In addition, the values of the design variables
and the constraints are available as a function of the iterations
performed. These functions may easily be viewed as xy-plots
with direct mapping of xy-results to model entities. The
export of sensitivities is also possible.
Shape, bead and sizing optimization differ in the kind of
design change:
Shape Optimization
The usual approach to parametrize an existing mesh for shape
modifications is to let the user define shape basis vectors,
i.e. to define vectors of coordinate modifications associated
with design variables. The most user-friendly way to define
shape basis vectors is realized in PERMAS, can be easily
performed with VisPER and consists of only three steps:
 Defining a design element as the arbitrarily shaped area
to be modified by selection of an element set
 Defining coordinate modifications for a small subset of
design nodes within the design element
Symposium on International Automotive Technology 2011

 Assigning of design variables initial values and range  Damping parameter of damping elements
limits to the coordinate modifications of design nodes  Parameters of control elements
The coordinate modifications of all other FE-nodes within  Convection film coefficients
the design element are then smoothly interpolated between
 Material parameters
those of the design nodes and the zero values at the boundary
of the design element. The interpolant has the fundamental
properties of: WIZARDS FOR OPTIMIZATION
 C2-continuity inside the design element Because it is not yet standard in pre-processors to provide for
the definition of design elements, Wizards for optimization
 C0-continuity at the boundary of the design element support all steps to set-up the optimization model for shape,
 Minimizing the mean squared curvature of the complete bead, sizing and topology optimization as shown in Fig. 3.
shape deformation This allows to start from the existing finite element mesh
and one gets all additionally generated input for a full
 Being of global nature, i.e. every design node coordinate
optimization specification.
modification affects every interpolated coordinate
modification Basic definition is for all types of optimization the definition
of the suited design elements. Visual feedback for all steps
With additional restraints like symmetries, constant or linear
avoid wrong definitions for all steps during the input. Fig.8
interpolation or further boundary conditions the fundamental
shows the visualization of symmetry conditions for design
properties listed above may be modified to gain application-
elements of a car body.
oriented shape deformations. Furthermore the possibility
to superimpose different shape deformations defined for
different design elements allows to enrich the solution space
for the shape optimization by an arbitrary variety of shape
changes. Finally also sizing and shape design variables may
be combined, i.e. they may affect the same finite elements
simultaneously.

Bead Optimization
Compared to the design elements for shape optimization
described above, the only difference of design elements used
for bead pattern optimziation is, that the user only needs to
specify one design node and a design variable, and instead
of interpolating the coordinate modification of the other
nodes, bead design variables according to this user-defined
reference are generated automatically. This way, the specified
design area is equipped with required optimization degrees of
freedom for bead pattern design. Again additional conditions Figure 8. Visualization of Symmetry Conditions
allow for specific properties of the resulting bead patterns.
The definition of design nodes and the direction of shape
Sizing Optimization
changes is supported by one step of the wizard. Even large
For optimal sizing problems property dependencies may be models from the industry with complex connections and three
defined for the whole design element. They are valid for all dimensional transitions between several parts are supported.
corresponding finite elements, independent on its location After the definition of the design nodes in the next step the
within the design element. shape basis vectors are calculated. This is one big advantage
resulting from the common data structures for solver and
The following design variables are provided: GUI (Fig. 2 and Fig. 9) and from integrated optimization.
 Areas of cross section, inertia moments and general Fig. 9 shows, based on the calculated shape basis vectors,
functions between these properties for beam elements the visualisation of the shape changes.

 All parameters of standard beam cross sections
 Thicknesses/offsets/nonstructural mass of membrane and
shell elements
 Stiffness and mass of spring elements
 Mass of mass elements
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The shape can be changed interactively and gives a
deeper understanding of the chosen design space and the
geometrical degree of freedoms (solution space). Additionaly
this visualization is used to define meaningful limits for the
design variables interactively and to check the possible mesh
distortions.

Figure 9. Visualization of Shape Changes Based on
Shape Basis Vectors
In the same way design nodes are visualized for bead
optimization (Fig. 10). For the best overview, even in
complex models, only one arrow is depicted per sheet.
As final step for an optimization design constraints and
objective function have to be defined (Fig. 11). This page
and the related subpage, that has individual type of design
Figure 10. Visualization of Bead Forming Direction
constraint dependent content, guides the user through the
complex input. At the same time the individual subpages
show all possibilities and supports the user by manual like
framework. Additional help is always very close by tool
tips and the “Help”-button, that is directly linked to the
suited manual page. In addition, the help function can be
complemented by company specific rules.
After finishing the wizard the optimization input is complete.
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Symposium on International Automotive Technology 2011
Figure 11. Shape Wizard Design Constraints Definition
CONCLUSIONS
Concepts have been presented which support solver-oriented
model editing and visualization in combination with
integrated optimization. By this way, the following goals
will be achieved:
 Inspection and checking of complete solver models,
 Completion of not ready-to-run models,
 Facilitating complex analysis tasks like fluid-structure
analysis and optimization,
 Supporting new solving features.
Such a tool is perfectly fitting into a FE analysis process
because it is simply the missing link between standard pre-
processing and post-processing and computation. The related
benefits are reduced modelling times and cost savings for
model completion. Moreover, all methodological innovations
introduced by the corresponding solver can be taken up faster
by the users. Wizards are the means to facilitate the use of
complex analysis tools.
Future analysis tasks will be characterized by more physics
(like coupled phenomena), optimization and larger models.
Solver-oriented model editing and visualization will be the
aid to cope with this model complexity.
NVH process for optimization tasks gets best support by
the wizards for:
Symposium on International Automotive Technology 2011

 Adding a fluid mesh to an existing structure and REFERENCES

 Define complex optimization tasks 1. PERMAS version 13: “Users’ Reference Manual”,
INTES Publication No. 450, Stuttgart 2010
Integrated optimization adds new features to the GUI and
makes optimization possible with large models, because the 2. Fischer R, Helfrich R and Wulf C, “Integrated
high efficiency of the solver is combined with the efficiency Optimisation in Static and Dynamic Structural Analysis”,
of integrated optimization. The key features for the big Proceedings: NAFEMS World Congress, Malta, May
advantage of integrated optimization for NVH are: 2005
 Simultaneous sizing, bead and shape optimization
3. Helfrich R, “New Concepts For Finite Element Model
 Simultaneous static and dynamic load cases in Editing And Visualization”, Proceedings of NAFEMS
optimization World Congress, Vancouver, Canada, May 2007
 Optimization using static and dynamic substructuring
 Manufacturing constraints and symmetry conditions and
CONTACT INFORMATION
Michael Klein
 Using efficient optimization algorithms to have as few
analyses as possible klein@intes.de

Integrated optimization will support the future needs of Guled F D

optimization tasks by a complete set of features, the build gfd@nfotecindia.com
in high efficiency. Both together, integrated optimization and
solver-oriented model editing, make it possible to integrate
optimization in the standard workflows without big additional
effort.
ABBREVIATIONS
GUI Graphical User Interface

NVH Noise Vibration Harshness

The Technical Paper Review Committee (TPRC) SIAT 2011 has approved this paper for publication. Positions and opinions advanced in this paper are those of the author(s) and not necessarily those of
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