Innovation Intelligence®Application of OptiStruct to Solutionof Powertrain ProblemsWoytek TworzydloAETC - April 24, 2013
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Altair OptiStruct• A comprehen...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct for Powertrain Appl...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Powertrain Modeling Requiremen...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct 12.0 – Pretensioned...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct 12.0 – Gasket Eleme...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Gasket Elements – cont’d• Resu...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct 12.0 Plasticity Enh...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct 12.0 CONTACT/Fricti...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.STANDARD IMPROVEDOptiStruct 12...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Thermal (Heat Transfer) in Opt...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Powerful NVH Capabilities• Cor...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Setup in Hypermesh and SimLab ...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Contact Definition Tools• Hype...
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Example: Engine Assembly Syste...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Gasket loading curveGasket un-...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.• Apply Pre-tension Loading (4...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 1: Stresses in Bolts
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 1: Gasket Pressure and...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.• Lock Pre-tension Displacemen...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Cylinder HeadSubcase 2: Temper...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 2: Stress Contour
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 2: Contact Pressure Di...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.• Lock Pre-tension Displacemen...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 3: Combustion Pressure...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 3: Stress Contour
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.The top and bottom edgedeforma...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 2Scaled 300xSubcase 1S...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Example – Connecting Rod Optim...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Results of Free Shape Optimiza...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Results of Free Shape Optimiza...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct for Powertrain - Su...
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Upcoming Version 12.210• Prepr...
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Application of OptiStruct to Solution of Powertrain Problems

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Application of OptiStruct to Solution of Powertrain Problems

  1. 1. Innovation Intelligence®Application of OptiStruct to Solutionof Powertrain ProblemsWoytek TworzydloAETC - April 24, 2013
  2. 2. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Altair OptiStruct• A comprehensive high-performance FE-solver and optimizer• Solution sequences:• Statics (small deformations)• Non-linear contact• Non-linear materials• Heat Transfer• Comprehensive NVH Solution• Normal modes• Frequency response• Transient Analysis• Acoustic Analysis• Easy to use• robust element formulations• thorough model check, informative messages• Seamlessly integrated with optimization
  3. 3. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct for Powertrain ApplicationsNew advanced analysis and optimization capabilities have been added inversion 12.0 addressing specific needs of Powertrain modeling:GasketsFine detailsContactLarge modelsHeat transferVibrationsSecond orderelementsGlobal - localBolttensioningMoving partsThermal loadsNonlinearPre-tensioningGaskets
  4. 4. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Powertrain Modeling RequirementsContact• Hertz contact conditions with friction• Contact friendly 2nd order solid & 3D gasket elements• Thermal contact – conductivity ƒ(gap, pressure)• Coupled thermal and static analysis3-dof Gaskets• Nonlinear behavior in thickness direction• Optional 3D stiffness• Pressure, Leakage statusPretensioned bolts (1D & 3D)Non-linear materials w/ plasticity• Isotropic, kinematic and mixed hardening• Metals, gray cast iron
  5. 5. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct 12.0 – Pretensioned Bolts• Pretensioning of bolted assemblies• “Cut and Load” approach• 1D bolts• Surface cut on a 3D bold model• Logical and general flow• pretension Force• pretension Adjustment• arbitrary combinations and sequencing• Available for use with• Static analysis (linear and nonlinear)• Preloaded normal modes• Preloaded frequency response• Optimization…SurfacePretension and Ignition
  6. 6. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct 12.0 – Gasket Elements• Single material to model behaviorof complex gasket profiles• FE Modeling• Unique behavior in normal direction• Highly nonlinear• Large “strain” (closure)• Based on experimental curves• First and second-order elements• CGASK6, … 8, 12, 16• Contact-friendly version availableComplex structurein real lifeOne ‘material’in FE world
  7. 7. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Gasket Elements – cont’d• Result types• closure, stress, pressure, sealing status• Robust behavior• normal compression only, or full 3D stiffness• works over cutouts, etc.Displacements (to scale) Gasket pressure
  8. 8. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct 12.0 Plasticity Enhancements• Von Mises plasticity. Isotropic, kinematic and mixed hardening.• solids and shells• good nonlinear convergence• easy to use – automatically switch the element formulation for elasto-plasticregionsPlasticStrainResidual Stress after unloading
  9. 9. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct 12.0 CONTACT/Friction Improvements• Improved convergence with Friction• nonsymmetric solver• new friction model• stabilized Expert System – preventsfly-away of disconnected parts• Improved contact on imperfect meshes• CLEARANCE• ADJUST – (12.220)• smoother solutionPFCLEARANCE
  10. 10. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.STANDARD IMPROVEDOptiStruct 12.0 – Contact-Friendly Elements• Contact-friendly second-order elements (solids, gaskets – all types)• more realistic contact forces• elasticity and elasto-plasticity• Benefits• better nonlinear convergence• improved CONTACT pressure• improved open/closed status
  11. 11. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Thermal (Heat Transfer) in OptiStruct 12.0• Available thermal solutions (12.0 - linear)• Conduction, surface convection & heatgeneration• Coupled thermal / structural analysis• Transient thermal, coupled transient thermal /structural• Surface heating from fluid - Acusolve• Heat transfer across CONTACTs• gap-dependent conductivity• pressure-dependent (in 12.210)• Optimization for coupled thermal /structural problems pressuregap
  12. 12. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Powerful NVH Capabilities• Core NVH Solutions• Normal modes• Frequency response• Random Response• Transient Analysis• Acoustic Analysis• AMSES fast eigenvalue solver• Advanced Post-Processing• TPA (Transfer Path Analysis)• Modal Participation• DSA (Design Sensitivity Analysis)• Automatic filtering – PEAKOUTFrFfFrFfFtFe
  13. 13. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Setup in Hypermesh and SimLab - Pretension• Hypermesh• 12.0 - use Loads panel• Pretension Manager (in 12.0.110)• Simlab• specialized pretension setuppage and tools
  14. 14. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Contact Definition Tools• HyperMesh• Auto-Contact manager -(in 12.110)• SimLab• Automated Contact manager
  15. 15. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Example: Engine Assembly System ModelSubcase 1:• Bolt Pretension in Head BoltsSubcase 2:• Lock Pre-tension Displacements• Apply Temperature LoadingSubcase 3:• Lock Pre-tension Displacements• Continue Temperature Loading• Apply Combustion Pressure LoadingThermo-structural Model
  16. 16. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Gasket loading curveGasket un-loading curveModel Features• 3D pretension bolts• Gasket material• 2nd order modifiedtetrahedral elements• Contact with friction (0.1)• Tied contacts(total = 130)
  17. 17. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.• Apply Pre-tension Loading (41.25 KN) in Head BoltsSubcase 1
  18. 18. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 1: Stresses in Bolts
  19. 19. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 1: Gasket Pressure and Sealing Status
  20. 20. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.• Lock Pre-tension Displacements• Apply Temperature LoadingSubcase 2
  21. 21. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Cylinder HeadSubcase 2: Temperature Distribution Load Applied
  22. 22. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 2: Stress Contour
  23. 23. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 2: Contact Pressure Distribution
  24. 24. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.• Lock Pre-tension Displacements• Continue Temperature Loading• Apply Combustion Pressure LoadingSubcase 3
  25. 25. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 3: Combustion Pressure Load Application
  26. 26. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 3: Stress Contour
  27. 27. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.The top and bottom edgedeformation of the bores areshown in next slideTop edgeBottom edgeSubcase 3: Bore Deformations
  28. 28. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Subcase 2Scaled 300xSubcase 1Scaled 3000xSubcase 3Scaled 300xBore Deformations
  29. 29. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Example – Connecting Rod Optimization• Analysis setup• interference fit• bolt pretension• contact with friction• bearing pressure load• Free shape optimization setup• Design Constraints: Stresses• Objective: Minimize Volume
  30. 30. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Results of Free Shape Optimization
  31. 31. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Results of Free Shape Optimization• Weight – unchanged• Stress constraint violation (by 50%) eliminatedShape Change
  32. 32. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OptiStruct for Powertrain - SummaryCourtesy PSA Peugeot Citroën• Software of choice for Powertrain modeling• sealing pressure with bolt pretension• nonlinear structural analysis• thermal solution (heat transfer)• NVH• Highly accurate• Modeling errors detected*• Some are fixed automatically• Easy to use• Best formulation picked automatically• Integrated optimization
  33. 33. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Upcoming Version 12.210• Preprocessing• pretension manager in HyperMesh• auto-contact in HyperMesh• improved import/translation of other solver’s decks• CONTACT• ADJUST• more results (friction, contact status, …)• Gasket• temperature-dependent material properties• Thermal - Nonlinear• temperature-dependent materials• pressure-dependent contact• radiationA complete package for Powertrain Analysis and Optimization
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