Using Hyperstudy to pilot FEA-based designs of experiments on engine cooling module components

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The sensitivity and robustness analyses are more and more one of the main challenges of automotive suppliers. The use of Design of Experiments is one of the key to better understand the impact of the …

The sensitivity and robustness analyses are more and more one of the main challenges of automotive suppliers. The use of Design of Experiments is one of the key to better understand the impact of the factors linked to the production dispersion on the behavior of a product. They also enable to improve simulation methodologies thanks to simulation vs test correlations, or to identify target values for uncertain input data to finalise analyses. Authors propose here a non-exhaustive review of their first attempts of coupling between Hyperstudy and their standard simulation solver Abaqus, through meshes morphing operations, automated launch of numerous simulations or optimization of predefined model parameters.

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  • 1. Altair Technology Conference June 2014 I 1Property of Valeo. Duplication prohibited Altair Technology Conference June 2014 Property of Valeo. Duplication prohibited Using Hyperstudy to pilot FEA based Design of Experiment Dr Benjamin THOMAS Simulation & Vibration Expert
  • 2. Altair Technology Conference June 2014 I 2Property of Valeo. Duplication prohibited Summary Introduction Static stiffness scaling Test-simulation DOE comparison Sensitivity analysis Conclusion
  • 3. Altair Technology Conference June 2014 I 3Property of Valeo. Duplication prohibited June 2014 Property of Valeo. Duplication prohibited Introduction1
  • 4. Altair Technology Conference June 2014 I 4Property of Valeo. Duplication prohibited Valeo activities Transmission Systems Electrical Systems Climate Control Driving Assistance Interior Controls Wiper Systems Lighting Systems Thermal Powertrain Thermal Systems Powertrain Systems Comfort & Driving Assistance Visibility Systems
  • 5. Altair Technology Conference June 2014 I 5Property of Valeo. Duplication prohibited Team presentation Valeo Thermal Systems, Thermal Powertrain FEA Simulation-Reliability Team 20 Persons (14 La Verrière-France , 6 Shangai-China) Mechanical simulation and expertise for the worldwide network Static, Dynamic, Thermomechanical, Rheology, Optimisation Specification analysis/development Thermal Powertrain
  • 6. Altair Technology Conference June 2014 I 6Property of Valeo. Duplication prohibited Use of Design of Experiment in our team New activity for our team Parameters scaling Introduce unknown or non-measurable properties Test-simulation correlation Compare response surface from test and simulation DOE Sensitivity analysis Understand the physics of our models
  • 7. Altair Technology Conference June 2014 I 7Property of Valeo. Duplication prohibited Process to link Hyperstudy and Abaqus Template file (Templex) Simulation DOE Abaqus input file List of parameters Text file Abaqus CAE or Hypermesh Hyperstudy Text Editor for automatic translation Hyperstudy generates the DOE input files, launch runs and post processings based on a nominal run The process is only based on text files manipulation
  • 8. Altair Technology Conference June 2014 I 8Property of Valeo. Duplication prohibited June 2014 Property of Valeo. Duplication prohibited Parameters Scaling2
  • 9. Altair Technology Conference June 2014 I 9Property of Valeo. Duplication prohibited Position of the problem Heat exchanger vibration simulation Axial and radial rubber stiffnesses are unknown 2 Modes frequencies can be identified form test FRF
  • 10. Altair Technology Conference June 2014 I 10Property of Valeo. Duplication prohibited First attempt to scale rubbers properties Data Test K=X N/mm K=100X N/mm First mode frequency 21 Hz 25Hz 79Hz Trial/Error x100 on axial stiffness x3 on the frequency Find the parameters may be long and difficult!
  • 11. Altair Technology Conference June 2014 I 11Property of Valeo. Duplication prohibited Parameters scaling on Hyperstudy Two main options: Direct optimisation of the model: Optimisation solver used Parameters values obtained are exact values to use In case of fast convergence, no data about the link between responses and factors Design of experiment Potentially more runs than using optimisation Complete information about the sensitivity of the model Enables to create a meta model The DOE is used to get a better comprehension of the model
  • 12. Altair Technology Conference June 2014 I 12Property of Valeo. Duplication prohibited DOE based on our process Parameters in the Templex are K1 and K2, 4 levels each K1 and K2 must ensure the 2 first mode frequency to be in line with test results The first mode frequency depends on both K1 and K2, but the second mode frequency depends only on K2 The response surfaces enables to scale the value to use thanks to surface approximation K1 K1 K2 K2 F1 F2
  • 13. Altair Technology Conference June 2014 I 13Property of Valeo. Duplication prohibited June 2014 Property of Valeo. Duplication prohibited Test-simulation DOE comparison3
  • 14. Altair Technology Conference June 2014 I 14Property of Valeo. Duplication prohibited Problem introduction 2 different ways to modelise cycled pressure on mechanical radiators tank Test DOE based on the pressure and temperature variation is available Tank + header alone: investigation on header stresses Quick Precise enough for a wide majority of case Piece of the whole core More complex and ressource consuming Give information on tubes stresses
  • 15. Altair Technology Conference June 2014 I 15Property of Valeo. Duplication prohibited Test-simulation comparison Location in the header Test results Simple model results Complex model results Location 1 Location 2 Location 3 Location 4 Some values are well corelated on Location 1, but improvement is needed. 2nd DOE leads to a better tendancy and shows a way to improve stresses accuracy even if location 1 is not a usual failure location
  • 16. Altair Technology Conference June 2014 I 16Property of Valeo. Duplication prohibited June 2014 Property of Valeo. Duplication prohibited Sensitivity Analysis4
  • 17. Altair Technology Conference June 2014 I 17Property of Valeo. Duplication prohibited Sensitivity analysis Aim Identify the design factors contributing to the frequency shift of 2 modes of a fan to reduce acoustic emergencies using morphing operations Examples of identified thickness Several parameters identified to define designs for a DOE
  • 18. Altair Technology Conference June 2014 I 18Property of Valeo. Duplication prohibited Specific process HYPERMESH: Mesh HYPERMORPH: Shapes creation and export to Abaqus Format HYPERSTUDY: DOE generation and results post processing ABAQUS: Solver
  • 19. Altair Technology Conference June 2014 I 19Property of Valeo. Duplication prohibited The mesh retained is only 1/7th of the fan Quicker runs Mix tetra-hexa linear, the purpose in only to obtain a tendancy Abaqus is able to understand the cyclic periodicity of the mesh, modes to analyse are complient with the periodicity hypothesis Mesh
  • 20. Altair Technology Conference June 2014 I 20Property of Valeo. Duplication prohibited HYPERMORPHMorphing The different shapes variations are stored as nodes perturbation Hypermorph shapes are transformed in design variables and then exported as a text file in Abaqus format
  • 21. Altair Technology Conference June 2014 I 21Property of Valeo. Duplication prohibited Difficulties met & Results Non morphable regions Local material change used Runs with cluster not so easy Model still too big Transfer of runs/outputs to be improved (Compute Manager?) One of the mode is changing of position Follow the mode is necessary, frequency must be corrected from the Abaqus dat file to be sure to work on the corresponding mode The DOE enabled to identify significant impacts: Up to 10% difference on frequencies with 0.3mm changes local thicknesses Direct modification of the hub is possible to ensure desired behavior
  • 22. Altair Technology Conference June 2014 I 22Property of Valeo. Duplication prohibited June 2014 Property of Valeo. Duplication prohibited Conclusion5
  • 23. Altair Technology Conference June 2014 I 23Property of Valeo. Duplication prohibited Conclusion Interaction between Hyperstudy and external solver is very easy thanks to Templex Strong benefits and interests of Hyperstudy piloted DOE compared to the investment Quick parameters scaling Quick sensitivity investigation Automated simulation of test DOE The main need on our side is a possibility to launch runs on cluster directly from Hyperstudy
  • 24. Altair Technology Conference June 2014 I 24Property of Valeo. Duplication prohibited