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Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff
1. Optimization of a Family
of Supporting Frames
Under Multiple Analysis
Constraints Using
HyperStudy
Yimin Zhan, Ph.D.
Malisha Djokic, M.Sc.Tech., P.Eng.
Van-Rob Kirchhoff Automotive
Aurora, Ontario,
Canada L4G 0A2
2. Contents
• Preface
• Objectives and Description
• Modeling in HyperMesh
• Baseline Analysis using HyperWorks Solvers
• Optimization using HyperStudy
• Validation using HyperWorks Solvers
• Conclusions
3. Preface
• Van-Rob Kirchhoff, based in Aurora Ontario Canada, is a tier-one full
service global supplier of automotive OEMs
• 29 production plants in 12 countries serving both domestic and
overseas customers
• Use of Altair HyperWorks Suite since year 2002 to optimize designs
and improve performance
• Meshing and modeling, linear (static and dynamic) and non-linear
6. Baseline Analysis
using HyperWorks Solvers
Analysis Type #1:
Push-test stiffness under boundary condition #1
Z Z
Z
Z Z Z
Z
Z Y Y Z X
Y X
Y Z Y X
Y X X X
Y X
Y X Y X
Y X
Short Version Long Version
11. Optimization using HyperStudy
Morphing variables:
S1S for short version
S1L for long version
Morphing variables:
S2S for short version
S2L for long version
30. Validation
using HyperWorks Solvers
Analysis Type #1: Push-test stiffness under boundary condition #1
Location 1 Location 1
X
1 mm 1 mm
Y
0.1 mm 0.1 mm
Z
0.2 mm 0.2 mm
Short version Long version
31. Validation
using HyperWorks Solvers
Analysis Type #2: Push-test stiffness under boundary condition #2
Y
2 mm 2 mm
Short version Long version
32. Validation
using HyperWorks Solvers
Analysis Type #3: Norm mode
30 Hz 30 Hz
Short version Long version
33. Validation
using HyperWorks Solvers
Analysis Type #4: Non-linear impact
Target: < 0.5 mm Target: < 0.5 mm
Short version Long version
34. Conclusions
• HyperStudy is capable to perform simultaneous analysis on multiple FEA
models with multiple types of FEA analysis, design variables and constraints;
• Some components can be shared in different models. This means significant
reduction of processing cost and time;
• All design constraints are achieved and violation level is under 2%;
• Objective is met with mass penalty 0.5 Kg;
• HyperStudy is a quite powerful package for conducting structural optimization;
• Time saving: months versus days or even hours;
35. Conclusions
Wish list:
(a) Topology optimization variables, e.g.
element densities under extrusion
constraints, should be convertible to
become design variables acceptable to
HyperStudy;
(b) Hope to have an “Uncheck” option for the
post-processing panel, so that quick
uncheck of all items and then re-pick of
items needed to display are enabled.
Optionally, a multiple selection of items,
using SHIFT button and left mouse button,
is needed.