Optimization of a Familyof Supporting FramesUnder Multiple AnalysisConstraints UsingHyperStudyYimin Zhan, Ph.D.Malisha Djo...
Contents• Preface• Objectives and Description• Modeling in HyperMesh• Baseline Analysis using HyperWorks Solvers• Optimiza...
Preface• Van-Rob Kirchhoff, based in Aurora Ontario Canada, is a tier-one full  service global supplier of automotive OEMs...
Objectives and Description                             Long Version            Short Version
Modeling in HyperMesh                           Long Version           Short Version
Baseline Analysisusing HyperWorks Solvers                          Analysis Type #1:Push-test stiffness under boundary con...
Baseline Analysisusing HyperWorks Solvers                        Analysis Type #2:Push-test stiffness under boundary condi...
Baseline Analysisusing HyperWorks Solvers                       Analysis Type #3:Modal analysis       Short Version       ...
Baseline Analysisusing HyperWorks Solvers                        Analysis Type #4:Non-linear impact analysis        Short ...
Optimization using HyperStudy                           g2                                               g3           g1  ...
Optimization using HyperStudyMorphing variables:S1S for short versionS1L for long version                                 ...
Optimization using HyperStudy     Morphing variable:         Morphing variable:            S3                         S4
Optimization using HyperStudy Create study
Optimization using HyperStudy Create models
Optimization using HyperStudy Create design variables
Optimization using HyperStudy Do nominal run
Optimization using HyperStudy Create responses
Optimization using HyperStudy Link design variables
Optimization using HyperStudy Create optimization study
Optimization using HyperStudy Define design variables
Optimization using HyperStudy Apply constraints
Optimization using HyperStudy Create objective
Optimization using HyperStudy Post processing
Optimization using HyperStudy Post processing
Optimization using HyperStudy Post processing – Visualize…
Optimization using HyperStudy Post processing – Visualize…
Optimization using HyperStudy                                                                         Baseline...
Optimization using HyperStudy          Baseline                                                                     ...
Validationusing HyperWorks Solvers
Validation  using HyperWorks SolversAnalysis Type #1: Push-test stiffness under boundary condition #1                   Lo...
Validation  using HyperWorks SolversAnalysis Type #2: Push-test stiffness under boundary condition #2 Y                   ...
Validation  using HyperWorks SolversAnalysis Type #3: Norm mode                            30 Hz                    30...
Validation  using HyperWorks SolversAnalysis Type #4: Non-linear impact                     Target: < 0.5 mm         Tar...
Conclusions• HyperStudy is capable to perform simultaneous analysis on multiple FEA  models with multiple types of FEA ana...
ConclusionsWish list:(a) Topology optimization variables, e.g.    element densities under extrusion    constraints, should...
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Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff

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Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff

  1. 1. Optimization of a Familyof Supporting FramesUnder Multiple AnalysisConstraints UsingHyperStudyYimin Zhan, Ph.D.Malisha Djokic, M.Sc.Tech., P.Eng.Van-Rob Kirchhoff AutomotiveAurora, Ontario,Canada L4G 0A2
  2. 2. Contents• Preface• Objectives and Description• Modeling in HyperMesh• Baseline Analysis using HyperWorks Solvers• Optimization using HyperStudy• Validation using HyperWorks Solvers• Conclusions
  3. 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
  4. 4. Objectives and Description Long Version Short Version
  5. 5. Modeling in HyperMesh Long Version Short Version
  6. 6. Baseline Analysisusing 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 XY X Y X Y X Short Version Long Version
  7. 7. Baseline Analysisusing HyperWorks Solvers Analysis Type #2:Push-test stiffness under boundary condition #2 Short Version Long Version
  8. 8. Baseline Analysisusing HyperWorks Solvers Analysis Type #3:Modal analysis Short Version Long Version
  9. 9. Baseline Analysisusing HyperWorks Solvers Analysis Type #4:Non-linear impact analysis Short Version Long Version
  10. 10. Optimization using HyperStudy g2 g3 g1 g4 g6L g6S g5 Short Version Long Version
  11. 11. Optimization using HyperStudyMorphing variables:S1S for short versionS1L for long version Morphing variables: S2S for short version S2L for long version
  12. 12. Optimization using HyperStudy Morphing variable: Morphing variable: S3 S4
  13. 13. Optimization using HyperStudy Create study
  14. 14. Optimization using HyperStudy Create models
  15. 15. Optimization using HyperStudy Create design variables
  16. 16. Optimization using HyperStudy Do nominal run
  17. 17. Optimization using HyperStudy Create responses
  18. 18. Optimization using HyperStudy Link design variables
  19. 19. Optimization using HyperStudy Create optimization study
  20. 20. Optimization using HyperStudy Define design variables
  21. 21. Optimization using HyperStudy Apply constraints
  22. 22. Optimization using HyperStudy Create objective
  23. 23. Optimization using HyperStudy Post processing
  24. 24. Optimization using HyperStudy Post processing
  25. 25. Optimization using HyperStudy Post processing – Visualize…
  26. 26. Optimization using HyperStudy Post processing – Visualize…
  27. 27. Optimization using HyperStudy   BaselineBaseline Optimization Optimization  
  28. 28. Optimization using HyperStudy Baseline  Optimization 
  29. 29. Validationusing HyperWorks Solvers
  30. 30. Validation using HyperWorks SolversAnalysis 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. 31. Validation using HyperWorks SolversAnalysis Type #2: Push-test stiffness under boundary condition #2 Y   2 mm   2 mm Short version Long version
  32. 32. Validation using HyperWorks SolversAnalysis Type #3: Norm mode   30 Hz   30 Hz Short version Long version
  33. 33. Validation using HyperWorks SolversAnalysis Type #4: Non-linear impact  Target: < 0.5 mm  Target: < 0.5 mm Short version Long version
  34. 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. 35. ConclusionsWish 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.
  36. 36. Thank you
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