OptiStruct Workshop
                           Americas HyperWorks Technology Conference
                           Warren Dias
Innovation Intelligence®   May 15, 2012
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Workshop Agenda


• Optimization for Noise, Vibration and Harshness (NVH)
                •          Model Updating / System Identification
                •          Optimization with Frequency Sub-Ranges
                •          Global Search Option


• Equivalent Static Load Method
                •          Optimization of MBD Systems
                •          Optimization for Nonlinear Responses


• Composites Optimization
                •          Zone vs. Ply Based Modeling
                •          Generating Design Concepts
                •          Ply Shape Interpretation
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Altair OptiStruct


• Award-winning technology for concept design synthesis and
          optimization.


• At the forefront of developing new and innovative techniques.


• Rapidly develop lightweight, structurally efficient designs by creating
          innovative concepts.

• Powerful design fine-tuning
          capabilities to further improve
          the design.


• Solve real world optimization
          problems, efficiently!
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




                  Optimization Solutions

                                                                                                                              HyperStudy
                                                                                                                 OptiStruct
Component Level
System Level




                                   Concept Design                                                                               Detailed Design
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




OptiStruct: An Overview


          Static with                                                                                     Coupled thermo-
           Contact                                                                                          mechanical
                                                                                               Topology
                                                                                                           Manufacturing
    Normal Modes
                                                                                                            Constraints


                                                                                                          Equivalent Static
   Linear Buckling
                                                                                                           Load Method


         Frequency                                                                                          AMSES
         Response                                                                                         AMLS Interface


          Acoustic                                                                                        Direct & Iterative
          Response                                                                                            Solvers


          Random                                                                                              Design
          Response                                                                              Shape      Interpretation


                                                                                                             Parallel
             Fatigue
                                                                                                            Processing
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Workshop Agenda


• Optimization for Noise, Vibration and Harshness (NVH)
                •          Model Updating / System Identification
                •          Optimization with Frequency Sub-Ranges
                •          Global Search Option


• Equivalent Static Load Method
                •          Optimization of MBD Systems
                •          Optimization for Nonlinear Responses


• Composites Optimization
                •          Zone vs. Ply Based Modeling
                •          Generating Design Concepts
                •          Ply Shape Interpretation
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




NVH with HyperWorks




                                                                                           Solution
  Model                                                                              Super Elements                          Optimization
                                                                                                       Diagnostics
Management                                                                               AMSES
                                                                                                      Post Proc. Toolkit
                                                                                                                               Model Updating
Build and Assembly                                                                        FRF                                 TPL, TPG, FRSZ
                                                                                                      Fluid Grid Particip.
Full FE, CMS, etc.                                                                      Transient                              SZ, SH, FRSHP
                                                                                                             DSA
Subcase Manager                                                                           TPA                                Internal Responses
                                                                                                              …
        …                                                                              PEAKOUT                                        …
                                                                                           …
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Optimization Problem Formulation

     Min(max)
                  Minimize : max[d i ( x)]                                              i = f 0 ,..., f n
                  Subject to :                   g j ( x) ≤ 0                           j = 1,K, m



     Min (max) with Frequency sub
     ranges

               Minimize : max[d i ( x )]                                          i = f sub1 ,..., f sub 2
               Subject to :                   g j ( x) ≤ 0                           j = 1,K, m


     System Identification
                                                                                               2
                                                       n
                                                           f ( x) − T 
                    Minimize :                       ∑  wi i T i 
                                                          
                                                     i =1 
                                                                       
                                                                  i    
                    Subject to :                   g j ( x) ≤ 0                          j = 1,K , m


                    or
                                                                             f i ( x) − Ti
                    Minimize : β with wi                                                   ≤β
                                                                                   Ti
                    Subject to :                   g j ( x) ≤ 0                          j = 1,K , m
                                                                                                             Curve Fitting
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Demonstration


• Acoustic Cavity Model
• Match a Target Curve
• Optimize Acoustic Pressure Response
• GSO
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Workshop Agenda


• Optimization for Noise, Vibration and Harshness (NVH)
                •          Model Updating / System Identification
                •          Optimization with Frequency Sub-Ranges
                •          Global Search Option


• Equivalent Static Load Method
                •          Optimization of MBD Systems
                •          Optimization for Nonlinear Responses


• Composites Optimization
                •          Zone vs. Ply Based Modeling
                •          Generating Design Concepts
                •          Ply Shape Interpretation
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Equivalent Static Load Method


• Dealing with dynamic problems considering true time history and not
          just worst case time step




                                       Analysis                                                  Load                  Optimization
       Dynamic / Nonlinear Problem                                                                                Static Response Problem
           Load time history                                                                   Design variables    Equivalent static loads


                                                                                               OptiStruct


                                                                   d
                                                                                                                  fteq = Kdt


                                                                                                                  t
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Demonstration 1


• Topology Optimization of the Pivot Structure




• Force on Tire Spindle
• Gravity Loading
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Demonstration 2


• Analysis Type: Geometric Non-Linearity (NLGEOM)
• Material: Johnson-Cook Elastic-Plastic Material
• Problem Formulation:
                •          Objective Function: Minimize Volume
                •          Design Constraints: Displacement
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Workshop Agenda


• Optimization for Noise, Vibration and Harshness (NVH)
                •          Model Updating / System Identification
                •          Optimization with Frequency Sub-Ranges
                •          Global Search Option


• Equivalent Static Load Method
                •          Optimization of MBD Systems
                •          Optimization for Nonlinear Responses


• Composites Optimization
                •          Zone vs. Ply Based Modeling
                •          Generating Design Concepts
                •          Ply Shape Interpretation
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Composite Zone Based Modeling


•         One Property is Required for Each Laminate Zone
                                                                                                                   Zone 1   Zone 2    Zone 3    Zone 2   Zone 1

•         Plies are not Linked across Zones                                                                                          P1
                                                                                                                                     P2
                                                                                                                                          45
                                                                                                                                          90
                                                                                                                                     P3   -45
                •          Data Duplication, No Ply Shape                                                                            P4    0
                                                                                                                                     P5   -45
•         No Relationship to the Manufacturing Process                                                                               P6   90
                                                                                                                                     P7   45

•         Design Change Requires 3 Updates                                                                         Zone 1


      Zone 1 – Property Table                                                         Zone 3 – Property Table
 Ply           Ma              Thk                 Theta                         Ply           Ma   Thk    Theta            Zone 2
                t                                                                               t
 P7            M1             0.01                    45                         P7            M1   0.01    45
                                                                                                                                     Zone 3
 P4            M1             0.01                      0                        P6            M1   0.01    90
 P1            M1             0.01                    45                         P5            M1   0.01    -45
                                                                                 P4            M1   0.01    0
      Zone 2 – Property Table
                                                                                 P3            M1   0.01    -45
 Ply           Ma              Thk                 Theta
                t                                                                P2            M1   0.01    90
 P7            M1              0.01                    45                        P1            M1   0.01    45
 P5            M1              0.01                   -45
 P4            M1              0.01                     0
 P3            M1              0.01                   -45
 P1            M1              0.01                    45
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




      Composite Ply Based Modeling

      •         A Composite Part is made up of “n” Plies and One Laminate

      •         No Data Duplication
                                                                                                     P1   45
      •         Direction Relationship to the Manufacturing Process                                  P2   90
                                                                                                     P3   -45
                                                                                                     P4    0
      •         Ply Based Modeling Process                                                           P5   -45
                                                                                                     P6   90
                      •          Define Ply Shapes and Related Ply Data                              P7   45

                      •          Define Stacking Sequences

      •         Design Change Requires only 1 Update


               Stack Table
Ply       Ma              Thk                 Theta
           t
P7        M1              0.01                   45
P6        M1              0.01                   90
P5        M1              0.01                  -45
P4        M1              0.01                     0
P3        M1              0.01                  -45
P2        M1              0.01                   90
P1        M1              0.01                   45
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




    Composite Optimization Process




                         Phase 1

                     Ply Shapes
                                                                                                       Phase 2            z
                                                                                                   Number of Plies
y

            x             Free Sizing                                                                                            Phase 3
                                                                                                                           Laminate Stacking
                                                                                                                                                 45
                                                                                                                           0                     -45
                                                                                                                                                  0
                                                                                                    Ply Bundle Sizing             Rule based      0
                                                                                                                                                 45
                                                                                                                           45                    -45
                                                                                                                                                 90
                                                                                                                                                 90
                                                                                                                                                 -45
                                                                                                                           -45                   45
                                                                                                                                                  0
                                                                                                                                 ply shuffling    0
                                                                                                                                                 -45
                                                                                                                           90
                                                                                                                                                 45


                                                                                                                        Stacking Sequence Optimization
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Demonstration


• Loading Conditions
                •          Natural frequency
                •          Centrifugal force due to rotational speed of 7.4 RPM
                •          Gravity
                •          Buckling
                •          Fluid load as determined by a coupled FSI (fluid-structure interaction) analysis


• Topology for Spars


• Free Size on Skins
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.




Thank You for Your Attention!


• Optimization for Noise, Vibration and Harshness (NVH)
                •          Model Updating / System Identification
                •          Optimization with Frequency Sub-Ranges
                •          Global Search Option


• Equivalent Static Load Method
                •          Optimization of MBD Systems
                •          Optimization for Nonlinear Responses


• Composites Optimization
                •          Zone vs. Ply Based Modeling
                •          Generating Design Concepts
                •          Ply Shape Interpretation

Altair HTC 2012 Optistruct Training

  • 1.
    OptiStruct Workshop Americas HyperWorks Technology Conference Warren Dias Innovation Intelligence® May 15, 2012
  • 2.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Workshop Agenda • Optimization for Noise, Vibration and Harshness (NVH) • Model Updating / System Identification • Optimization with Frequency Sub-Ranges • Global Search Option • Equivalent Static Load Method • Optimization of MBD Systems • Optimization for Nonlinear Responses • Composites Optimization • Zone vs. Ply Based Modeling • Generating Design Concepts • Ply Shape Interpretation
  • 3.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Altair OptiStruct • Award-winning technology for concept design synthesis and optimization. • At the forefront of developing new and innovative techniques. • Rapidly develop lightweight, structurally efficient designs by creating innovative concepts. • Powerful design fine-tuning capabilities to further improve the design. • Solve real world optimization problems, efficiently!
  • 4.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Optimization Solutions HyperStudy OptiStruct Component Level System Level Concept Design Detailed Design
  • 5.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. OptiStruct: An Overview Static with Coupled thermo- Contact mechanical Topology Manufacturing Normal Modes Constraints Equivalent Static Linear Buckling Load Method Frequency AMSES Response AMLS Interface Acoustic Direct & Iterative Response Solvers Random Design Response Shape Interpretation Parallel Fatigue Processing
  • 6.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Workshop Agenda • Optimization for Noise, Vibration and Harshness (NVH) • Model Updating / System Identification • Optimization with Frequency Sub-Ranges • Global Search Option • Equivalent Static Load Method • Optimization of MBD Systems • Optimization for Nonlinear Responses • Composites Optimization • Zone vs. Ply Based Modeling • Generating Design Concepts • Ply Shape Interpretation
  • 7.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. NVH with HyperWorks Solution Model Super Elements Optimization Diagnostics Management AMSES Post Proc. Toolkit Model Updating Build and Assembly FRF TPL, TPG, FRSZ Fluid Grid Particip. Full FE, CMS, etc. Transient SZ, SH, FRSHP DSA Subcase Manager TPA Internal Responses … … PEAKOUT … …
  • 8.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Optimization Problem Formulation Min(max) Minimize : max[d i ( x)] i = f 0 ,..., f n Subject to : g j ( x) ≤ 0 j = 1,K, m Min (max) with Frequency sub ranges Minimize : max[d i ( x )] i = f sub1 ,..., f sub 2 Subject to : g j ( x) ≤ 0 j = 1,K, m System Identification 2 n  f ( x) − T  Minimize : ∑  wi i T i   i =1   i  Subject to : g j ( x) ≤ 0 j = 1,K , m or f i ( x) − Ti Minimize : β with wi ≤β Ti Subject to : g j ( x) ≤ 0 j = 1,K , m Curve Fitting
  • 9.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Demonstration • Acoustic Cavity Model • Match a Target Curve • Optimize Acoustic Pressure Response • GSO
  • 10.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Workshop Agenda • Optimization for Noise, Vibration and Harshness (NVH) • Model Updating / System Identification • Optimization with Frequency Sub-Ranges • Global Search Option • Equivalent Static Load Method • Optimization of MBD Systems • Optimization for Nonlinear Responses • Composites Optimization • Zone vs. Ply Based Modeling • Generating Design Concepts • Ply Shape Interpretation
  • 11.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Equivalent Static Load Method • Dealing with dynamic problems considering true time history and not just worst case time step Analysis Load Optimization Dynamic / Nonlinear Problem Static Response Problem Load time history Design variables Equivalent static loads OptiStruct d fteq = Kdt t
  • 12.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Demonstration 1 • Topology Optimization of the Pivot Structure • Force on Tire Spindle • Gravity Loading
  • 13.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Demonstration 2 • Analysis Type: Geometric Non-Linearity (NLGEOM) • Material: Johnson-Cook Elastic-Plastic Material • Problem Formulation: • Objective Function: Minimize Volume • Design Constraints: Displacement
  • 14.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Workshop Agenda • Optimization for Noise, Vibration and Harshness (NVH) • Model Updating / System Identification • Optimization with Frequency Sub-Ranges • Global Search Option • Equivalent Static Load Method • Optimization of MBD Systems • Optimization for Nonlinear Responses • Composites Optimization • Zone vs. Ply Based Modeling • Generating Design Concepts • Ply Shape Interpretation
  • 15.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Composite Zone Based Modeling • One Property is Required for Each Laminate Zone Zone 1 Zone 2 Zone 3 Zone 2 Zone 1 • Plies are not Linked across Zones P1 P2 45 90 P3 -45 • Data Duplication, No Ply Shape P4 0 P5 -45 • No Relationship to the Manufacturing Process P6 90 P7 45 • Design Change Requires 3 Updates Zone 1 Zone 1 – Property Table Zone 3 – Property Table Ply Ma Thk Theta Ply Ma Thk Theta Zone 2 t t P7 M1 0.01 45 P7 M1 0.01 45 Zone 3 P4 M1 0.01 0 P6 M1 0.01 90 P1 M1 0.01 45 P5 M1 0.01 -45 P4 M1 0.01 0 Zone 2 – Property Table P3 M1 0.01 -45 Ply Ma Thk Theta t P2 M1 0.01 90 P7 M1 0.01 45 P1 M1 0.01 45 P5 M1 0.01 -45 P4 M1 0.01 0 P3 M1 0.01 -45 P1 M1 0.01 45
  • 16.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Composite Ply Based Modeling • A Composite Part is made up of “n” Plies and One Laminate • No Data Duplication P1 45 • Direction Relationship to the Manufacturing Process P2 90 P3 -45 P4 0 • Ply Based Modeling Process P5 -45 P6 90 • Define Ply Shapes and Related Ply Data P7 45 • Define Stacking Sequences • Design Change Requires only 1 Update Stack Table Ply Ma Thk Theta t P7 M1 0.01 45 P6 M1 0.01 90 P5 M1 0.01 -45 P4 M1 0.01 0 P3 M1 0.01 -45 P2 M1 0.01 90 P1 M1 0.01 45
  • 17.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Composite Optimization Process Phase 1 Ply Shapes Phase 2 z Number of Plies y x Free Sizing Phase 3 Laminate Stacking 45 0 -45 0 Ply Bundle Sizing Rule based 0 45 45 -45 90 90 -45 -45 45 0 ply shuffling 0 -45 90 45 Stacking Sequence Optimization
  • 18.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Demonstration • Loading Conditions • Natural frequency • Centrifugal force due to rotational speed of 7.4 RPM • Gravity • Buckling • Fluid load as determined by a coupled FSI (fluid-structure interaction) analysis • Topology for Spars • Free Size on Skins
  • 19.
    Copyright © 2012Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Thank You for Your Attention! • Optimization for Noise, Vibration and Harshness (NVH) • Model Updating / System Identification • Optimization with Frequency Sub-Ranges • Global Search Option • Equivalent Static Load Method • Optimization of MBD Systems • Optimization for Nonlinear Responses • Composites Optimization • Zone vs. Ply Based Modeling • Generating Design Concepts • Ply Shape Interpretation