Altair HyperWorks: A Platform for Innovation

Copyright © 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Altair HyperWorks: A Platform for Innovation

Uwe Schramm

CTO HyperWorks

Altair Engineering


Altair HyperWorks: A Platform for Innovation


Liebherr, Germany:

Innovative Crane with Light-Weight Boom

Challenge:

Reduce the weight of the new industrial stick

systematically and at the same time increase load

capacity

Solution:

• Altair OptiStruct topology optimization to locate

excess material in no-load areas

• The findings were incorporated into a “bionic frame”

concept

Business Impact:

• 20% weight reduction.

• Load capacity increased by up to 400 kg (880 lb)

• Improved protection for equipment attached to it

“The component’s dead weight was reduced by approximately 20 % and load capacity was increased by

up to 400 kg. Apart from its higher handling efficiency, the redesigned stick now provides improved

protection for equipment attached to it.”

– Liebherr Bauma 2010 Exhibition Blog

http://www.liebherr.com/de-DE/default_lh.wfw


PSA Peugeot Citroën, France:

HyperWorks Improves Development Process

Challenge:

Define a new simulation process development that

includes accurate component data (thickness,

residual strains, etc.)

Solution:

• Use HyperForm and RADIOSS in product

development

• Evaluate the impact of the manufacturing process

onto the component formability

• Seamlessly include forming results into RADIOSS

crash simulations

Business Impact:

• Reduce overall development time

• Get a better correlation with test results

• Improve product quality and process robustness

“We are in the position to predict crash results via simulation much better than in the past. Building

on this approach will lead to sustainable time savings and better products for our customers.”

– Fabien Beda, Senior Engineer Crash & Fluid Simulations PSA Peugeot Citroën

Different deformation patterns (Reference, Without and With Blankholder) at 0,008 Sec


Motorola, USA:

Efficient Phone System & Component Modeling

Challenge:

Generate more complex models for structural, thermal

and mechanism analysis while reducing the pre and

post processing time

Solution:

• System Modeling: Motorola Model Mesher automation

to batch mesh a complex assembly in few clicks

• Component Modeling: Designer Compass (using

Process Manager) ties Pro-E, HM and Abaqus

seamlessly

Business Impact:

• Total pre-processing time reduced from weeks to days.

• Enabled designers to perform nonlinear component

level simulations freeing up analysts for more

complicated system level simulations

“HyperWorks enabled us to tailor simulation processes to our specific requirements and

significantly improved our simulation efficiency."

– Dr. Kinzy Jones Manager, Advanced Mechanics Group, Motorola, USA

http://commons.wikimedia.org/wiki/File:Motorola_Milestone.jpg


Honda R&D North America: Streamline Frequency Response Analysis of Exhaust System

Challenge:

Streamline the simulation time for frequency response

analysis of exhaust systems to optimize the design and meet

the test requirements.

Solution:

• HyperWorks Process Manager to automate the most tedious

CAE tasks

• RADIOSS to run the analysis

• One integrated process from CAD to reports

Business Impact:

• Three different applications and an intensive user interaction

replaced by one semi-automated and user friendly GUI

• 80% time saving in model setup, analysis, and reporting

• Any design engineer can perform the analysis with minimal

training


Volkswagen Motorsport, Germany:

Vertical Dynamics of an Off-road Race Car

Challenge:

Find the best suspension setup simulating standard

tests of race vehicles in extreme conditions, such as

kick-backs over an artificial hill.

Solution:

• Parametric modeling using MotionView.

• MotionSolve for vehicle Dynamics simulations.

• Correlation of the results with experimental test

Business Impact:

• Optimal suspension setup to improve the race

performance

• Fast and stable simulations with MotionSolve.

• Close match of parametric virtual studies and physical

test

“Using MotionSolve we were able to run fast and stable simulations, getting a close match between

test and simulation data and a better understanding on the effect of payloads on kickback.”

– Dirk Bordiehn & Katja Fritzsch, VW Motorsport, Germany @ Altair Dynamics 2009


Crash Simulation in Five Minutes

Challenge:

Perform a crash simulation of a 1 million element

model for 80 ms in under 5 minutes

Solution:

• Hybrid-MPP solver parallelization with extended

scalability to over 1000 cores

• Advanced mass scaling to increase simulation time

step without significant loss of accuracy

Business Impact:

• Shortening the crash simulation time allows higher turn

around of model variants

• Enabler for robust design and optimization

“Accelerating simulation times while increasing the quality and robustness of crash computation are

challenges we are attaching importance to"

– Laurent Di Valentin, Expert in Numerical Simulation, PSA Peugeot Citroen.


CAD2Crash24 – Grand Challenge

Challenge:

Turn around meshing, assembly, setup, validation,

simulation, result reporting in 24 hours

Solution:

• Batch meshing and assembly of the model from CAD

• HyperCrash model validation

• RADSIOSS - Scalability, Quality and Repeatability

• PBS Pro job management and scheduling

• HyperView report automation

Business Impact:

• Shortening the model build and checking process from

weeks into a day

• More model variations can be produced and hence

design iterations can be performed faster


Durability Overnight

Challenge:

Setting up a durability analysis during the day and run

a design study overnight

Solution:

• HyperWorks process automation including

BatchMesher and HyperStudy

• Durability Director modeling process

• RADSIOSS - Scalability, Quality, Repeatability

• PBS Pro job management and scheduling

• HyperWorks Partner Alliance - nCode

Business Impact:

• Shortening the durability analysis process into a day

• More model variations can be produced and hence

design iterations can be performed faster


A Platform for Innovation

Simulation-driven

Innovation

Simulation is the

source for evaluating

design performance

and hence provides

the basis for decisions

and rapid innovation

Liberate Creativity

Best-in-class tools to

generate, evaluate,

optimize and manage

virtually unlimited

design concepts

Extend

Collaboration

Open-architecture to

provide the maximum

flexibility adapting to

different enterprise

needs, enabling the

automation of CAE

processes


Modeling &

Visualization

Visualization

HyperView

Multi-Body MotionView

Finite Elements RADIOSS

Concept & Design

OptiStruct

Simulation Optimization Manufacturing

Multi-Disciplinary

HyperStudy

Extrusion

HyperXtrude

Molding

HyperMold

Welding

HyperWeld

CAE Data Management

HyperWorks Data Manager

Complete, Fully Integrated Software Solution

Process Automation HyperWorks Process Manager

Stamping

HyperForm

Math Modeling

HyperMath

Multi-Body MotionSolve

Finite Elements HyperMesh


Altair HyperWorks 11.0

Novel Enterprise

User Experience

Next-generation

technology to leverage

years of experience in

product lifecycle

management fully

integrated with

engineering experience

Integrated

Desktop

Building models and

visualizing results easily

and quickly, in a user-

friendly, flexible,

automated, open,

customizable, and

collaborative framework

Engineering

Solutions

Advanced meshing,

assembly, sub-modeling,

model-checking, morphing,

animation technology

Crash, NVH, durability,

manufacturing, suspension

and CFD environments


Altair HyperWorks 11.0

Optimization

Leadership

Innovative technologies

for optimization with

non-linear physics.

Fully integrated with

solvers and modeling

environment.

FE-Solver

Advancements

Superior scalability,

quality, repeatability.

Leadership in crash,

safety, durability and

NVH simulation.

New implicit non-linear

simulation

Multi-body

Design Solution

Multi-body Simulation

environment, solver, and

utilities for automotive

and mechanism design.

Complete, customizable,

integrated, user-friendly

end-to-end solution.


Integrated Desktop

• Streamlining user experience thru

common graphical interfaces

• Browser driven

• Easy to learn

• View synchronization

• Integration of pre- and post-

processing

• Integration with HyperWorks

Enterprise

• Interoperability with PDM and CAD

• Providing the framework for modeling

and visualization for finite element

models and multi-body systems

• Providing automation environment

• Open CAD and solver interfaces

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../../../../Documents and Settings/schramm/Desktop/WEBEXS/buildplots_lowres.wrf

../../../../Documents and Settings/schramm/Desktop/WEBEXS/HM11_BROWSERS_tables_1024x768.wrf


Interfacing, Integration, Open System

CATIA

UG

Pro/E

IGES

STEP

Tribon

SolidWorks

Adams

Abaqus

Ansys

CFD++

Dyna

Femfat

Fluent

Madymo

Matlab

Moldflow

Moldex3D

MotionSolve

Nastran

nCode

Permas

PamCrash

RADIOSS

OptiStruct

Samcef

Simpack

StarCD


HyperMesh Highlights

• Meshing

• Acoustic cavity

• Power train meshing

• All quad shell meshing with flow control

• CFD meshing

• Local Tetmesh refinement

• Geometry

• New and Improved CAD readers

• New: SolidWorks, Tribon

• More functions to create and modify

geometry easily

• Parametric geometry editing

• Enhanced Mid-surfacing

• Usability

• Cross-referencing

• Transformations

• Visualization modes

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CAD Interoperability

• Geometry manipulation in HyperMesh

• On-screen manipulation

• Automatic mesh update

• More ways of creating geometry

• SimLab Technology

• Feature-based meshing

• Template driven

• Design connection

• Data exchange with CAD

• Bi-directional exchange of parameters

• Currently WIP

• HyperShape/CATIA

• HyperWorks Collaboration Tools

• Integration with enterprise


HyperWorks Collaboration Tools

• Explore Dialog integrated into desktop

• Integrated into all Desktop native file dialogs

• Search & retrieve files

• View properties associated with files, with

automatic metadata extraction

• Connect to PLM systems

• Seamlessly connect to corporate PLM

systems for CAD retrieval

• Search directly within PLM repository

• Retrieve and load CAD files directly into HM

• Teamcenter adapter

• Organize CAE data in the Data Manager

Browser

• Easily search for information by using

simple or advanced queries

• Synchronize libraries and workspaces

• Manage personal data or collaborate with

team database


HyperView, HyperGraph Highlights

• Biggest Overhaul Since Inception

• New and Updated Frameworks

• Browser Driven Workflow

• Session, Parameter

• Model, Loadcase, Results

• Result Math

• Interactive (Expression Builder)

• Batch

• HyperGraph, HyperMath, HyperStudy

• HvTrans, HgTrans

• Scripted plugins

• TCL, Templex, HyperMath

• Video Overlay

• Graphic Manipulators

• Section cuts, Image planes, Rakes

../Local Settings/Temporary Internet Files/OLKB/WebExs/cfd_manipulators.wrf


Domain Specific Engineering Solutions

• Automotive specific user profiles

• Durability Director

• Suspension Director

• NV Director

• CFD Director

• HyperCrash • FTSS dummy support

• Extended LS-Dyna interfacing

• Integration with HyperMesh

• Manufacturing

• Moldex user profile

• HyperXtrude/Polymer

• Composite Layup and Optimization

• Ply-based modeling

• Optimization processes

• Drop Testing… and more


NVH Director: Assembly and Connectors

• NVH Assembly Browser

• New assembly level data structure

• Multiple, interchangeable model

representations selectable based on

simulation needs

• Large component FE models are kept

in include files

• Assembly to include data mapping

and reconciliation managed thru

Assembly Browser

• Simplified model visualization in the

graphics area – used to facilitate

assembly and post-processing tasks

• Tightly integrated with RADIOSS

Predisplay PostdisplaSolver

Plotels PlotelsFRFDetailed Mesh

Plotels

CMS

FRF

Predisplay PostdisplaSolver

Plotels PlotelsFRFDetailed Mesh

Plotels

CMS

FRF

Detailed Mesh

Plotels

CMS

FRF


NVH Director: Integrated Post-processing

• Modal Participation Visualization

• Response Studies using Modal

Participation Data

• Grid participation

• Panel Participation Visualization

• Element Normal Velocity RSS Tool

• Transfer path analysis

• Engine order analysis

• Result server of HyperWorks

Enterprise

• Unique in Industry

Fr

Ff

Fr

Ff Ft

Fe


HyperCrash: Crash, Safety Environment

• Automotive safety modeling environment

• Intuitive, process driven GUI

• Dummy positioning

• Airbag folding

• Seatbelt routing

• System swap

• Mass balancing

• Result mapping

• Fast penetration checking

and de-penetration

• Multi-solver support

• RADIOSS

• Dyna


Durability Director

• Three pre-defined processes

• Duty cycle definition

• Multi-body dynamics

• Stress analysis

• Fatigue analysis

• Post-processing

• Solver neutral • RADIOSS

• Nastran

• MotionSolve

• Adams

• nCode

• FEMFAT


Advanced Finite-Element Solutions

• SQR – Scalability, Quality,

Repeatability

• Crash solver leadership

• Hybrid-MPP

• Multi-domain

• Advanced Mass-scaling

• NVH solver leadership

• CMS sub-modeling

• New implicit analysis

• Contact, materials

• Small & large deformations

• Concurrent Simulation

• Multi-disciplinary

• Integrated, parallel solver

• Optimization ready


SQR – Scalability, Quality, Repeatability

• Parallelization throughout all solution

types

• Hybrid-MPP for iterative solutions

• Subcase and frequency decomposition for

linear solutions

• Choice of numerical implementations that

are suited for best scalability

• Striving for linear speedup

• Accurate modeling of physics

• Precise contact

• Validated material and failure models

• Multi-domain methods

• Rigorous model checking

• Taking the necessary care to make

solution repeatable regardless of

number of processors

25292522

2610

3311

1301 1289

1314

1772

675 668697

906

361358356

473

227 203 205256 246

135126

152287

12799 95

0

500

1000

1500

2000

2500

3000

3500

Ela

ps

ed

(s

)

8 16 32 64 128 256 512 #core

1 thread

2 threads

4 threads

8 threads


INTEL Nehalem 2.80 GHz Cluster

Neon 1 million elements

8 ms simulation

• Combines SMP and SPMD

• Merges everything into one

executable

• Scales further than SPMD

• 1M elements typically scale to

528 cores

• With H-MPP same scales to

1024 cores

• Highly flexible to adapt to new

hardware requirements

• Repeatability guaranteed

Hybrid-MPP – Extended Scalability

Speedups

16 SPMD domains vs # SMP threads

1

1.88

1

1.95

3.65

5.08

2.9

3.8

1

2

3

4

5

6

1 2 3 4 5 6 7 8

#threadsS

pe

ed

up

s

RADIOSS

competitor*



Multi-Domain – Accurate Local Results

• Global model is replaced by

physically equivalent sub-domains

• Decomposition is based on time

step

• Significant reduction of

computation time

• Boundary conditions between

domains insure stability and

equilibrium

• No loss in accuracy

• Refined mesh brings more accurate

prediction of deflection behaviour

including fracture

• Multi-domain reduces the cost of

fine mesh components

• Development collaboration with PSA

Four times faster


Standard AMS

Time step (s) 4.5e-7 4e-6

Energy error 1.15% 0

Number of

cycle 224450 25340

Cpu time (s) 3988 710

Speed-up - 5.6

AMS for quasi-static analysis

3 point bending test

Advance Mass-Scaling (AMS) – Extreme Speed-up

• New Technology based on

modifying the mass matrix to

increase time step

• Management of accuracy

• Only influence on high

frequencies

• Highly scalable

• Applicable to full scale, complex

models


Noise, Vibrations Solver Leadership

• Building on success

• More benchmarks

• Capturing automotive NV

• Adding what is necessary to win

• Nastran compatibility and beyond

capabilities

• CMS super-element Method

• Structural super-elements

• Fluid-structure super-elements

• Modal, panel, grid, super-element

participation factors

• Single H3D file super-elements

• New solutions

• Complex Eigenvalues

• Response spectrum

• Pre-stressed normal modes

Dr. Dennis D. Schwerzler, GM Technical Fellow , Noise & VibrationDr. Dennis D. Schwerzler, GM Technical Fellow , Noise & VibrationDr. Dennis D. Schwerzler, GM Technical Fellow , Noise & Vibration


Non-linear Implicit Analysis

• Large and small displacements and

rotations

• Quasi-static

• Dynamic

• Post-buckling (RIKS method)

• Sliding and small sliding contact

• Non-linear materials

• Elastic-plastic

• Hyper-elastic

• Compatible with explicit and linear

analyses

• Under both input formats

• Bulk Data format (NASTRAN type)

• Block format

../ISM/H3D/lapani.h3d

../ISM/H3D1/HGGear.h3d

../ISM/H3D/doorani.h3d

../ISM/H3D/sealani.h3d


Solver Integration, Concurrent Simulation

• Integrate under Bulk Data format for

optimization readiness

• All solutions including explicit are

now available

• Subcase selects solution sequence

• Complex load scenarios can be

defined

• Model contained in Bulk Data section

• True multi-disciplinary solver

• Integrated, parallelized

• RADIOSS Block Format continued too

BULK DATA

SUBCASE

Loads

MFREQ NLGEOM

STATIC

HEAT

EXPDYN

Elements

Materials

Properties


Multi-body Design Solution

• Automotive design

• Suspension

• Steering and handling

• Ride

• NVH

• General mechanism design

• Mechatronics

• Durability

• MotionSolve Solutions

• Kinematic

• Dynamic

• Static and quasi-static

• Linear

• Flex-bodies

• Adams compatible

• Customizable, User routines



Altair HyperStudy / Altair OptiStruct



• End-to-end Solution

• MotionView

• HyperView

• Tires

• Htire – Handling tire

• Ftire – Durability tire

• Domain specific verticals


• Durability Director

• Superior Flex-body handling

• RADIOSS

• H3D binary format

• Unique integration with OptiStruct for Optimization

• Flex body shapes and topology

• System responses




• Suspension Design environment

• Modular Model database

• Context sensitive browsers

• Re-usable parametric systems to reduce

repetitive tasks

• Custom Top Menu’s & Context Menu’s

• Built-In customizable report

• ADAMS/Car to Suspension Director

translator

• Library Manager

• Improved Group Efficiency

• Maintain, extend and customize vehicle

libraries

• Control model, data, and file variations

through version control.

• Configure access control


Optimization Leadership

• Utilize all analysis capabilities for

optimization in an integrated multi-

disciplinary solver

• Multi-body systems optimization

• Novel Equivalent Static Load Method

• Mix of methods to allow complex setup

• Topology optimization of dynamic

systems

• Non-linear physics optimization

• Equivalent Static Load Method

• Impact (explicit)

• Quasi-static (implicit)

OptiStruct

BULK DATA

SUBCASE

Loads

MFREQ NLGEOM

STATIC

HEAT

EXPDYN

Elements

Materials

Properties


Optimization with Non-linear Deformations

• OptiStruct capability

• Multi-disciplinary solver integration

• Equivalent Static Load Method

• Minimize intrusion

• Size and shape variables

31.4mm 25.7mm

Initial: 11.8kg, 31.4mm

Final: 13.0kg, 25.8mm

Analysis

Dynamic Problem Load time history

Optimization

Static Problem Equivalent static loads

Load

Design variables

fteq = Kdt

t

d


Optimization Leadership

• Concept and design optimization

• Manufacturability

• No hole option

• Sheet metal concepts

• Composites design

• Improved methods

• Better HyperMesh support

• Thermal optimization

• Robust and Multi-objective Design

• Rating and Evaluation

• New optimization algorithms

• HyperStudy/Excel Integration

• HyperStudy facelift


HyperMath Solutions

• Not all engineering math is finite

element or multi-body simulation

• Controls

• Systems simulation

• Co-simulation

• General optimization

• Test data evaluation

• Spreadsheets

• Result math

• Historically good number of tools

• Templex

• HyperGraph

• HyperStudy

• Need to provide math toolset


HyperMath (First with HyperWorks 10.0)

• Matrix based math engine suitable for

solving large scale problems

• Intuitive & simple high-level scripting

language

• Powerful scripting capability

• Plotting capabilities

• Extensive math libraries

• Batch mode execution

• HyperWorks integration

• HyperView, HyperGraph

• HyperStudy, OptiStruct

• Direct readers

• Interactive Development Environment

HyperMath Solutions


HyperStudy

• General purpose, solver neutral

• End-user level tool, easy to learn

• Automates processes for parametric study

• State-of-the art Design of Experiments,

Approximations and Optimization

methods

• HyperWorks Integration

• HyperMesh for shape optimization

• Easy model parameterization

• Direct readers

• New and improved framework and GUI

in Mid-2011

HyperMath Solutions

Model

ResultsResultsResultsResultsResults

ResultsResultsResultsResultsResults

VariantVariantVariantVariantVariant

VariantVariantVariantVariantVariant

SimulationSimulationSimulationSimulationSimulation

SimulationSimulationSimulationSimulationSimulation

Study Results- Optimal parameters

- Sensitivities

- Model Robustness

- …


- Sensitivities

- Model Robustness

- …


- Sensitivities

- Model Robustness

- …


- Sensitivities

- Model Robustness

- …

CreationCreation

Job

Management

Job

Management

ExtractionExtraction

Study

Engine

Study

EngineStudy

Engine

Study

Engine


Scicos Professional (Mid-2011)

• Hierarchical and powerful block

diagram modeling system

• Extensive block libraries

• Supports component modeling with

Modelica

• HyperWorks Integration

• Co-simulation with MotionSolve

• HyperMath

• HyperStudy

• Originated from the METALAU

research project at the Paris-

Rocquencourt center of INRIA, France

HyperMath Solutions


HyperWorks - A Platform for Innovation

Revolutionary business model for customer value

Simulation driven innovation

Liberate creativity

Extend collaboration