Slide Notes OS 10.0 Optimization

7/28/2019 Slide Notes OS 10.0 Optimization

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SLIDE 1 COVER

Welcome to OptStruct training!The instructor should describe the environment, rest room, kitchen, etcThe objective today is to introduce what is and how to use OptiStruct. This training will

give you too basic overview about optimization too. We hope you enjoy these 2 days and takeadvantage of this fabulous tool when you get back to your company.

Information about the class and instructor:o Name, company and position!o What the attendee know about Optimization and HyperWorks!o Why he is attending this course!

On your computer there is a folder named training on your desktop, on this folder youwill find all electronic files you need:

o Manual : Folder with the manual in pdf format:Book with chapters and exercises.

o Model Files : Folder with all model files that will be used during the exercises.o Solved : Folder with the final files from the exercises.

On your desk you should have a folder with a DVD that has all these files and thePowerPoint printed as handouts to take notes during the exposition.


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SLIDE 2 DAY 1 Agenda

Today we will cover the first part of a product development, called Concept Design .The idea is to give you an1. INTRODUCTION

o

A HyperWorks Overviewo How OptiStruct is integrated with the other HyperWorks solvers.o An OptiStruct overview

FEA, MBD and Optimization.

o 2 examples where OS was used to optimize a design.2. THEORETICAL BACKGROUND

o Optimizationa. Design Variable

b. Responsec. Objectived. Constrainte. Feasible and unfeasible

o Gradient-base methodo Sensitivity Analysiso Move Limit Adjustmento Constraint screeningo Regionso Discrete DV

3. OPTIMIZATION INTERFACE AND SETUPo Model Definition Structure

a. Subcase Information Section b. Bulk Data Sectionc. Optimization Cards

o OPTIMIZATION GUIa. Optimization Panel

b. Optimization Menuc. Model Browser

4. CONCEPT DESIGNo Topology

Exercise: step by step on a 2D model Exercise: A Solid Control arm.

o Topography Exercise: Determine the optimum hard drive disc slider suspension beads.

o Free-size Exercise: Determine the optimum hard drive disc slider suspension beads.


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SLIDE 3- Day 2 AgendaOn the second day we start with a review on what was learned mainly to record whatConcept Design was.

Then we start the new chapter Fine Tuning5. Fine tuning Design

This chapter is called fine tuning because the techniques we will learned herecan be used to achieve very precise solution and at the same time dont permit inalmost all cases big changes on the design.

o Size OptimizationIn size optimization, the properties of structural elements such as shellthickness, beam cross-sectional properties, spring stiffness, and mass aremodified to solve the optimization problem.

Size Optimization of a Rail Joint (Step by step)

o Shape Optimization.

In shape optimization, the outer boundary of the structure is modified tosolve the optimization problem. Using finite element models, the shapeis defined by the grid point locations. Hence, shape modificationschange those locations.Shape variables are defined in OptiStruct in a way very similar to that of other shape optimization codes. Each shape variable is defined by usinga DESVAR bulk data entry .

Shape Optimization of a Rail Joint (Step by step)

o Free-shape OptimizationFree-shape optimization uses a proprietary optimization techniquedeveloped by Altair Engineering Inc., wherein the outer boundary of astructure is altered to meet with pre-defined objectives and constraints.The essential idea of free-shape optimization, and where it differs fromother shape optimization techniques, is that the allowable movement of the outer boundary is automatically determined, thus relieving users of the burden of defining shape perturbations.Free-shape design regions are defined through the DSHAPE bulk dataentry. Design regions are identified by the grids on the outer boundaryof the structure (the edge of a shell structure or the surface of a solidstructure). These grids are listed on the DSHAPE entry.


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SLIDE 4 Introduction cover

We will start the training with a small introduction describing:

What is HyperWorks?

and

What is OptiStruct?

SLIDE 5 HyperWorks Overview

HyperWorks Overview A Platform for Innovation, is an enterprise simulation solution for rapid designexploration and decision-making. Used for: Modeling, Analysis, Optimization,Visualization, Reporting, Performance data management .

HyperWorks Tool Descriptions

HyperWorks has a set of tools some of them that we will use during this training are:

HyperMesh: Universal finite element pre- and post-processor

RADIOSS: Finite element solver for linear and non-linear problems

OptiStruct: Design and optimization software using finite elements and multi-body dynamics

HyperView: High performance finite element and mechanical system post-processor, engineering plotter, and data analysis tool

HyperGraph: Engineering plotter and data analysis tool

There are other tools that the user may need on future developments, to learnabout them go to the on-line help.


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SLIDE 6 OptiStruct in HyperWorks

As we described before OptiStruct is part of the HyperWorks toolkit.

OS is an optimizer coupled with finite element and MBD solver.

The solvers consist of loosely integrated executables (see picture). To the user the integration is seamless thru the run script provided. Based on the file namingconvention the right executable or combination of executables is chosen.

The pre-processing for OptiStruct is made using HyperMesh and the post-processing using HyperView and HyperGraph . HyperStudy is another HyperWorks tool that can be used with OptiStruct for Robust design, DOE andOptimization.

During the next exercises the HyperWorks integration with OptiStruct will beshowed in detail, and for more about it the user should go to our online documentation.

SLIDE 7 OptiStruct Overview (FEA)

OptiStruct is a finite element and multi-body dynamics optimizer which can beused to design and optimize structures and mechanical systems.

The graphical interface for OptiStruct within HyperWorks allows you to performcomplete modeling, optimization problem setup, job submission, and post-processing

quickly and easily.

The Finite Elements Analysis includes: linear static, modal, linear buckling andthermal-stress analysis for steady state .

It support advanced analysis as FRF direct and modal, Random response or PSDanalysis, Transient direct and modal, Contact non-linear, acoustic with coupled fluidand structure, fatigue analysis for high and low cycle.


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SLIDE 8 OptiStruct Overview (MBD)

KinematicKinematics is the study of the motion of a systemwith no consideration of forces

StaticStatics is the study of systems in equilibriumPerformed for systems having D.O.F >= 1System at rest or having constant velocityGives information about the equilibrium forces

Quasi-static

Quasi-static simulation is a sequence of staticsimulations where bodies are moving very slowlyPerformed for systems having D.O.F >= 1Quasi static simulation is a sequence of staticsimulationsYou must have a time dependent force or motion inyour modelQuasi means almost. So the results are valid only if

things are moving sufficiently slowlyMethod I Force Imbalance MethodMethod II MKEAM Method

DynamicDynamics deals with systems which are not inequilibrium and are accelerating. It studies motion,taking into account forces


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SLIDE 9 Optistruct Optimization Overview

This training focus on OptiStruct , but it is important for the user to understand all optimization resource it is available on HyperWorks.

- Lets take a look on how HyperWorks can be used during the Design Process.CLICK

- Topology : Or the best material distribution. CLICK - Free-size: Used to determine the best thickness distribution, mainly used on

composite structures. CLICK - Topography: Used on 2D to determine the optimum topography of a component.

CLICK - Free-shape: As the name says is a shape optimization where the shape variables

are determined automatically by the solver using the normal of the elements.CLICK

- Shape: As we can see shape optimization is the change on any geometric featurelike a hole, thickness, radio, etc. CLICK

- Size : This is known too as parametric optimization, it is the change of numerical parameters, for example a plate thickness modeled with shell elements. CLICK

- On OptiStruct we can divide the optimization in 2 phases- Concept Design (That will be our chapter 4) CLICK - Design Optimization or Fine Tuning (this will be discussed in detail on

our chapter 5) CLICK - And all these optimizations are available on OptiStruct. CLICK

When we use HyperWorks there is another tool called HyperStudy that cancomplement and improve the optimization and the study of our design.

With HST is possible to do Multidisciplinar optimization, DOE, and stochastic studies with any solver.


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SLIDE 10 - Lightweight SUV Frame Development

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SLIDE 11 - Optimization Process for Torsion Links ADD NOTES

SLIDE 12 Cover Theoretical Background

We will now take some time to understand what Optimization means in the contest of product design.

We will introduce Optimization Concepts and Definitions that will be very important toyou during the exercises, then if you have any doubt here please feel free to ask atany time.

SLIDE 13 - Structural Optimization Concepts

Now that we had already learned based in an example how a function or response

can be optimized in 2D graphical. Lets define formally a optimization problem:1. Objective is the functions/properties/responses that you want to maximize or minimize.

2. DVs/parameters are what you can change to achieve the objective.3. Constraints are again as the objective responses/functions/properties that

need to be higher or lower then a target value.These function can be of any type, linear, non-linear, dynamic, implicit or explicit,when working in OptiStruct we will work only with continuous functions.

SLIDE 14 - Optimization Definitions

1. Toplogy optimization

SLIDE 15 Optimization Definitions

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SLIDE 16 - Optimization Terminology DV, DS

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SLIDE 17 - Optimization Terminology Response

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SLIDE 18 Optimization Terminology Objective, Constraint.

SLIDE 19 - Optimization Problem Example

It is good to start with an example that every engineer knows the response. A cantilever beam with a constant length of 1, remember this is just an example!!!We will consider that the beam theory is valid for all the design space proposed.

The section dimensions (b,h) of the beam are our DVs. The goal is to find theminimum weight subject to some constraint on stress.

SLIDE 20 - Optimization Problem Example

We can state this problem as:1. Minimize the weight that is a function of b and h.2. where the parameters or design variables are b and h

3. The Design space is defined as all possible beams that can be generatedwithin the limits of b and h .4. The maximum bending stress (normal stress) cant be higher than 160 MPa .5. And the maximum shear stress cant be higher then 60 MPa6. There is another constraint applied directly on the DVs, where the beam is

only valid if h 2*b .


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SLIDE 21 Optimization Problem Example

1. This is the weight function level where each line represents a constant weightvalue and these are decreasing when both b and h decrease. CLICK

2. This green line represents the max normal stress = 160 MPa and the regionbelow in pink is unfeasible because the stress is higher then it. CLICK

3. The blue line represents the shear stress = 60 MPa, as we can see it isinactive because the non valid region is inside the other non-valid region andwill not change the results. CLICK

4. This light blue line represents the h = 2b region and the pink region above itis not valid because h > 2b. CLICK

5. Then we can plot the DV limits using dot lines. This show that only the whiteregion is valid. CLICK

6. And based on the level curves we can see that the minimum weight is on theleft rand corner, where the constraints cross each other. This is a verycommon situation for almost all Engineer problems. CLICK

SLIDE 22 Optimization Terminology Feasible, infeasible and Optimum

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SLIDE 23 - Optimization Terminology Gradient-based Optimization

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SLIDE 24 - Optimization Terminology - Sensitivity Analysis

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SLIDE 25 Interpreting the Results

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SLIDE 26 Interpreting the Results

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SLIDE 27 - Optimization Interface and Setup (cover)


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SLIDE 28 Optimization GUI

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SLIDE 29 Optimization Setup module in HyperMesh

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SLIDE 30 - Optimization Setup module in HyperMesh

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SLIDE 31 - Optimization Setup module in HyperMesh

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SLIDE 32 Optimization Setup module in HyperMesh

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SLIDE 33 Model Definition Structure

o We will get a little deep on the model definition, the user dont need to beworry about understand all things here, the idea is more to put every one onthe same page.

o A description how we set up the problem will be done very quickly, if someone has difficulty on follow the steps let me know.

o The mainly objective on the next it is to leave with the user a basic recipe of how to set up optimization.

SLIDE 34 - Model Definition Structure

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SLIDE 35 - Model Definition Structure

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SLIDE 36 Constraint and Objective definition

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SLIDE 37 - Optimization Cards

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SLIDE 38 - Constraint and Objective Definition: Load CaseReference

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SLIDE 39 - Optimization Setup


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SLIDE 41 - Optimization Setup ADD NOTES



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SLIDE 47 - Concept Design (Cover)

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SLIDE 48 How Structural Optimization CutsDevelopment Time

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SLIDE 49 -Topology Optimization

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SLIDE 50 - Design Variables Topology Optimization

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SLIDE 51 OptiStruct Input: Topology Optimization

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SLIDE 53 - Topology Optimization using ManufacturingConstraints

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SLIDE 54 Topology Optimization using ManufacturingConstraints

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SLIDE 55 Manufacturing Constraints: Minimum MemberSize Control

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SLIDE 56 - Manufacturing Constraints: Maximum MemberSize Control

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SLIDE 57 - Manufacturing Constraints: Pattern Repetition

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SLIDE 58 Pattern Repetition

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SLIDE 59 - Pattern Repetition

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SLIDE 60 - Draw Direction Constraint

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SLIDE 61 Draw Direction Constraint

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SLIDE 62 - Draw Direction Constraint

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SLIDE 63 - Extrusion Constraint

ADD NOTESSLIDE 64 Combination of Manufacturing Constraints

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SLIDE 65 Applications of Topology Optimization

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SLIDE 66 - Common Topology Optimization Problems

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SLIDE 67 - Additional Optimization Considerations

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SLIDE 68 Topology Optimization with stress Constraints

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SLIDE 69 - Exercise 4.1: Topology Optimization of a Hook with Stress Constraints

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SLIDE 70 - Exercise 4.1: Topology Optimization of a Hook with Stress Constraints ( RESULTS )

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SLIDE 71 OSSmooth: Geometry Extraction of Optimization Results

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SLIDE 72 - Topology Optimization Example: BulkheadStiffeners

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SLIDE 73 - Topology Optimization Example: BulkheadStiffeners ( Results )

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SLIDE 74 - Topology Optimization Example: BulkheadStiffeners ( Performance )

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SLIDE 75 Exercise 4.2: Topologic Optimization of aControl Arm

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SLIDE 76 Exercise 4.2: Topologic Optimization of aControl Arm

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SLIDE 77 - Topography Optimization

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SLIDE 78 - Molded Pressure Tank

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SLIDE 79 Molded Pressure Tank ( Symmetry )

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SLIDE 80 - Molded Pressure Tank ( Results )

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SLIDE 81 - Molded Pressure Tank ( Performance)

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SLIDE 82 Topography Optimization ( Torsion plate - performance )

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SLIDE 83 - OptiStruct Input: Topography Optimization

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SLIDE 84 Topography Optimization Setup

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SLIDE 85 Topography Optimization Setup

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SLIDE 86 - Topography Optimization Setup

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SLIDE 87 - Bead discreteness control

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SLIDE 88 Combining Optimization Types

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SLIDE 89 - Exercise 4.3: Topography Optimization of aSlider Suspension

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SLIDE 90 - Exercise 4.3: Topography Optimization of aSlider Suspension ( Results )

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SLIDE 91 Free-Size Optimization

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SLIDE 92 - Free-Size Optimization

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SLIDE 93 - Free-Size Optimization

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SLIDE 94 Free-Size Optimization on PCOMP

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SLIDE 95 Exercise 4.4: Free-size Optimization of FinitePlate with Hole


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SLIDE 96 - Exercise 4.4: Free-size Optimization of Finite

Plate with Hole ( Results )

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SLIDE 97 - Fine Tuning Design (Cover)

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SLIDE 98 Size Optimization

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SLIDE 99 - Size Optimization

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SLIDE 101 Size Optimization

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SLIDE 104 Exercise 5.1 Size Optimization of a Rail Joint

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SLIDE 105 Exercise 5.1 Size Optimization of a Rail Joint(Results )

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SLIDE 106 - Shape Optimization

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SLIDE 108 Shape Optimization

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SLIDE 111 Morphing with Domain and Handle

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SLIDE 112 - Morphing with Domain and Handle

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SLIDE 117 - Shape definition for Optimization

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SLIDE 118 Exercise 5.2 Shape Optimization of a RailJoint

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SLIDE 119 - Exercise 5.2 Shape Optimization of a RailJoint ( Result )

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SLIDE 120 - Free Shape Optimization

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SLIDE 121 Free Shape Optimization

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SLIDE 124 Free Shape optimization

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SLIDE 126 - Free Shape optimization

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SLIDE 127 - Free Shape optimization

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SLIDE 129 - Example 2: shape change history

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SLIDE 130 - Exercise 5.3 - Free-shape optimizationCompressor Bracket


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SLIDE 131 Exercise 5.3 - Free-shape optimizationCompressor Bracket ( Result )

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Slide Notes OS 10.0 Optimization