Altair's Student Guides - Instructor's Manual - CAE and Design Optimization - Advanced

Student Project Summaries CAE and Design Optimization - Advanced
Contents
Introduction.............................................................................................2
Installation Instructions: .......................................................................2
Sensitivity To Support Stiffness .................................................................3
Description of the Problem ....................................................................3
The Analysis Model ...............................................................................4
Design of Experiment ............................................................................5
Further Work ........................................................................................6
Summary .............................................................................................6
Multi-objective Optimization – Battery Tray................................................8
Description of the Problem ....................................................................8
The Analysis Model ...............................................................................9
Design of Experiment ............................................................................9
Further Work ...................................................................................... 11
Summary ........................................................................................... 11
Optimization With Load-Redistribution ..................................................... 13
Description of the Problem .................................................................. 13
The Analysis Model ............................................................................. 14
Design of Experiment .......................................................................... 14
Further Work ...................................................................................... 16
Summary ........................................................................................... 17
Geneva Mechanism – Effect Of Friction.................................................... 18
Description of the Problem .................................................................. 18
The Analysis Model ............................................................................. 19
Design of Experiment .......................................................................... 19
Further Work ...................................................................................... 21
Summary ........................................................................................... 21
1
Introduction
This material is best used after reading the book CAE And Design
Optimization - Advanced.
Access to HyperWorks software is not essential for you, the instructor. Of

course, if you choose to solve the problem yourself before working with your
students, you will need HyperStudy, HyperMesh and OptiStruct.
This book describes 4 assignment problems that highlight different

applications of HyperWorks. Each problem is independent, and is complete
in itself. Students may choose to do more than one, depending on their
interest.
To make best use of this material you will need a computer with a sound-
card and speakers. Your computer should have a media-player programme
(such as Windows Media Player) and an Internet Browser that supports
JavaScript. The material can be copied to a server and accessed by clients.
You can customize the HTML files to suit your

requirements. After opening the file, double-
click on any text to edit it. Use the save changes
link on the left of your Browser window when
you are finished.
Installation Instructions:
1. Copy the folders to your computer or to your server. If you are
working on a server, it is a good idea to set the folders to “read
only” to prevent inadvertent modifications.
2. The videos are best played in full-screen at a resolution of 1024 x
768. You may need to install the CamStudio Codec to view video on
your computer. To do this, right-click on the file camcodec.inf and
choose Install from the popup menu. You may need administrator
privileges to do this.
3. Ensure that JavaScript is enabled on your browser.
4. Each folder contains one HTML file. Double-click on it to open the
instructions.
5. Data files are provided as relevant – IGES files, HM files, etc.
6. In case you need support, contact your distributor or email
edu.support@altair.india.com
2
Sensitivity To Support Stiffness

Areas covered:
• Construction of an FE Model for thermo-mechanical
analysis
• Creation of a Template for Study-construction
• Design Of Experiment
• Design Space Exploration
Software used:
• HyperStudy
• HyperMesh
• OptiStruct/Analysis
Description of the Problem

A design proposal has been received for a
subassembly, and the task is to simulate its
performance. The screw-shaft subassembly,
which fits into a housing, is manufactured to
very close tolerances. The dimensional
accuracy is measured in 10s of microns.
In the test chamber, the complete assembly is

cooled to -40 degrees Kelvin and tested. It is
subsequently raised to 135 degrees Kelvin and
tested. The designer needs to know whether
the sub-assembly will function correctly.
A standard Finite Element approach is to

analyze the component assuming the
surrounding housing is rigid. How reasonable
is this assumption? Can we gain an insight into
the impact of the housing's flexibility, without
modeling the housing itself?
If the behavior of the shaft and plugs is not

sensitive to the stiffness of the supports, then
the analyst can repose a high degree of
confidence in the FE model. If this were not
the case, it would be prudent to suggest that
the analysis would be more reliable if the
housing too were supplied for analysis.
3
The Analysis Model

A numerical experiment can be quite
expensive. A good high-fidelity model is
always preferable to ensure that returns justify
the investment. Refer to the the assignment
that accompanies A Designer's Guide To
Finite Element Analysis for a detailed
description on how to create a hexahedral
mesh of the shaft and the plugs, and apply
loads and restraints.
In this assignment, our focus is not on

creation of the high-fidelity model: our focus is
on setting up and interpreting the results of
the experiment.
This assignment starts with an IGES file

containing the quarter-model of the shaft. A
relatively coarse FE mesh that uses the less
accurate tetrahedral elements is constructed.
Also, the plug is omitted in this coarse model.
A local cylindrical coordinate system is used to

generate spring supports on the circumference
of the mating face, and one end of each
spring is “grounded”. The stiffness assigned
to the springs is a part of the experiment,
since we want to study the impact of varying
the support stiffness.
Remember that computer models treat "zero"

and "infinity" differently because of finite
precision. Since computers use finite precision
arithmetic, we vary the levels between a small
value and a large value, rather than using zero
and infinite stiffnesses.
The restraints, temperatures, loads and

subcase definition are applied, as in the
assignment named above – Thermo-
Mechanical Analysis Of Screw Shaft.
An analysis is performed and deformation
4
viewed, to ensure that the behavior of the model with spring supports is
correct.
Design of Experiment
This assignment involves exploration of the Design Space. The FE model
addresses "ideal" conditions - where the supports are infinitely rigid. Our
task is to gain in insight into how the
component will behave if the housing is not
infinitely rigid.
Since the data for the housing is not available,

the analyst has no way to include it in the
analysis. Instead of glossing over the
ambiguity, we devise an experiment that
allows us to investigate the impact on the
model.
Since the Study requires data that cannot be

accessed using the ready-made template, we
use the Templex programming language to
extract data we need. In this approach, we
use an initial "master" data set - in this case
the "fem" file generated by HyperMesh - to
define the changes we want for each
evaluation required by the experiment. Once
the changes are defined, HyperStudy
generates a different data set (or "deck") for
each set of levels that we choose for the
factors. In this case, we vary the stiffness of
the springs - we define the upper and lower
bounds for the stiffnesses. The levels are set
when we choose the experiment design.
Once the nominal run has been executed, we

use the results-translators to extract results
from the binary files generated by OptiStruct /
Analysis. The Expression Builder gives us ways
to build a wide range of responses.
Since each spring element has its stiffness

assigned individually, we link the design
variables. This way, when the levels are varied
as a part of the experiment, the springs all
5
change together - reflecting the radial symmetry.
There are no black-and-white rules that define how many levels to use for
each factor, or to decide which type of experiment to use. We use the
Fractional Factorial design for the controlled factors and the Central
Composite design for the uncontrolled factors.
After performing the analyses, the results must be extracted from the results
files. That is, the output files should be examined for the values of the
responses, and these should then be tabulated and graphed. The tedium of
this task is eliminated by the elegant results-translation performed by
HyperStudy. This leaves the designer free to focus on interpreting the
results.
Since this is an experiment intended to explore the Design Space, the main
focus is on understanding the "Main" effects - that is, the variation of
responses with the controlled parameters.
Further Work
The experiment offers an excellent way to tackle, in a rigorous fashion, the
many assumptions implicit in an FE analysis.
You may choose to assign further investigations to your students based on

their level of proficiency on statistics and design, the time available, etc.
Some of the areas include

• the use of an approximation for the contact analysis
• a study of possible alternate steel-alloys for the plugs, to see how a
different thermal expansion coefficient affects the design
• use of a Monte Carlo method to build a confidence level
Summary
By the end of this assignment, the student will know how to
• import IGES files
• use the Model Browser
• zoom, pan and rotate
• create collectors for materials, elements, forces and restraints
• use consistent units
• build hexahedral meshes
• use local coordinate systems
• create and use spring elements
• check for different types of element-edges - free, shared, etc.
• fill and stitch surfaces
6
• perform a thermo-mechanical analysis

• plan and setup an experiment for Design-Space Exploration
• create and troubleshoot a Templex template
• link variables in an experiment
• plot stress contours
• view deformed shapes
• view the effects of design variables on design responses
7
Multi-objective Optimization – Battery

Tray
Areas covered:
• Construction of FE Models for static and normal-
modes analyses
• Creation of a Template for Study-construction
• Trade-Off Study
Software used:
• HyperStudy
• HyperMesh

A design for the tray to hold the battery of an
automobile has been proposed. The basis for
the model is a study of earlier designs. The
Instructor's Manual that accompanies the book
CAE And Design Optimization - Basics
addresses optimization for FRF response.
The designer's have another query too: can

they reduce the maximum deformation as
much as possible, while raising the minimum
frequency as much as possible?
In other words, both the responses -

maximum-deformation and base-frequency -
are to be treated as objectives. One should be
minimized while the other should be
maximized.
We use two different finite element models -

one for static analysis, under the dead-weight
of the batteries and the other for the normal-
modes calculation. A numerical experiment is
constructed to sample the design space, and
an approximation built from the results of the
DOE. A trade-off study is then used to choose
the optimal combination of the design
variables for the two objective
8
The Analysis Model

A numerical experiment can be quite
expensive. A good high-fidelity model is
always preferable to ensure that returns justify
the investment. In this assignment, our focus
is not on creation of the high-fidelity model:
our focus is on setting up and interpreting the
results of the experiment and the subsequent
trade-off study.

containing a simplified geometry of the tray,
though you should ask your students to work
with the detailed model to better learn the
issues involved in building FE models from
CAD geometries.
Two different models are used for the FEA -

one for static analysis and the other for the
normal modes calculation. The first can take
advantage of symmetry, and is likely to
require a finer mesh. Before proceeding with
the numerical experiment, your students
should perform convergence studies to ensure
that their models are adequate.
The battery is modeled as a dead-weight, that

is, under the affect of gravity. SI units are
used to ensure that calculations are
consistent.
Since we have a Finite Element model
available, we can invoke HyperStudy from
HyperMesh. This gives us access to several
model parameters. We can also invoke
HyperStudy as a standalone application. Each
has its advantages. If the Study requires data
that cannot be accessed using the ready-made
template, we can use the Templex
programming language to extract data we
need.
9
In this approach, we use an initial "master"

data set - in this case the "fem" file generated
by HyperMesh - to define the changes we
want for each evaluation required by the
experiment.
Once the changes are defined, HyperStudy

generates a different data set (or "deck") for
each set of levels that we will choose for the
factors. In this case, we vary the thickness of
the sheet-metal. We define the upper and
lower bounds for the thickness. The levels will
be set later when we choose the experiment
design. Since sheet-metal comes in standard
thicknesses, it does not make sense to treat
the design variables as continuous.
Accordingly, we define the discrete
thicknesses that should be used for the
experiment.

from the files generated by OptiStruct /
Analysis. The Expression Builder can build a
wide range of responses - we are interested in
the deformation at selected nodes.
Since the thickness of the sheet-metal must

vary consistently for both analysis models, we
link the variables between the two FE models.
There are no black-and-white rules that define

how many levels to use for each factor, or to
decide which type of experiment to use. We
use a Central Composite design to study the
behavior. Your students should be encouraged
to evaluate other studies, so that they clearly
understand the advantages and disadvantages
of various designs. 11 levels for each factor
means 121 runs are required for each FE
model for a full factorial! The rigorous
statistical approach allows the problem to be
brought under control in terms of the time
involved.
10
After performing the analyses, the output files should be examined for the
values of the responses, and these should then be tabulated and graphed.
The tedium of this task is eliminated by the elegant results-translation
performed by HyperStudy. This leaves the designer free to focus on
interpreting the results.
Your students should be encouraged to use HyperStudy to perform more

than one experiment! The results of the first experiment should help cast
light on the various assumptions implicit in the model. Ensure that your
students can enumerate the assumptions - for instance the nodes at which
response values were tracked - and use the software to enhance their
understanding of the behavior of the component.
Recall the importance of a trade-off study - it should be usable in a design

review meeting to quickly answer questions from the designers.
HyperStudy provides three different types of approximations. We start with

the Least-Squares Regression (LSR) model, and go on to see how good it is.
We review the scatter plot and conclude that the approximation is not as
good is it should be. Your students should review the relationship between
the number of runs involved in the DOE and the permissible approximations.
The trade-off study is performed in real-time, interactively, illustrating the

impact of variable-changes on the responses. We review the ANOVA plot to
understand which design variables have an effect on the responses.
Further Work
he assignment illustrates how to use two separate FE models to generate
different objectives, and study the impact of the design variables on these.

Some of the areas for deeper research include
• the use of the FRF results to estimate the maximum deformation

• addition of stress as an objective
• an investigation into the use of laminated composites for the battery-tray
Summary
11

12
Optimization With Load-Redistribution

Areas covered:
• Construction of an FE Model with gravity loads
• Construction of an Approximate Model
• Optimization with change in applied loads
Software used:
• HyperStudy
• HyperMesh

A housing, used to hold an actuator, is the
subject of this optimization study. The
Instructor's Manual that accompanies the book
CAE And Design Optimization - Basics
addresses optimization for failure-stress, with
a changed material.
That analysis assumed that the "internal"

weights - of the actuator electronics, etc. -
could be taken as "given data". The designers,
however, have another query.
Since some leeway is available in designing

and mounting the "internals" themselves,
should they redistribute these weights at the
same mounting points? Will it reduce stress?
Optimization techniques such as topology

optimization cannot change the boundary
conditions - loads and restraints. In this case,
we explicitly need to study the effect of
changing the loads. Going one step further, we
need to suggest the best distribution. That is,
we need to suggest the "optimum"
distribution.
13
The Analysis Model

A numerical experiment can be quite expensive.
A good high-fidelity model is always preferable
to ensure that returns justify the investment. In
this assignment, our focus is not on creation of
the high-fidelity model: our focus is on setting
up and interpreting the results of the
experiment and the subsequent trade-off study.

containing a simplified geometry of the housing,
though you should ask your students to work
with the detailed model to better learn the
issues involved in building FE models from CAD
geometries.
A coarse tetrahedral mesh is constructed, and

concentrated masses created to simulate the
weights of the "internals". We choose a point
roughly midway between the "pairs" of bolt
holes to monitor the stress. Your students
should use their converged-model to pick the
elements which are better indicative of the
effects - remembering, of course, that stress
decays fairly rapidly as you go away from the
point of application of load.
Since we have a Finite Element model available,
we invoke HyperStudy from HyperMesh. This
gives us access to several model parameters.

from the binary files generated by OptiStruct /
Analysis.
The Expression Builder gives us ways to build

a wide range of responses - for our design,
however, we are interested only in the stress at
selected locations. The "pairs" of bolt-holes
should be loaded such that the total weight
bolted at the pair is the same. Remember that
14
the designers can change the distribution of

weight between the bolt holes, not the actual
weight itself. We link variables to establish this
behavior.

decide which type of experiment to use. We
use a Central Composite design to study the
behavior. Your students should be encouraged
to evaluate other studies, so that they clearly
understand the advantages and disadvantages
of various designs.
Your students should appreciate the

importance of DOE - the rigorous statistical
approach allows the problem to be brought
under control in terms of the time involved.
There are no uncontrolled factors in the

experiment since the factors are all under the
designer's control.
After performing the analyses, the results must

be extracted from the results files. That is, the
output files should be examined for the values
of the responses, and these should then be
tabulated and graphed.
The tedium of this task is eliminated by the

elegant results-translation performed by
HyperStudy. This leaves the designer free to
focus on interpreting the results.
Your students should be encouraged to use

HyperStudy to perform more than one
experiment! The results of the first experiment
should help cast light on the various
assumptions implicit in the model. Ensure that
your students can enumerate the assumptions
- for instance the stresses at which response
values were tracked - and use the software to
enhance their understanding of the behavior of
the component.
15
Ann approximation is not essential for an

optimization since the FE model is well
behaved. The main advantage in a scenario
such is this is the reduction in analysis time,
allowing more analyses to be performed.
HyperStudy provides three different types of

approximations. We start with the Least-
Squares Regression (LSR) model, and go on to
see how good it is. Your students should
review the relationship between the number of
runs involved in the DOE and the permissible
approximations.
We review the ANOVA plot to understand

which design variables have an effect on the
responses, and see the utility of trade-offs
before setting up the optimization.
There are no constraints on the optimization.

Remember that the variables are linked, and
bounds have been specified for the variation of
the parameters. The objective is to choose the
proper distribution of weight to achieve the
minimum stress.
There are three bolt hole pairs that are

involved in the study. Your students should be
encouraged to consider whether a multi-
objective optimization is required, or whether
the objectives can be treated independently.
We review the system identification feature

which would be useful if we had a target value
for the stress.
We set the parameters that govern the

behavior of the optimizer and use the
approximation to perform the minimization.
Further Work
The assignment illustrates how to use two separate FE models to generate
different objectives, and study the impact of the design variables on these.
16

• a stochastic study to determine the reliability of the design

• an optimization study that uses the material data as parameters -
several alloys can be evaluated and the best one suggested
• an optimization study on the design suggested by the topology
optimization
Summary
17
Geneva Mechanism – Effect Of Friction

Areas covered:
• Use of a Multi-Body-Dynamics (MBD) Model to
simulate a mechanism
• Construction of an Approximation
• Use of Monte Carlo methods for stochastic analysis
Software used:
• HyperStudy
• MotionView
• MotionSolve

A Geneva Mechanism is a widely used indexing
mechanism. It relies on friction between the
crank and the slotted-disk for the indexing.
Friction is hard to pin down perfectly. At best,
we can estimate the range between which the
friction coefficient can vary.
Further complicating the issue, there is more

than one "kind" of friction coefficient the
designer has to grapple with. We have static
friction at the initiation of motion, dynamic
friction when the mechanism is running, and
"stiction" or stick-friction, which can be a
nightmare for a designer.
With this, what is the reliability of the design?
There are two areas the designer is interested

in.
First, the forces on the crank during motion. If

these can be evaluated, a stress analysis can
be carried out to ensure that the crank is safe
for all ranges of expected forces. That is, at
the best and worst case friction-coefficient
scenarios.
Second, which ranges of coefficients are the

worst and best case scenarios?
18
We perform a Monte Carlo study to investigate

the behavior of the mechanism given the
designer's interest.
The Analysis Model

Refer to the assignment that accompanies
CAE and Multi-Body Dynamics for a
detailed description on how to create a multi-
body dynamics model using MotionView.
In this assignment, our focus is not on creation

of the high-fidelity model: our focus is on
setting up and interpreting the results of the
stochastic study. Accordingly, we start with an
existing model of the Geneva Mechanism.
This assignment starts with an "MBD" model -

a Multi-Body-Dynamics model. We review the
structure of the model. Our attention is on the
various control elements and the tessellated
geometry that provides both the graphical
display and the surface-definitions for contact.
We also review the contact parameters,

choose the output we want, and plot the
forces on the body.
Since we have an MBD model available, we
can invoke HyperStudy from MotionView. This
gives us access to several model parameters.
We can also invoke HyperStudy as a
standalone application. Each has its
advantages, as we will see.

decide which type of experiment to use.
We use a Central Composite design to study

the behavior. Your students should be
encouraged to evaluate other studies, so that
19
they clearly understand the advantages and disadvantages of various

designs.
Your students should appreciate the importance of DOE - the rigorous

statistical approach allows the problem to be brought under control in terms
of the time involved.
There are no uncontrolled factors in the experiment since the factors are all
under the designer's control.
An approximation is almost essential for a stochastic study since it allows us

to perform many more analyses at a marginal increase in computation cost.
HyperStudy provides three different types of approximations. We start with

the Least-Squares Regression (LSR) model, and go on to see how good it is.
Your students should review the relationship between the number of runs
involved in the DOE and the permissible approximations.
We review the ANOVA plot to understand which design variables have an

effect on the responses, and see the utility of trade-offs before setting up
the optimization.
The Monte Carlo approach uses a large number of trials to estimate

behavior. We could have skipped the DOE and Approximation and directly
created a Stochastic Study using the high-fidelity model. That is, we could
have used MotionSolve to perform each trial.
However, if a MotionSolve analysis takes 60 CPU seconds, and the Monte

Carlo study is to be conducted with as few as 500 analyses, this means
each study takes over 6 hours of CPU time.
This can inhibit design-exploration. The use of the DOE to construct the
approximation effectively removes this inhibitor. You should encourage your
students to review the different forms of stochastic studies HyperStudy
offers, and to understand the impact of changing the number of trials.
Your student should also be encouraged to understand the various ways to

measure reliability and robustness in the context of engineering design.
20
Further Work
The assignment illustrates how to use Monte
Carlo methods to conduct a stochastic study of
a random variable.
You may choose to assign further

investigations to your students based on their
level of proficiency on statistics and design,
the time available, etc.
• the generation of nomograms for various

material combinations
• use of system-identification to achieve
target values for forces on the components
• the impact of friction on the timing of the
device
Summary
By the end of this assignment, the student will
know how to
• create collectors for materials,
elements, forces and restraints
• check for different types of
element-edges - free, shared, etc.
21
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Student Project Summaries CAE and Design Optimization - Advanced

Access to HyperWorks software is not essential for you, the instructor. Of

This book describes 4 assignment problems that highlight different

You can customize the HTML files to suit your

Sensitivity To Support Stiffness

Description of the Problem

In the test chamber, the complete assembly is

A standard Finite Element approach is to

If the behavior of the shaft and plugs is not

The Analysis Model

In this assignment, our focus is not on

This assignment starts with an IGES file

A local cylindrical coordinate system is used to

Remember that computer models treat "zero"

The restraints, temperatures, loads and

An analysis is performed and deformation

Since the data for the housing is not available,

Since the Study requires data that cannot be

Once the nominal run has been executed, we

Since each spring element has its stiffness

change together - reflecting the radial symmetry.

You may choose to assign further investigations to your students based on

Some of the areas include

• perform a thermo-mechanical analysis

Multi-objective Optimization – Battery

Description of the Problem

The designer's have another query too: can

In other words, both the responses -

We use two different finite element models -

The Analysis Model

This assignment starts with an IGES file

Two different models are used for the FEA -

The battery is modeled as a dead-weight, that

In this approach, we use an initial "master"

Once the changes are defined, HyperStudy

Once the nominal run has been executed, we

Since the thickness of the sheet-metal must

There are no black-and-white rules that define

Your students should be encouraged to use HyperStudy to perform more

Recall the importance of a trade-off study - it should be usable in a design

HyperStudy provides three different types of approximations. We start with

The trade-off study is performed in real-time, interactively, illustrating the

You may choose to assign further investigations to your students based on

Some of the areas for deeper research include

• the use of the FRF results to estimate the maximum deformation

• use the Model Browser

Optimization With Load-Redistribution

Description of the Problem

That analysis assumed that the "internal"

Since some leeway is available in designing

Optimization techniques such as topology

The Analysis Model

This assignment starts with an IGES file

A coarse tetrahedral mesh is constructed, and

Once the nominal run has been executed, we

The Expression Builder gives us ways to build

the designers can change the distribution of

There are no black-and-white rules that define

Your students should appreciate the

There are no uncontrolled factors in the

After performing the analyses, the results must

The tedium of this task is eliminated by the

Your students should be encouraged to use

Ann approximation is not essential for an

Altair's Student Guides - Instructor's Manual - CAE and Design Optimization - Advanced

Altair's Student Guides - Instructor's Manual - CAE and Design Optimization - Advanced