Altair HyperWorks: A Platform for Innovation. Vladimir Obukhov Technical Consultant Altair Engineering GmbH

Transcription

1 Altair HyperWorks: A Platform for Innovation Vladimir Obukhov Technical Consultant Altair Engineering GmbH

2 HyperWorks Desktop Integration Typical FEA Process IMPORT FROM CAD or CAE World CAD CAE 1) GEOMETRY PRE-PROCESSING 2) FINITE ELEMENT MODEL 3) ANALYSIS SOLVING ALTAIR SOLVER EXTERNAL SOLVER POST-PROCESSING Results Visualization

3 Integration Matters: Flexibility Open, adaptable to your environment CAD ACIS CATIA V4 / V5 IGES (in) IGES (out) JT Precise Parasolid (in) Parasolid (out) Pro/E SolidWorks STEP Tribon UG/NX CAE Adams Abaqus Actran AcuSolve Ansys CFD++ Femfat Fluent Ls-Dyna Madymo Marc Matlab Moldflow Moldex3D MotionSolve Nastran ncode Permas Pam-Crash RADIOSS OptiStruct Samcef Simpack StarCD Custom User-defined Interfaces Scripting Results Math

4 Modeling and Visualization: Pre-Processing Pre-Processing HyperMesh FEA/CFD Modeling, Customizable to capture best practices, Native CAD Support for better model quality Simlab CAE Pre-Post Processing Tools to automate and reduce the simulation time without compromising quality MotionView Multi-body modeling, Parametric modeling, Solver-neutral data model, Highly customizable

5 Meshing Time Reduction HyperMesh, SimLab Superior mesh quality Hexaherals Tetrahedra Shells Complete solution Geometry cleanup & Meshing Loads & boundary conditions Morphing Broadest set of direct CAD and CAE interfaces Abaqus Ansys Dyna Nastran Radioss Extensive geometry repair functionality

6 Modeling and Visualization: Altair SimLab Simplified Modeling Processes for Complex Problems Feature based Create high quality Knowledge capture Extremely well-suited finite-element mesh easily and and sharing via for powertrain modeling rapidly templates modeling

7 Example: Turbine Blade Meshing Strategy at Siemens Presentation European HTC 2011

8 Cutting CAE Modeling Time by up to 50% at Dunlop Aerospace Challenge Need for complex solid mesh models for simulation of aircraft braking systems Creation of HEXAEDER meshes took sometimes weeks Solution HyperMesh s HEX mesh capabilities Solid Map functionality: intelligent extrusion of shell meshes into volumes Direct geometry input to eliminate time to repair surfaces Morphing to quickly realize mesh based design changes Benefits Up to 50% reduction in meshing time Extremely stable environment Easy to learn & use

9 Analysis: HyperWorks Solver Technology Structural Analysis Crash, Safety, Impact & Blast Thermal Analysis Fluid Dynamics Systems Simulation Manufacturing Simulation Electro- Magnetics Multiphysics Analysis and Optimization

10 HyperWorks Solvers OptiStruct RADIOSS MotionSolve AcuSolve FEKO Statics Highly Non-Linear NVH Thermal Crash Safety Forming Multi-body Dynamics Thermal and CFD Electro- Magnetics Non-Linear Optimization Smart Multiphysics

11 OptiStruct: Optimization-driven Structural Analysis Stiffness, Strength, Stability Noise and Vibrations Powertrain Durability Thermal Analysis Kinematics & Dynamics Optimization Smart Multiphysics

12 Torque Plate Design Objectives Design Problem Secure contract for Airbus A380 wheel and brake systems Respond to Airbus demands for lower mass, reduced package space and lower costs Mass under 10kg (from 10.9kg) Optimization Statement Minimize Mass Constraints on Displacements and Stress Methodology Topology Optimization followed by Shape Optimization of the torque plate walls Courtesy of Dunlop Aviation Braking Systems

13 Torque Plate Conventional Design and Analysis Results Mass 10% over target of 10 Kg Stress 55% over target of 680 MPa Project in jeopardy 1050 MPa 5 weeks 5 weeks of conventional analysis work without reaching mass targets before optimization 13 Kg 10.9 Kg Courtesy of Dunlop Aviation Braking Systems

14 Torque Plate Conventional Design and Analysis Results Mass 5% under target Stress on target at 680 MPa 10.9Kg 1050 MPa 9.5Kg 680 MPa Courtesy of Dunlop Aviation Braking Systems

15 Torque Plate Conventional Design and Analysis Results Final design mass: 9.5 kg Final Peak Stress: 680 Mpa Financial penalties avoided Improved forging performance Out-of-plane bending avoided 13.0 kg Mass 9.5 kg 1050 MPa 680 MPa Peak Stress Courtesy of Dunlop Aviation Braking Systems

16 Design Exploration: Altair HyperStudy Multi Disciplinary design exploration, study and optimization software +17% in reliability Before After Perform what-if studies Calibrate simulation models to match with test results Design better performing products Increase the reliability of the designs Find robust designs that are less sensitive to variations Increase the return on CAE investments

17 Optimization and Reliability Analysis of a Mars Lander ESA Aurora Exploration Program Launch in 2011 or 2013 New Lander Design Concept Vented airbag, coming to rest on 2nd bounce Traditional concepts come to rest after 10 to 20 bounces Failure modes Roll-over (payload overturns), Dive-through (payload impacts rock) Rupture (fabric tears) Full scale terrestrial testing expensive / difficult: virtual design approach

18 Reliability Study: Range of Conditions Controlled/Uncontrolled conditions Wind speed (Weibull) Rock Height (Exponential) Lander pitch attitude (+/- 20 deg) Probability Density Function f(h) Lander pitch rate (+/- 30 deg/s) k = 10% k = 20% k = 30% Probability Density (m^-1) Rock Height H (m)

19 RADIOSS The Standard behind Structure Safety Crash Safety Drop & Impact Blast & Hydrodynamic Impact Fluid Structure Interaction Terminal Ballistic Forming & Composite Mapping Multiphysics Analysis and Optimization

20 Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Automotive Crash Simulation

21 Improving Helicopter Survivability Challenge Improve survivability Reduce costs and risk of qualification tests Solution Employ Radioss for impact and crash simulations Landing phase analysis Impact studies Seat behavior analysis MotionView Results Improved survivability Reduced number of qualification tests We appreciate the responsiveness of the development team to Eurocopter s specific requirements Pierre Prudhomme Lacroix, Manager Structural Analysis

22 Multi-Domain Approach / ALE v. Lagrange modeling in FSI AIRBUS-ONERA benchmark airplane ditching Structure Domain 1 9,000 shells dt = 1.4 ms FLUID Domain 2 130,000 bricks (~15x) dt = 14 ms Elapsed times ( 8 cores ) Monodomain : 65h50mn Multi-Domain: 12h18mn Fluid-structure interaction Normal Force

23 Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Example 3: Aero Simulation Helicopter Survivability Model: Helicopter floor structure Objective: Improve survivability of cabin crew under crash landing Loading: Crash landing Vi= 3-10 m/s

24 Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Example 3: Aero Simulation Helicopter Sinus Beam

25 Impact Simulations Cracks Pattern: opening and closure Front Side Back Side Animation from t=0ms to t=150ms

26 AcuSolve Better Technology, Better Solution Fluid- Structure Interaction Thermal Management Computational Aero-acoustics Non- Newtonian Flow Simulation Electronic Cooling Aerodynamics Multiphysics Analysis and Optimization

27 Wind turbine Motivation Rotor diameter of 10m FSI between rotating blades and tower Numerical model Transient analysis DES turbulence model 20 structural modes (from Radioss) Sliding mesh approach for rotating blades Deforming mesh around the blades (boundary layer mesh deforms with the structure) 14Mio cells 48 cores 4h per blade revolution

28 MotionSolve - Optimize System Performance Kinematics & Dynamics Statics & Quasi-statics Linear and Vibration Loads Extraction Effort Estimation Packaging Synthesis Multiphysics Analysis and Optimization

29 Altair s MBS Solution at DaimlerChrysler Consult Graz GmbH Challenge Generate Load Histories for Durability Analyses Solution Modular simulation model to serve multiple configurations Frame and body structure modelled as flexible bodies Results Validated vehicle model Virtual prototype to assess different methods for virtual durability testing "MotionSolve delivers accurate component loading histories for durability analysis" Nenad Bozic Senior Engineering Manager

30 Case Study Virtual Testing at Daimler Chrysler Challenge Assess and optimize durability performance of body parts Static load cases do not correlate with physical tests Solution Replicate physical test procedure within MotionView Combine multibody simulation with fatigue life predictions Results Simulated critical fatigue locations match physical tests Optimized durability performance baseline optimized

31 FEKO Leader in High-frequency Electro-Magnetics Antenna Analysis & Placement EMC Analysis Bio-EM Cable Coupling Radar Cross Section Wave Guides Multiphysics Analysis and Optimization

32 Altair Manufacturing Solutions Metal Extrusion Polymer Extrusion Forming Friction Stir Welding Metal Rolling Process Simulation and Design Optimization

33 HyperForm

34 HyperXtrude / HyperStudy Optimization of a Profile Flow Velocities of material flow are influenced to a great amount by the friction length of the tool (called bearing length) Changing the bearing lengths leads to different velocity results, short bearing = high velocity, longer bearing = slower velocity

35 Ideation and Conceptual Design: SolidThinking EVOLVE 3D industrial design and conceptual modeling tool Сreate surface and solid geometry easily, rapidly and cost-effectively Create photo-realistic renderings of models Geometry H3D results

36 Traditional Development-Process Construct Build Test

37 Simulation Driven Design Simulation Inspiration Innovation

38 Air Spring Carrier Original Design: * Inspire Design Proposal Final Design: - 55% mass! *Source:. Hoepke, S. Breuer (Hrsg.),Nutzfahrzeugtechnik, Vieweg+Teubner, Wiesbaden 2013

39 Modeling and Visualization: Post-Processing Post-Processing and Data Analysis HyperView Result Visualization, High performance architecture, Advanced reporting functionality, Solver independent HyperGraph Data analysis with automatic plot generation Mathematical library for advanced analyses 3D Result plotting HyperMath General purpose numerical computing Allows to easily develop and perform custom mathematical operations

40 Automated Reporting Overview Create / exchange / present simulation result reports frequently Applicable when simulations need to be analyzed part / component / group based Embedded in HyperView solution loops over all defined groups and load case and creates a single report page each Independent of industry, product type, simulation type or simulation result type Analysis is based on given results and load cases, e.g. frequency responses analysis or eigenforms (NVH) Analysts performing Stress analysis, frequency response analysis, durability calculation, model optimization Reduce the time to assess the simulation results for 10 components and 10 loadcases from 6 h to 45 min

41 PBS Works PBS Professional is an open workload management solution that maximizes the efficiency and utilization of high-performance computing (HPC) resources and improves job turnaround in a number of industries. Projects Policy for resource allocation Applications CPUs Input Files PBS Pro Memory Custom Codes License Servers Disks

42 Value-based Business Model: HyperWorks Licensing Innovative licensing system to reduce software costs and increase utilization translates into immediate cost saving and increased flexibility

43 Number of HWU used Copyright 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. HyperWorks Unit Chart Leveling Product 1 Product 2 Product 3

44 Altair Partner Alliance (APA) NVH Composites Thermal Analysis Manufacturing Additive Manufacturing Durability & Fatigue Complexity Management MBD Rendering Project Management Material Library Stress Mathematics & Analytics CFD EMS 1D Systems Engine Simulation Impact

45 HyperWorks: Performance Enhancing Software Suite