Intro To RADIOSS v14 Exercises HM 2017-03-17

Intro to RADIOSS for Impact Analysis
Including Examples using HyperCrash and HyperMesh Desktop
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Table of Contents
Intro to RADIOSS for Impact Analysis
Examples using HyperMesh Desktop
Chapter 3: Running RADIOSS Exercises ................................................................................... 4

Exercise 3: First Run with RADIOSS......................................................................................... 5
Chapter 5: Material Characterization Exercises ....................................................................... 18

Exercise 5a: Tensile Test Setup .............................................................................................. 19
Exercise 5b: HyperElastic Bushing.......................................................................................... 26
Exercise 5c: Ball Drop on Glass Plate ..................................................................................... 36
Chapter 6: Interface Modeling Exercises ................................................................................... 51

Exercise 6a: TYPE7 Contact in a Crush Tube ........................................................................ 52
Exercise 6b: TYPE24 Contact in a bolted cantilever beam ..................................................... 70
Chapter 7: Kinematic Condition Exercises ............................................................................... 79

Exercise 7: Three Point Bending ............................................................................................. 80
Chapter 9: Timestep Control Exercises ................................................................................... 102

Exercise 9: Time Step Control on Bottle Top Load Simulation ............................................. 103
Capstone Exercises ................................................................................................................... 116

Capstone: Cell Phone Drop ................................................................................................... 117
Capstone: Bumper Impact ..................................................................................................... 121
Appendix A: Using RADIOSS with HyperStudy ...................................................................... 125

Exercise A1: Material Calibration Using System Identification ............................................. 130
HS-4220: Size Optimization Study on an Impact Simulation Using RADIOSS ..................... 141
HyperWorks 14.0 Intro to RADIOSS for Impact Analysis 3

Proprietary Information of Altair Engineering, Inc.
Chapter 3:
Running RADIOSS Exercises
4 Intro to RADIOSS for Impact Analysis HyperWorks 14.0

Exercise 3: First Run with RADIOSS
Objectives
Become familiar with the format of RADIOSS Engine and Starter files
Know how to use HyperWorks Solver Run Manager to execute a RADIOSS simulation
Analyze starter and engine output files
Learn to post-process key results from an explicit analysis with HyperView.
Model Description
The model simulates an impact of a thin-walled, closed hat section on a rigid wall.
Simulation time: 50 ms
Uniform thickness = 1.5 mm
Input files for this tutorial: FIRST_RUN_0000.rad and FIRST_RUN_0001.rad
Units: Length (mm), Time (ms), Mass (g), Force (N) and Stress (MPa)
Results requested:
o /ANIM/VECT/DISP Displacements
o /ANIM/VECT/VEL Velocities
o /ANIM/ELEM/EPSP Plastic Strain
o /ANIM/ELEM/VONM VonMises Stress
o /ANIM/ELEM/ENER Energies
o /ANIM/ELEM/HOURG Hourglass Energy
Johnson-Cook Elasto-Plastic Material /MAT/LAW2.
o = 7.8e-3 g/mm3 [Rho_I] Initial density
o E = 210,000 MPa [E] Youngs modulus
o = 0.29 [nu] Poissons ratio
o y = 180 MPa [a] Yield stress
o = 450.0 MPa [b] Plasticity hardening parameter
o n = 0.5 [nu] Plasticity hardening exponent
o MAX= 350 MPa [SIG_max0] Max Stress
Problem Setup
Copy the files: FIRST_RUN_0000.rad, FIRST_RUN_0001.rad into a working directory.

Step 1: Scroll through the RADIOSS Engine and Starter Files, FIRST_RUN_0000.rad
and FIRST_RUN_0001.rad in a text editor and observe Keyword cards denoted with a
/
With a modulus of 210,000 MPa and a density of 0.0078, calculate the speed of sound in the material.
Speed of sound in steel rail = _________________________
The length of the rail is about 1,000 mm. Using the speed of sound and the rail length, calculate the time
it takes for a shock wave to travel from one end of the rail to the other and enter this value as
SIMULATION_ TIME in the Engine file: FIRST_RUN_0001.rad file.
Time for sound to travel length of rail = ______________________________________
We would like to have 20 animation outputs of our analysis. Using the total simulation time, calculate the
time frequency animation output such that 20 animation steps are created. Enter this value as
ANIMATION_OUTPUT_FREQUENCY.
/VERS/140
# Simulation Time
/RUN/FIRST_RUN/1/
SIMULATION_ TIME
# Animation Output Frequency
/ANIM/DT
# TSTART TFREQ
0.000000 ANIMATION_OUTPUT_FREQUENCY
/PRINT/-10
/RFILE
# NCYCLE IREAD IWRITE
5000 0 0
/TFILE/0
Note that the time history file output request /TFILE is set to 0.1 ms for the restart later in this exercise.
Also note that the engine keyword /DT/NODA tells the solver to use nodal time step.

Step 2: Open the RADIOSS Run Manager from the Windows Start Menu
Step 3: Select the Starter file FIRST_RUN_0000.rad as the Input file and Run with
onestep option.
Tip: Option onestep tells RADIOSS to only run a single step of the simulation (in this case the
starter) and stop. If not specified, then the engine will run automatically if the starter finds no fatal
errors and if there is an engine file in the directory).

Step 4: Review the Starter output file FIRST_RUN_0000.out and verify the model:
Use a text editor or select view -> Output File from the window as shown below to view the Starter output
file: FIRST_RUN_0000.out and look for errors or warnings at end of the file. Note how the Starter output
file echoes the input defined in the Starter input deck.
The time step calculated by the RADIOSS Starter is reported in the Starter output file. Search the file for
time step and review the value for Shell, Spring and Nodal time step. Which of these is controlling a
stable solution?
Step 5: Select the Engine file FIRST_RUN_0001.rad as the Input file and Run.
Tip: Option nt 4 tells RADIOSS to run the analysis on 4 threads (using 4 CPU) this should speed
up the analysis
Step 6: Review the Engine output file FIRST_RUN_0001.out with a text editor

What time step is the solver using? Based on what entity?
Check the % Energy Error (ERROR) and Mass Addition (MAS.ERR) at the end of the
computation.
Step 7: Review the results file FIRST_RUN.h3d with HyperView

1. Click the Results button in the Solver View window
2. Or, open HyperView, load the file FIRST_RUN.h3d, and then Apply.
3. Click the Entity Attributes button to bring up the Entity Attributes panel. Click on
the Rigid Wall component in the graphics area and select the Transparent shading
button to make the component transparent.
4. Click the Contour button to enter the Contour panel. Select Velocity (v) for the
Result type: and click Apply.
This will contour the velocities at Time=0 to verify initial conditions.

5. Change the contour to VonMises(s) stress.
6. Use the Next Time/Angle/Step button on the animation toolbar to incrementally step
through the animation of the Stress Contour.
This allows you to see the stress wave propagating from the front of the rail to the rear of the rail.
Check the time it takes the stress wave to reach the back end of the rail. How does it compare to
your calculation from Step 1?

When this step is completed, close the HyperView session.
Step 8: Continue the simulation by setting a longer run time
1. Make a copy of the RADIOSS engine file FIRST_RUN_0001.rad and change the name
to FIRST_RUN_0002.rad.
2. Update the engine file with a new end time of 50 msec by updating the line beneath the
/RUN/FIRST_RUN/2/ command to 50.0 and updating the animation output to 2.5 msec
beneath /ANIM/DT as shown below.

/VERS/140
# Simulation Time
/RUN/FIRST_RUN/2/
50.0
# Animation Output Frequency
/ANIM/DT
# TSTART TFREQ
0.000000 2.5
/PRINT/-10
/RFILE
# NCYCLE IREAD IWRITE
5000 0 0
/TFILE/0
Select the second Engine file (FIRST_RUN_0002.rad) as the Input file and Run
Notice that the animation files continue numbering from where the first run left off. Also notice that a
second time history file (T02) is created.

Step 9: Prepare a four-window layout for reviewing the results
1. Open a new HyperView session. .
2. Split your page into 4 windows using the Page Window Layout:
3. In the first window, use the HyperView client to load the FIRST_RUN.h3d file with
a transparent rigid wall and contoured with Von Mises stress as in Step 7.

4. In the 3 new windows, load the HyperGraph 2D client using the client selector if they
are not automatically loaded.
5. Click on the top right window to make it current.
Step 10: Plot the Rigid Wall Force as a function of time
1. From the Build Plots panel , load the Time History File FIRST_RUN_T01 - note
that the second file FIRST_RUN_T02 will also be loaded.
2. Select the Y-type, Y-Request, and Y-Component as Rigid wall > RIGID WALL 1 >
Resultant and click Apply.

Step 11: Plot energy curves in the lower left-hand window
1. Click on the left bottom window to make it current.
2. From the Build Plots panel, select the Y-Type: Global Variables, multiple Y Request:
Internal Energy, Kinetic Energy, Hourglass Energy, and TTE-Total Translational Energy
by control-clicking on each selection, and select the Y Component: MAG. Click Apply
to create the plot.
Step 12: Plot Global Variables > Time Step vs Time in the remaining window

Step 13: Save the session to a file
Once the post-processing is done, it can be saved by writing a session file or a report
template:
1) A session file (*.mvw) exactly reloads your post-processing on the same results files, or
results files of the same names (e.g. after a re-run)
2) A report template (*.tpl) allows post-processing of new simulation results (new run,
different filenames) based on the template format.
For this exercise we will create both a session file (*.mvw) and a template file (*.tpl) which
will be used in later exercises.
1. Click on File > Save > Session and save the file as Rail_Results.mvw.
2. Click on File > Save as > Report Template and save the file as Rail_Results.tpl.

Chapter 5:
Material Characterization
Exercises

Exercise 5a: Tensile Test Setup
Objectives
Become familiar with Johnson-Cook Material Law 2

Understand how to define boundary conditions /BCS and imposed velocity /IMPVEL
Define key Engine file cards
Model Description
The uniaxial tensile test uses a quarter size mesh with symmetric boundary conditions to reduce the
solver run time.
UNITS: Length (mm), Time (ms), Mass (kg), Force (kN) and Stress (GPa)
Simulation time: 10.0 ms
Boundary Conditions:
o The 3 upper right nodes (TX, and RY, RZ)
o The center node on right is totally fixed (TX, TY, TZ, RX, RY, RZ)
o A symmetry boundary condition on all bottom nodes (TY, RX, RZ)
At the left side a constant velocity is applied = 1 mm/ms on -X direction.
Tensile test specimen dimensions = 11 x 100 with a uniform thickness = 1.7 [mm]
Note the slight perturbation of the top right node so that necking will form at the center of
the specimen
Johnson-Cook Elastic Plastic Material /MAT/PLAS_JOHNS (Aluminum 6063 T7)

= 2.7e-6 Kg/mm3 [Rho_I] Initial density
E = 60.4 GPa [E] Youngs modulus
= 0.33 [nu] Poissons ratio
a = 0.09026 GPa [a] Yield Stress
b = 0.22313 GPa [b] Hardening Parameter
n = 0.374618 [n] Hardening Exponent
max = 0.175 GPa [SIG_max] Maximum Stress
max = 0.75 [EPS_max] Failure Plastic Strain
Problem Setup
Copy the files: tensile_0000.rad to a working directory

Step 1: Start HyperMesh Desktop using the RADIOSS Block140 User Profile and
import the solver deck tensile_0000.rad
Step 2: Create and assign the material Aluminum to the test specimen
1. Right-click in the Model Browser and select Create > Material.
2. Use the Entity Editor to input the values as shown:
3. In the Model Browser, select the component PSHELL1 and click on the Mat_ID and select
Aluminum to set the material.

Step 3: Create and assign the shell property sheet_1.7 to the test specimen
1. Right-click in the Model Browser and select Create > Property.
2. In the Entity Editor, set the Name: to sheet_1.7 and enter Thick: of 1.7.
3. In the Model Browser, select the PSHELL1 component and click on the Prop_ID in the Entity
Editor and select sheet_1.7 to set the property.
Step 4: Create boundary conditions for symmetry and general constraint

1. From the pull-down menu, select Tools > BCs Manager.
2. For Name, enter constraint1, set Select type to Boundary Condition and set GRNOD
to Nodes.
3. Click on the nodes entity selector. Select the three nodes shown in the figure below and click
proceed.
4. Fix degrees of freedom Tx, Ry and Rz.

5. Click create at the bottom of the tab to create the constraint.
6. Create a new boundary condition with the Name of constraint2 with the following node
selected and all six degrees of freedom constrained.
7. Create a third boundary condition with Name constraint3 with the following nodes
constrained in DOFs Ty, Rx, and Rz.
Step 5: Create Imposed Velocity

1. Using the BCs Manager, create a new boundary condition with Name velocity, Select type
set to Imposed Velocity and set GRNOD to Nodes. Select the nodes shown in the image
below.

2. Set the Direction to X with Scale X set to 1 and Scale Y set to -1.0.
3. Click the Create/Select curve button to set the Curve ID. A curve editor appears.
4. Create a new curve with the Name Load with values as shown in table below.
5. Close the Curve editor to assign the created curve to this constraint.
6. Click create to create the velocity boundary condition.
Tip: Note that the graphics may not take the Y scale factor into account.
Step 6: Create the engine file.

1. From the pull-down menu, select Tools > Engine file assistant. Assign the following:

This tool creates the following basic Engine file:
Step 7: Export the model as TENSILE_0000.rad
Step 8: Run TENSILE_0000.rad in RADIOSS
Step 9: Review the listing files for this run and verify the results
7. See if there are any warnings or errors in the .out files. If so, list them below.
8. Using HyperView, plot the displacement and strain contour and compare to the results on the
following page.

EXERCISE EXPECTED RESULTS
Displacement Contour (mm) @ Time=8.0s
Plastic Strain Contour at Time=8.0s

Exercise 5b: HyperElastic Bushing
Objectives
Become familiar with RADIOSS Hyperelastic material law
Understanding how to set up sequential loading conditions.
This exercise demonstrates how to simulate a rubber bushing given the following load
sequence:
o Translation, Transverse (10 mm)
o Translation, Longitudinal (5 mm)
o Torsion (20 Degrees)
Simulation time: 1.5 ms in three steps of 0.05 ms for each load case
The outer circumference area is fixed on all translational DOFs (TX, TY, TZ) and the center node
is fixed in the X translation and the X and Y rotation (TX, RX, RY)
The bushing dimensions are: thickness = 100 mm, External Diameter = 200 mm and internal
diameter = 50 mm.
Hyper-Elastic Material /MAT/LAW42 (Rubber)
= 6.0 e-6 [kg/mm3] Initial density
= 0.495 [-] Poissons ratio
1 = 0.600 [GPa] Ground Shear mod. 1
1 = 2 [-] Alpha 1
2 = -2 [-] Alpha 2
Problem Setup
Copy the files: GASKET_0000.rad to a working directory

Step 1: Load HM Desktop Block140 profile & import GASKET_0000.rad
Step 2: Create a new M42_OGDEN material named Rubber and assign as the
Mat_Id for the GASKET component

Step 3: Create a new P14_SOLID property named Bushing and assign as the
Prop_Id for the GASKET component

Step 4: Create a rigid body at the center of the gasket
1. Create a new component named RigidBody2.
Tip: When created, the component name should appear in bold, indicating it is the current
component and all new elements created will be assigned by default to this part.
2. In the 1D > rigids panel, switch the selector nodes 2-n to multiple nodes, and switch the
primary node to calculate node.
3. Click on the nodes entity selector and pick any node on the inner face of the gasket.
4. Click on the nodes entity selector to bring up the advanced selector menu and select by face.
HyperMesh Desktop will find and select all nodes on that inner face.
5. Click create to create the rigid body and click return to exit the panel.

Step 5: Define a inner fixed boundary condition on the bushing new boundary
condition on the outer circumference of bushing
9. From the Tools drop-down menu, start the BCs Manager.
10. For Name, enter OInneruter_BC, set Select type to Boundary condition and set the
GRNOD to Nodes.
11. Select the master node of rigid body created in the previous step. Click Proceed.
12. Check the Tx translational and Rx, Ry rotational degrees of freedom.
13. Click Create at the bottom of panel to create the inner fixed boundary condition.

Step 6: Define the imposed displacements on the master node of the rigid body
14. In the BCs Manager, create a new boundary condition named DISP_Y of type Imposed
displacement and set the GRNOD to Nodes, selecting the master node of rigid body.
15. Set the Direction to Y, and Scale X and Scale Y to 1.0.
16. Create a new curve under Curve ID using the XY curve editor named DISP_Y containing the
points {0, 0}, {0.5, 10}, and {1.0, 10}. Click update and close the XY curve editor
GUI.
17. Click create to create the boundary condition.

18. Create a new Imposed Displacement boundary condition named DISP_Z on the master node
of rigid body with the Direction to Z, and Scale X and Scale Y to 1.0 which uses a new curve
named DISP_Z containing the points {0, 0}, {0.5, 0}, {1.0, 5}, and {1.5, 5}.
19. Create a third Imposed Displacement boundary condition named ROT20DEG_Z on the master
node of rigid body with the Direction to ZZ, and Scale X and Scale Y to 1.0 which uses a new
curve named ROT20DEG_Z containing the points {0, 0}, {1, 0}, {1.5, 0.349}, and
{2, 0.349}.
Step 7: Define a new boundary condition on the outer circumference of bushing

20. From the Tools drop-down menu, start the BCs Manager.
21. For Name, enter Outer_BC, set Select type to Boundary condition and set the GRNOD
to Nodes.
22. Click on the nodes entity selector and pick any node on the outer face of the gasket.

23. Click on the nodes entity selector to bring up the advanced selector menu and select by face.
HyperMesh Desktop will find and select all nodes on that outer face. Click Proceed.
24. Check the Tx, Ty, and Tz to fix the translational rotational degrees of freedom.
25. Click Create at the bottom of panel to create the outer fixed boundary condition.
Step 78: Set the control cards to a final run time of 1.51 ms with time frequency of
0.05 ms, a print to the *.out file and screen every 100 cycles, time history
information written in 0.0015 increments, and von Mises (VONM), density (DENS),
and pressure (P) outputs to the A* and h3d files
Tip: Use the HyperMesh Solver Browser from View > Browsers > HyperMesh > Solver to set up
the following control cards and parameters:
Keyword Type Keyword Parameter Parameter Value
ENGINE KEYWORDS TITLE_ENGINE Status [Checked]
CONTROL CARDS TITLE TITLE GASKET
ENGINE KEYWORDS RUN RunName GASKET
ENGINE KEYWORDS RUN Tstop 1.5
ENGINE KEYWORDS PRINT Status [Checked]
ENGINE KEYWORDS PRINT N_print -100
ENGINE KEYWORDS ANIM/ELEM Status [Checked]
ENGINE KEYWORDS ANIM/ELEM VONM [Checked]
ENGINE KEYWORDS ANIM/ELEM DENS [Checked]
ENGINE KEYWORDS ANIM/ELEM PRES [Checked]
ENGINE KEYWORDS ANIM/DT Status [Checked]
ENGINE KEYWORDS ANIM/DT TStart 0
ENGINE KEYWORDS ANIM/DT Tfreq 0.05
ENGINE KEYWORDS /TFILE Time_frequency 1.5e-3

Step 98: Export the model to GASKET_0000.rad
Step 109: Run the model in RADIOSS
Step 110: Review the listing files for this run and verify the results
26. See if there are any warnings or errors in .out files.
27. Using HyperView plot the displacement and strain contour and vectors.

Displacement Contour for the load condition (mm)
Von Mises Stress Contour at the end of the simulation

Exercise 5c: Ball Drop on Glass Plate
In the course of this exercise, users will become familiar with /PROP/SH_SANDW properties,
learn how to create brittle material models with failure criteria based on forming limit
diagram (FLD) information, and compare results from baseline models to that of a model
incorporating XFEM setup.
This exercise demonstrates how to set up a ball impact on regular glass versus safety glass
that has a thin layer of plastic. In all cases an FLD failure model is defined for shell rupture.
These models are then updated to include XFEM (eXtended Finite Element Method) in which
failure can propagate across elements (rather than along mesh lines). Note: XFEM
requires version 14.0.220 or later.
UNITS: Length (mm), Time (s), Mass (Mg), Force (N) and Stress (MPa)
Simulation time: *_0001.rad [0 0.025 s]
o All degrees of freedom will be constrained on the master node of a rigid
body connected to top and bottom of rubber frame
o An initial velocity is given to a spherical rigid wall
Johnson-Cook Elastic Plastic with Brittle Failure Material /MAT/PLAS_BRIT
(Glass)
= 2.5e-9 Mg/mm3 [Rho_I] Initial density

E = 70,000 MPa [E] Youngs modulus
a = 80.0 MPa [a] Yield Stress
b = 500.0 MPa [b] Hardening Parameter
Johnson-Cook Elastic Plastic with Brittle Failure Material /MAT/PLAS_BRIT
(Plastic)

= 2.5e-9 Mg/mm3 [Rho_I] Initial density
E = 100.0 MPa [E] Youngs modulus
a = 10.0 MPa [a] Yield Stress
b = 20.0 MPa [b] Hardening Parameter
Eps_t1 = 0.6 [t1] Strain at the beginning of tensile failure in
principal strain direction 1
Eps_t2 = 0.6 [t2] Strain at the beginning of tensile failure in

Eps_m1 = 0.7 [m1] Max tensile strain in principal strain direction 1

Eps_m2 = 0.7 [m2] Max tensile strain in principal strain direction 2
Eps_f2 = 0.8 [f2] Max tensile strain for element deletion in
Eps_f1 = 0.8 [f1] Max tensile strain for element deletion in

Problem Setup
You should copy the files: BallDrop-Start_0000.rad

Step 1: Import BallDrop-Start_0000.rad into HyperMesh Desktop RADIOSS
Block140 profile
Step 2: Define a new M27_PLAS_BRIT material named Glass with the following
properties and apply this material as the Mat_Id for the Glass plate component:

Step 3: Define a P11_SH_SANDW property named Glass_sandw with the
following properties and apply this property as the Prop_Id for the Glass plate
component:
Tip: For the N: Data layer information within the Table Data , enter the following:

Step 4: Define the FAIL_FLD type failure property for the glass using the FLD
curve Glass failure model included in the model
Step 5: Create a rigid body at center of rubber frame

Create a new component named RigidBody with no card image.
In the rigids panel on the 1D page, switch nodes 2-n to multiple nodes and switch
primary node to calculate node.
Click on the nodes entity selector and select one node apiece on the outer faces of both
Fixed upper and Fixed lower, respectively. Click again on the nodes entity
selector to bring up the advanced selector and choose by face.
Tip: HyperMesh Desktop will pick all of the nodes on the upper and lower faces.
Click create to create the rigid body and click return to exit the panel.

Step 6: Create a new load collector named Constraint and constrain the central
node of the rigid body in all 6 DOFs
Step 7: Create a spherical Rigid Wall with an Initial Velocity

In the nodes panel on the Geom page, create a new node with the XYZ coordinates
{250, 250, 50.1}.
In the Model Browser window, right-click and select Create > Rigid Wall.
Complete the new Rigid Wall definition with the following parameters, selecting the
newly created node as the Base node for the sphere and selecting the Glass plate
component for gr_nod1 (S):

Step 8: Set the control cards to a final run time of 0.025 s with time frequency for
data output of 0.0001 s, time frequency of 0.001, plastic strain (EPSP) and von
Mises (VONM) element results, shell tensor stress (STRESS) and strain (STRAIN)
for all layers, and velocity (VEL) and displacement (DISP) vector outputs and
setting the engine file to export separate from the starter file.
Keyword Type Keyword Parameter Parameter Value
ENGINE KEYWORDS TITLE_ENGINE Title Ball Drop
ENGINE KEYWORDS RUN RunName Ball Drop
ENGINE KEYWORDS RUN Tstop 0.025
ENGINE KEYWORDS TFILE Time_frequency 1.0E-04

ENGINE KEYWORDS ANIM/ELEM EPSP [Checked]
ENGINE KEYWORDS ANIM/ELEM VONM [Checked]
ENGINE KEYWORDS ANIM/SHELL/TENS/STRAIN ALL [Checked]
ENGINE KEYWORDS ANIM/SHELL/TENS/STRESS ALL [Checked]
ENGINE KEYWORDS ANIM/VECT VEL [Checked]
ENGINE KEYWORDS ANIM/VECT DISP [Checked]
ENGINE KEYWORDS ANIM/DT TStart 0
ENGINE KEYWORDS ANIM/DT Tfreq 1.0e-03
Step 9: Export the model as BallDrop-Finish_0000.rad and run in RADIOSS
Step 10: Check the *.out files for warnings or errors and then review
the results in HyperView, plotting the displacement contour

EXPECTED RESULTS
Glass only Model
Displacement Results

Step 11: Update the model to include a middle layer of plastic
Continue with the model in HyperMesh Desktop from the previous steps, adding a new
material, Plastic Film, as shown below:
Edit the laminate property to replace the middle glass layer with the plastic film material
just created.

Step 12: Save the model as BallDrop-PlasticLayer_0000.rad and run in
RADIOSS
Step 13: Check the *.out files for warnings or errors and then review
the results in HyperView comparing the plot of the displacement
contour with that of the previous run

EXPECTED RESULTS
Glass and Plastic (Displacement Legend MAX 50)
Displacement Results

Step 14: Import the previous models into new HyperCrash sessions
and update the failure model to change the XFEM flag to 1 and re-
export as BallDrop-Final_withXFEM_0000.rad and BallDrop-
PlasticLayer_withXFEM_0000.rad respectively

EXPECTED RESULTS
Glass with XFEM (shattered layers displayed)
Glass and Plastic with XFEM (shattered layers displayed)

Chapter 6:
Interface Modeling Exercises

Exercise 6a: TYPE7 Contact in a Crush Tube
This exercise demonstrates how to set up a crush tube impact consisting of two C-channels
seam welded together. The tube is 2mm thick in the first half of the tube and 3mm in the
second half. One end has extra mass applied using a rigid body body. An initial velocity is
applied to the tube and it impacts a rigid wall. Users completing this exercise will become
familiar with the use cases of a Type 7 interface and Type 7 interface parameters Igap,
Gapmin, and Inacti.
Rigid body
t=3 mm
t=2 mm
o All degrees of freedom except in the Z-direction will be constrained on the
master node of a rigid body connected to the end of the tube
o An initial velocity is given to all nodes in the model
Johnson-Cook Elastic Plastic /MAT/PLAS_JOHNS (Steel) parameters
= 7.85e-6 kg/mm3 [Rho_I] Initial density
E = 210 GPa [E] Youngs modulus


Steel Section Properties

Element Formulation = QEPH (Ishell = 24)
Gauge = 2mm and 3mm
Problem Setup
Copy the file: TubeCrush-Start_0000.rad to a working directory.
Step 1: Import TubeCrush-Start_0000.rad into HyperMesh Desktop
Step 2: Review the material properties of the Steel to verify that the parameters
match those given in the exercise introduction
Step 3: Review the shell property for the steel parts
Step 4: Edit the rigid body definition to include a mass of 500

1. Select Tools > RBODY Manager to access the RBODY Manager tab.
2. Right-click on the RBODY entry in the tab and select Edit Card to open the card
image editor for the element.
3. Scroll down in the top part of the editor to find the MASS entry and change the value to
500.
4. Click return to close the Card Image dialog. Close the RBODY Manager tab.

Step 5: Using the BC Manager, create a BC named Constraint on the rigid body
master node in all degrees of freedom except Tz
Step 6: Create a tied interface between the flanges of the C-sections making up
the tube. Recall that by default a Type 2 interface is a kinematic condition.
1. In the Model Browser window right click Create > Contact in the drop down menu to
open the Create Group dialog box. Change the Card Image TYPE2 and name the
contact Seamweld.
2. To set the slave nodes, click on the Grnod_id (S) Nodes entity selector. When the Add
entities panel appears, change the panels entity selector to nodes

Select the nodes on the ends of the C-channels as shown and click add in the
panel to add them to the interface:
3. Click return to exit the panel and return to the dialog box entries.
4. Select the Surf_id (M) Elements, entity selector and in the select entities dialog
change the entity selector to Elements. Select the inner area of the C-Channel elements
as shown in the next figure..
5. Set the dsearch to 5.

Tip: The dsearch distance will limit the search so only the relevant master surfaces will be found for the
slave nodes.
Step 7: Define a self contact Type 7 interface for the C-channels with the
following parameters shown below:
The default contact gap thickness method defined by Igap in TYPE7 contact is called
constant gap. This means that the actual thickness of the parts is not used for contact but
instead the thickness of the parts is considered the same for all parts and is defined by
GapMin. If GapMin is not defined then the constant gap thickness is calculated by
RADIOSS.
In this first example, constant gap thickness is used and the results will be compared to
another iteration that uses variable gap where the actual part thickness is used for contact.
1. In the Model Browser window right click Create > Contact in the drop down menu to open
the Create Group dialog box. Change the Card Image TYPE7 and name the contact
self contact.
2. Click on the Grnod_id (S) Nodes entity selector and change the entity type to Components
and click on Components and pick all the Components in the model.
3. Click on the GSurf_id (M) Element entity selector and change the entity type to
Components and click on Components and pick all the Components in the model.
4. Enter the best practices values of Istf = 4: K= min(Km,Ks) and Stmin= 1 kN/mm
5. Enter GapMin = 1.0 mm.
Note: The value of Gapmin was chosen to be less than thickness of the thinnest part
which should be small enough to avoid any initial penetrations but large enough to allow the
contact forces to prevent penetration.
6. Enter a steel against steel friction value as Fric = 0.2.
7. Enter additional best practice value of Iform = 2.

-
Step 8: Create infinite plane rigid wall named Wall at front of tube
1. In the Nodes panel, select the XYZ option , place the model in the XZ view ,
and click one of the nodes on the bottom of the c-channel three times to load its X, Y,
and Z coordinates, respectively, into the display fields.
Tip: The panel shows the Z-coordinate of the node is -304.5mm. This gives the user
enough information to determine the proper offset for the base node of the infinite wall.

2. Change the Z-coordinate of the node to -305 and click create to create a base node for
the wall offset from the front of the C-channels by 0.5 mm.
3. Right-click in the Model Browser and select Create > Rigid Wall
Rename the rigid wall to Wall and set the geometry type to Infinite Plane with the
newly created node selected as the Base node, and a Normal vector of {0, 0, 1},
SLIDE set to 2 to enable friction, a fric parameter of 0.2, and a d value of 100 mm.
Tip: d represents the distance to search for slave nodes, which is the distance inside of
which nodes are seen by the rigid wall as potential contacts.

Step 9: Set the Initial Velocity for every node in the model to -13.3 Vz
1. Select Tools -> BCs Manager and enter the Name IniVel, and select
type = Initial Velocity.
2. Switch GRNOD to Nodes and select all nodes in the model.
3. Define Vz as -13.3 mm/ms
4. Click create tab to create the initial velocity.

5. Close the Utility panel.
Step 10: Define time history output block for the rigid wall force
1. Right click in the model browser and select Create > Output Block.
2. The Output Block with name outputblock1 of solver keyword /TH/NODE
is created and appears in the Entity Editor (EE) in the bottom pane of the
model browser.
3. Change Entity IDs to Groups. Change Keyword to RWALL. Then select
Groups and select Wall.
4. Select NUM_VARIABLES and select 1. This will bring up a table in which
the Var DEF should be entered. (DEF is for default outputs, which for a
rigid wall are the forces: FNX, FNY, FNZ, FTX, FTY, FTZ). See EE image below:

Step 11: Review the engine file settings.
1. Expand the Card folder in the model browser. Review the engine cards ENG_XXXX.
Note that the ENG_TFILE card defines the frequency (Time_frequency) at which the
time history file will output the Rigid Wall forces defined in the output block in Step
11.
Step 12: Export and run in RADIOSS
1. Select File > Export > Solver Deck and click enter TubeCrush-Iter1_0000.rad
2. Check the Merger starter and engine file to try exporting the starter and engine files in one
file.
3. Click Export
Step 13: Review the output files for warnings and errors and view the animation
results in HyperView
1. While the model is running use a text editor to edit the TubeCrush-
Iter1_0000.out file and search for WARINING

2. Notice that there are two warning message #312 and #446 which are caused by
nodes being a slave to in both the tied contact and rigid wall. Rigid walls and
the default tied contact are both kinematic conditions and the same node cannot
be a slave to two kinematic conditions. Thus RADIOSS calls them INCOMPATIBLE
KINEMATIC CONDITIONS. In this situation RADIOSS automatically removes the
tied contact slave nodes from the rigid wall
3. Using HyperView, plot the displacements and plot results with a Y-section cut at
Y = 38.75.
EXPECTED RESULTS
TubeCrush-Iter1 (Constant Gap = 1.0), sectioned at Y = 40
Note: There are nodes that have penetrated the rigid wall. This is due to incompatible kinematic
conditions of the Type 2 interface and the rigid walls. The starter output file indicates that some
nodes in the Type 2 interface have been removed from the rigid wall slave set.
Step 14: Update the contact gap option to use variable gap (Igap = 2) in the Type 7
interface and rerun the model as TubeCrush-Iter2_0000.rad
1. Instead of using a constant contact gap thickness, it is more accurate to use the actual
thickness of the parts in contacts which is called Variable Gap in RADIOS.
2. Edit the self contact and enter the best practices values of Igap = 2: Variable gap
+ scale correction
Tip: For the most physical response, the contact gap for shells should use the shell
thickness.

3. Export the model as TubeCrush-Iter2_0000.rad and run in RADIOSS.
Iter2_0000.out file and search for WARINING.
5. Two more warnings message #343 and #477 are in the output file. The following
warning is most concerning and is the cause for the strange behavior of the
results.
WARNING ID : 343
** WARNING : INITIAL PENETRATIONS IN INTERFACE
DESCRIPTION :
-- INTERFACE ID : 2
-- INTERFACE TYPE : self contact
THERE ARE 860 INITIAL PENETRATIONS
( CONCERNING 550 NODES )
Step 15: Replot the results and compare to the TubeCrush-Iter1 and TubeCrush-
Iter2 runs in HyperView

EXPECTED RESULTS
TubeCrush-Iter2 (Variable Gap = 2)
*NOTE: This model blows up due to the initial penetration in the self contact of the 3 mm
shells at the top of the tube near the rigid body. The initial space between the flanges at the top
of the tube is 2.1mm but since the shells are 3 mm thick; the solver sees 0.9 mm of penetration
and applies a contact force as shown in the figure on the left to remove that penetration. The
forces from the initial penetration then cause the unphysical mesh deformation at Time=1.0 on
the right hand side. If there are no initial penetrations in a model, the contact force will be zero
at time=0.0.
Step 16: Review the initial penetrations in HyperMesh

1. From drop down Mesh menu > Check > Components > Penetration
2. Using the Comps entity selector pick all the parts in the model and click check

3. As shown in the next figure, expand the Penetrations section and pick PSHELL1 (1), and
then penetration vector (2). There are tools in HyperMesh that can be used to remove the
initial penetrations by moving the nodes of the mesh. However for this model the contact
interface option, Inacti, will be used to automatically reduce the contact thickness gap.
Step 17: Use option to automatically reduce the contact gap thickness in the
initial penetration area and rerun RADIOSS.
1. Edit the self contact and enter the best practices values of Inacti = 6: Gap is
variable with time which will in areas of initial penetration cause the contact gap to be
reduced by the penetration value plus 5%.
2. Export the model as TubeCrush-Iter3_0000.rad and run in RADIOSS.
Iter2_0000.out file and search for WARINING.
*NOTE: Edit the TubeCrush-Iter3_0000.out file in a text editor and notice the WARNING
message about the initial penetrations still exists but now there is an additional message
concerning the automatic reduction of the initial gap.
REDUCE INITIAL GAP
REDUCE INITIAL GAP
WARNING ID : 343
** WARNING : INITIAL PENETRATIONS IN INTERFACE
DESCRIPTION :
-- INTERFACE ID : 2
-- INTERFACE TYPE : self contact
THERE ARE 860 INITIAL PENETRATIONS
( CONCERNING 550 NODES )

EXPECTED RESULTS
TubeCrush-Iter3 (Variable Gap setup)
Plot the contact forces to make sure they are zero at time = 0.0

Step 18: Review the new model against the other variations in HyperView
NOTE: Iteration 3 is closer to the correct physical stack-up crush height compared to iteration 1
because using variable gap uses the actual part thickness for contact.
NOTE: A comparison of the rigid body master node Z-Displacement between iteration 1
constant gap and iteration 3 variable gap is shown below. The displacement of iteration 3 is
less because it does not crush as much.
NOTE: Plotting the rigid wall forces for the iteration 1 and iteration 3 below also shows the
effect of the gap thickness. Iteration 3 shows an earlier rebound as a result.

Step 19: Understanding WARNING ID : 477, WARNING IN INTERFACE GAP
WARNING ID : 477
** WARNING IN INTERFACE GAP
DESCRIPTION :
-- INTERFACE ID : 2
-- INTERFACE TITLE : self contact
MAXIMUM VARIABLE GAP=3.000000000000
HOWEVER GAP IS RECOMMENDED TO BE LESS THAN 1.339216052991
This message is similar to the FAQ in the RADIOSS help which deals with a self contact with
constant gap.
RADIOSS > Frequently Asked Questions:Contact Interfaces: What is the meaning of:
WARNING ID 94?
WARNING ID: 477 occurs when the maximum variable contact gap thickness > twice the
smallest side length of shell elements on the master side. When this happens there is a
possible over stiffening of the structure if the element is compressed by 50% as shown in the
following picture.

In this model, the length of elements in the crushing or compression direction is ~ 7mm which is
greater than the maximum variable gap so it should be fine to ignore this message. In a model
with elements with edge length that approaches the thickness, Igap=3 can be used to reduce
the contact thickness gap based on the element length which will remove this over stiffening
behavior.

Exercise 6b: TYPE24 Contact in a bolted cantilever
beam
This exercise demonstrates how to use TYPE24 contact to simulate solid to solid contact of a
bolted assembly. In this model, there is an initial intersection between the bolt and the parts
bolted together. Three different values of the TYPE24 interface parameter, Inacti, are tested
to see how TYPE24 handles the initial intersection.
o All translation degrees of freedom are constrained on the edge nodes of the
block
o
A total force of 0.72 kN is apply in the negative X direction on the end of the
cantivlever beam
Johnson-Cook Elastic Plastic /MAT/PLAS_JOHNS (Steel plate) parameters

Johnson-Cook Elastic Plastic /MAT/PLAS_JOHNS (Steel bolt) parameters
Steel Section Properties
Element Formulation = HEPH (Isolid = 24)
Problem Setup
Copy the file: bolted_cantilever-Start_0000.rad to a working directory.
Step 1: Import bolted_cantilever-Start_0000.rad into HyperMesh
Step 2: Review the material properties of the Steel plate and Steel bolt to
verify that the parameters match those given in the exercise introduction
Step 3: Review the solid property for the steel parts
Step 4: Review the already defined cross section which is used to calculate the
cross sectional force in the bolt.
1. Select the Model tab, under Components turn off the plate and block parts.
2. Under Cross Section right click on bolt_section and select Review.
Note: The RADIOSS section is defined with a group of element and group of nodes.

Step 5: Review the loading Force
1. In the Model tab, under Load Collectors right click on bolt_section and select Review to see the
nodes that the concentrate force are applied to.
2. In the Entity Editor right click on Ifunct and select Plot Curve. Notice that the force is not applied
until 5ms. This was done to see if there is any contact force applied in the first 5 ms due to initial
penetration.
Step 6: Define a Type 24 interface named contact which includes all the parts in
the model.
In the first simulation, the default Inacti option will be used.
1. In the Entity Editor right click and select Create > Contact and enter self contact for
the name.
2. Select Card Image = TYPE24 and select Yes to the pop-up message about changing the
card image.
3. Define the best practices value of Isft=4, which uses the minimum stiffness between the
slave and master entities. Enter Fric= 0.2, and Inacti = 1000, which means only small initial
penetrations will be taken into account and larger penetrations ignored.
4. To create a TYPE24 self-contact interface only Surface 1 needs defined. In the Surf_ID1 (S)
right click and change the entity type to Set.
5. To the left of the entity selector right click and pick Create to create a new set.
6. Beside name enter self contact surface

7. Select Card Image = SURF_EXT which creates surfaces from the external faces of the
solid elements.
8. Click on Components and select all three parts in the model and click Close
Step 7: Export the model and run in RADIOSS and run in RADIOSS
1. Using File > Export > Solver Deck export the model making sure to check the
Auto export engine file bolted_cantilever_inacti1000_0000.rad.
2. Start HyperWorks Solver Run Manager program by selecting RADIOSS from the
HyperWorks menu.
3. Submit an initial run using 4 cores by specifying np 4. Make sure the Use solver control
option is checked.
4. Note that a larger than normal amount of mass scaling is used make the
simulation run faster.

5. While the model is running use a text editor to edit the
bolted_cantilever_inacti1000_0000.out file and search WARINING to
find the WARNING : INITIAL PENETRATIONS IN INTERFACE message.
Notice the message printed right before the warning saying, INITIAL
PENETRATIONS WILL BE IGNORED.
EXPECTED RESULTS, Inacti=1000
By default TYPE24 contact ignores all initial penetrations except for very numerical small
penetrations. The initial penetrations between the top of the plate and bottom of the bolt head
cause the plate to slip through the bolt and contact the next row of bolt elements.
Step 8: Check for Initial intersections to better understand contact behavior

3. From drop down Mesh menu > Check > Components > Penetration
4. Using the Comps entity selector pick all three parts in the model and click check

5. In the Penetration tab click on plate as shown in the next image. To isolate the
intersecting element pick the other two options shown in the next image.
2 3
6. Use the display mode icon, , to change to wireframe mode and rotate the model to
see the intersecting elements.
7. In the lower right core of the Penetration tab Click the close icon.
Step 9: TYPE24 option INACTI=-1, initial penetrations will be taken into account.
1. Although we could manually translate the nodes to remove this initial penetration, we can
also use the INACTI option in to cause RADIOSS to apply forces based on the amount of
initial penetration.
2. Under Groups select self contact and change to Inacti= -1 which will cause RADIOSS
to apply contact forces at t=0.0 if there are intersections.
Step 10: Export the model and run in RADIOSS

1. Following the same instructions as before export the
bolted_cantilever_inacti-1_0000.rad and run RADIOSS.

bolted_cantilever_inacti-1_0000.out file and search WARINING to find
the WARNING : INITIAL PENETRATIONS IN INTERFACE message. Since all
the initial penetration are taken into account there is no message saying they
will be ignored.
EXPECTED RESULTS, Inacti=-1

Step 11: Plot the contact forces
1. Load the h3d in HyperView and change to wireframe view,
2. Click on the vector plot icon and change the Result type: Contact / Pressure
/Normal (v) and click on Apply.
Due to Inacti=-1 being used, RADIOSS applies contact forces at t=0.0 proportional to the
amount of initial penetration. These forces can sometimes remove the initial penetration
between the parts.
3. Change back to shaded elements mode, , and then use the contour panel to plot
Result type: Von Mises(s) with Averaging method: Simple and notice the stress on in the
parts before any load is applied due to the initial penetration. If desired use the section cut,
to create a section cut.

4. Change the simulation time to t=5.0 which is right before the concentrated forces are applied
and notice the initial stress in the bolt as shown in the following figure.
5. Animate the model to the end of the simulation and review, Von Mises(s), Displacement
(v) and Plastic Strain (s)
Step 12: TYPE24 option INACTI=5, the master segment is shifted by the initial
penetration value.
1. Under Groups select self contact and change to Inacti= 5 which will cause RADIOSS
to apply contact forces at t=0.0 if there are intersections. This will cause RADIOSS to offset
the master segment by the penetration value. The contact will now behave as though the
elements with initial penetrations at t=0.0 are touching but without any contact force.
Step 13: Export bolted_cantilever_inacti5_0000.rad and run in RADIOSS

bolted_cantilever_inacti5_0000.out file and search WARINING to find
the WARNING : INITIAL PENETRATIONS IN INTERFACE message. Notice
even though the message says that the penetrations will be ignored the master

segments is actually offset to remove the initial penetrations. This warning
message will be improved in a future version of RADIOSS.
EXPECTED RESULTS, Inacti=5

Step 14: Plot the contact forces and stress and compare to Inacti=-1 results.
1. Repeat steps described as before to display the vector contact force at t=0.0.
With Inacti= 5, there are no contact forces at t=0.0.
2. Repeat steps described as before to plot the cross section Von Mises(s), at t=5.0
3. Repeat steps described as before and review Von Mises(s), Displacement (v) and Plastic
Strain (s).
4. Last, use a text editor to edit the *0001.out engine output files for the 3
simulations and compare the %Energy Error. The simulation that used Inacti=
- 1 had a higher %Energy Error caused by the application of the initial contact
forces at t=0.0.
Step 15: Optional: plot and compare the bolt cross forces of the three models.
Step 16: Optional: plot and compare the contact and total energy of the three
models.

Chapter 7:
Kinematic Condition Exercises

Exercise 7: Three Point Bending
Objectives
Learn about kinematic conditions: boundary conditions, /BCS and rigid bodies, /RBODY
Define time history output for interfaces
This exercise demonstrates how to set up 3-point bending model with symmetric boundary in Y.
UNITS: Length (mm), Time (s), Mass (ton), Force (N) and Stress (MPa)
Simulation time: in Engine file 7.0e-002 s
Only one half of the model is modeled because it is symmetric.
The supports are fixed & an imposed velocity of 1000 mm/s Z- applied on the Impactor
Model size = 370 mm x 46.5 mm x 159 mm
Honeycomb Material /MAT/LAW28: HONEYCOMB
3
= 3.0e-10 ton/mm [Rho_I] Initial density
Eij = 200 MPa [E11], [E22] and [E33] Youngs modulus
Gij = 150 MPa [G11], [G22] and [G33] Shear modulus
Elasto-Plastic Material /MAT/LAW36: Inner, Outer and Flat
3
= 7.85-09 ton/mm [Rho_I] Initial density
E = 210000 MPa [E] Youngs modulus
= 0.29 [nu] Poisson's ratio
Elastic Material /MAT/PLAS_JOHNS: Impactor
3
= 8e-09 ton/mm [Rho_I] Initial density
E = 208000 MPa [E] Youngs modulus
= 0.29 [nu] Poisson's ratio
Stress-Strain Curve:
0 1 2 3 4 5 6 7 8 9
STRAIN 0 0.010 0.013 0.015 0.020 0.025 0.030 0.035 0.040 0.045
STRESS 300 310 320 330 340 350 360 370 380 400
Problem Setup
Copy the file: BENDING_0000.rad to a working directory.

Step 1: Import BENDING_0000.rad into HyperMesh.
Step 2: Create a law 1 elastic material named Rigid Material and assign to the
Impactor and Support parts

Step 3: Create a Piecewise Linear law 36 material named Shell Material and
assign for Inner, Outer, and Flat parts
4. Create the material stress-strain curve by right-clicking on the Curve section of the
model tree in the Model Browser and select Create from the context-sensitive menu to
bring up the Curve Editor.
5. Select New, enter StressStrain for the name of the new curve, and click proceed
to return to the Curve Editor.
6. Enter the following values in the XY values list:

7. Create the new law 36 material as shown below, selecting the new StressStrain
curve as the fct_ID for the function definition.

8. Assign the material to the Inner, Outer, and FLAT materials.

Step 4: Create a law 28 Honeycomb orthotropic material named Foam and assign
to the HCFoam part:
Tip: Note that functions 5-10 used in the HCFoam definition are already defined in the model.

Step 5: Create a shell property and assign to the Inner, Outer, and Flat parts
Step 6: Right-click the Shell Property in the Property section of the Model
Browser and select Duplicate. Rename it to Rigid Shell and assign this
property to Impactor and Support.
Note: This modeling practice, where shells are used to define the surface of a
rigid structure along with a rigid body, is useful for describing arbitrarily
shaped rigid surfaces. In this case, the shell property can be a simple 1-
integration point. The property is duplicated and N set to 1.

Step 7: Create a general solid type 14 property HCFoam and assign to the part
HCFoam.
Step 8: Create a rigid spider for the Impactor with a calculated primary node
1. From the Model Browser right-click and select Create > Component.
2. For name, enter Rigid Bodies.
3. In the entity editor set card image as none.
4. Go to 1D page, then select the rigids panel.
5. Verify that you are in the create subpanel.
6. For dependent nodes 2-n switch to comps.
7. For primary node switch to calculate node.
8. Click comps.
9. Select Impactor, then click select

10. Click create. Do the same thing for the comps Support. You should now
have 2 rigid bodies as shown below:

Step 9: Define three new boundary conditions for the model. Boundary condition
BCI will constrain the Impactor master node in all DOFs except Tz. Boundary
condition BCS will constrain the Support rigid master node in all 6 DOFs.
Boundary condition Symmetry will constrain all nodes in the Inner, Outer, and
FLAT parts on the Y- XZ-plane in Ty, Rx, and Rz.

Tip: Use the view orientation YZ plane to aid in selecting the nodes for the
Symmetry constraint.

Step 10: Define an imposed Z-velocity for the Impactor rigid master node using
the Imposed-Velocity predefined curve and a Y-Scale of -1000
Note that the imposed velocity arrow in the graphics window may not correspond to the
actual direction defined.
Step 11: Define a Type 7 contact between the Flat (Slave) and Support
(Master) parts named Support
Tip: In this case we choose GAPmin of 0.45 because that is half of the thinnest shell thickness. The
parameter Igap of 2 gives us variable gap , INACTI of 6 will adjust the gap if any initial penetrations exist.
Also, when selecting friction in contact, set to 0.1 here, the flag Iform should be set to 2 for Stiffness
formulation.
Hint: All of the slave nodes can be selected by component. Similarly the master segments can be chosen
by selecting the corresponding component. This will generate /GRNODE/PART and /SURF/PART/EXT,
respectively.

Step 12: Define a Type 7 contact between Impactor (Master) and Outer (Slave)
called Imp_Outer

Step 13: Define self-contact between beam components Inner, Outer, and FLAT
Note that all of the nodes from these three parts will be slave to all elements from these
parts as master to form the self-contact definition.

Step 14: Create Interface time history
1. Right-click in the Model Browser and select Create > Output Block.
2. In the entity editor for name, enter Contact-Forces.
3. Switch the EntityIDs to groups.
4. Click groups and select the interfaces Support and Imp_Outer from the
list. Click OK.
5. Right Click the outputblock Contact-Forces and choose Card Edit.
6. For VAR field, enter DEF.
7. Click return to exit the panel.
Step 15: Select the Delete Unused dialog box by going to Tools > Unused and
review the model to determine that all properties and materials are assigned.
Tip: This dialog only displays entities within the model which are unassigned through
reference in other entities and can be a quick way to determine if there are curves,
groups, properties, or materials which are unassigned.

Step 16: Use the Engine File Assistant to define the engine keywords as shown
below.
Step 17: Export the file as 3PBENDING_0000.rad and run in RADIOSS
Step 18: Review the output files for this run and view the results in HyperView

von Mises (Max) Stress Contour (MPa) Only steel parts shown
Plastic Strain (Max) Contour Only steel parts shown

von Mises Stress (Mid) Contour (MPa) Only foam shown
Step 19: Plot a graph of the Z-normal force resultant over time from the
Imp_Outer interface from the file 3PBENDINGT01 using HyperGraph
Contact Force for Impactor Interface

Chapter 9:
Timestep Control Exercises

Exercise 9: Time Step Control on Bottle Top Load
Simulation
Objectives
Become familiar with options for improving time step which will reduce the solution time of your
simulation.
This exercise demonstrates how to set up a bottle top load simulation and evaluate different
time step control treatments. The bottle is loaded using a rigid plate. A 0.25 inch imposed
displacement is applied to the plate.
Model Description
UNITS: Length (mm), Time (ms), Mass (Mg), Force (N) and Stress (MPa)
Simulation time *_0001.rad [0 0.03 seconds]
o The rigid plate applying the load is fixed except for the imposed displacement in the
vertical direction
o The bottom of the bottle is supported by a rigid wall
o A 0.25 inch imposed displacement is applied to the rigid plate
Objective is to calculate the max top load for bottle.
Input files for this tutorial: bottle_timestep_0000.rad,

bottle_timestep_0001.rad
Materials
Elastic Plastic Piecewise Linear Material /MAT/LAW36 (Bottle)
-10 3
= 9.75e Mg/mm [Rho_I] Initial density
E = 800.0 MPa [E] Youngs modulus
fct_ID1 Yield stress function

Properties
Exercise 9a: Evaluate the Time Step and review the Model
Purpose: Use various methods to determine the time step of a simulation and
improve the time step by modifying elements
Step 1: Load and review the RADIOSS Model

1. Launch HyperMesh, then select Preferences > User Profile > BRADIOSS Block140
2. From the pull down menu bar, File > Import > Solver Deck
3. Click the icon, navigate to the directory with the starting file and select the initial model
bottle_timestep_0000.rad
4. Using the Model Browser, review the material properties, shell properties, contact, rigid
wall, and boundary conditions. The top load is applied using an imposed displacement
applied to a rigid meshed plate. The bottom of the bottle is supported by a rigid wall,
/RWALL.
Step 2: Review Engine File and make initial run

1. In Model Browser, Card > ENG_ANIM_NODA > notice that DT is checked which creates
the following output request that will allow the contouring of the nodal time step in
HyperView. Alternatively, text editor could be used to review the
bottle_timestep_0001.rad.
/ANIM/NODA/DT Contour output for Nodal Time step

2. Start HyperWorks Solver Run Manager program by selecting RADIOSS from the
HyperWorks menu.
3. Submit an initial run using 4 cores by specifying np 4. Make sure the Use solver control
option is checked.
4. Notice the low time step, DT = 4.41E-08, and the long estimated remaining solution time,
REMAINING TIME= 3566.03 s. Note: this number will vary depending on the speed of
the computer and the number of CPUs used for the solution.
5. Stop the run by checking the Stop checkbox and selecting Send Command then Close
6. Using a text editor open the bottle_timstep_0001.out and find the section that shows
the run cycles. Notice that it says that SH_3N (a tria element) element number 9279 is
controlling the time step.
Next we will use a few different methods to find the time step of the whole model
Step 4: Find Nodal Time step in output file

1. Using a text editor open the bottle_timstep_0000.out
2. Use Find in the text editor to search for time step in the file. Notice that the time step is
listed for each element type and along with a nodal time step estimation.

Notice that there are 3 shell (quad) and 2 triangular elements with a low time step of ~ 5e-8.
These are the elements that are controlling the time step.
Step 5: Contour Plot time step with HyperView

The engine output option /ANIM/NODA/DT allows us to contour plot the nodal time step
1. Start HyperView then File > Open > Model and click the and select
the bottle_timstepA001.

2. Turn off the parts bottom plate and load applicator as shown in the next image.
3. Select the contour icon, and select Result type: Time Steps (s) click Apply
4. Press the M key to turn on the mesh.
5. Rotate the model to find the location with the low time step which will be dark blue by
default. Zoom in to see that some very small elements are causing the small time step

Note that typically elements with small edges cause low time steps. Both HyperMesh check
elems or HyperCrash Quality, Check Elements of Tree Selection can also plot an estimation
of the time step of elements.
6. In HyperMesh, press F10 for the Check Elems panel, toggle the Time
7. Set the time step for all types: 1.0e-7, and click check elems, then save failed
8. To isolate the elements that failed, press F5, for the Mask panel click elems, retrieve;
elems, by adjacent; elems, reverse; then the green mask button
9. Zoom in and find the 5 small thin elements that are controlling the timestep.
10. To delete the small elements, press F2 for the delete panel.
11. Select the 5 small elements and click delete entity, then return
12. Access the Edges panel by Pressing SHIFT+F3 keys
13. With comps entity selector highlighted click once on an element on the
screen
14. Enter tolerance = 0.1 and click preview equiv to see the nodes that
will be equivalence
15. Click equivalence to equivalence the nodes
16.Select File > Export > Solver Deck and click enter
bottle_element_0000.rad click Export
NOTE: The engine file bottle_element_0001.rad will automatically be

created if Auto export engine file is checked.
Exercise 9b: Run Simulation with Default Element time step
Purpose: Run updated model using the default element time step calculated by
RADIOSS.
1. Start HyperWorks Solver Run Manager program and submit an initial run using 4
cores by specifying np 4 . Make sure the Use solver control option is checked.
1. Using a text editor open the bottle_element_0000.out
1. Use Find in the text editor to search for time step in the file and notice that the time step is
now much higher listed for each element type and the nodal time step.
2. Compare the smallest element time step listed in the bottle_element_0000.out file to
the time step listed in the output while the model is running or in the
bottle_element_0001.out file. Why are they not the same?
3. After the solution has finished, look at the end of bottle_element_0001.out for
ELAPSED TIME = ________________ .
4. Start HyperView and use File > Open > Model to load the bottle_element.h3d file.

5. Select the contour icon, and select Result type: Stress (t): vonMises to create a
contour plot of the stress of the crushing bottle in HyperView.
6. Animate the bottle crush by clicking on the animate button on the toolbar,
Next click File > Open > Report Template, and select the report template file
force_displacement.tpl Click on PLOT_FILE_1 and select the file open icon and
select the bottle_elementT01. Last click Apply and a second page will be added to
HyperView with the force displacement plot of the load applicator as shown below.
7. Save a HyperView session file of these results, on File >Save > Session enter the name
bottle_results.mvw and click save.

Exercise 9c: Run Simulation with Nodal time step
Purpose: Re-run the model using a constant nodal time step to reduce total
runtime RADIOSS.
1. Copy the bottle_element_0000.rad and bottle_element_0001.rad files to
bottle_nodal1_0000.rad and bottle_nodal1_0001.rad into the new directory.
2. Using a text editor and open bottle_nodal1_0001.rad to add the following Engine
Control Card to enable nodal time step calculation.
/DT/NODA/CST
0.67 2.0e-6
/ANIM/NODA/DMAS
NOTE: The above command will cause RADIOSS to use the nodal method of calculating the
time step. The 0.67 is the time step scale factor while 2.0e-6 is the minimum constant time
step (CST) that will be used by the RADIOSS simulation. This /DT/NODA/CST option will cause
RADIOSS to add mass to any node whose time step is less than 2.0e-6 / 0.67 3.0e-6.
When mass is added to a node its time step increases. /ANIM/NODA/DMAS causes RADIOSS
to create a contour output of the, change in mass / original mass.
3. As before, start the HyperWorks Solver Run Manager and start running the
bottle_nodal1_0000.rad file using 4 cores.
4. Observe the amount of mass added in the last column of the bottle_nodal_0001.out
simulation by text editing the bottle_nodal_0001.out file. This MAS.ERR is the
(change in mass) / (original mass). To get % mass added multiply this number by 100. So
in this simulation 117.4% mass has been added which is too much.
NOTE: Good engineering judgement must be used to determine how much mass is an
acceptable amount to be added to a model to reduce the runtime. Adding too much mass can
affect the physics of a drop or impact simulation. This is because the object being simulated
weighs more than the real part. In general it is recommended to keep the amount of mass
added to less than 5% but more may be acceptable depending on a particular simulation.
5. Click on the Open Report Panel Icon to plot the force

displacement curve for the nodal time step. Click beside the PLOT_FILE_1 and pick the

bottle_nodal1T01 file. Uncheck Use report colors and select Overlay under
Mode and click Apply.
6. Compare the force displacement (f-d) curves of the two models. Adding too much mass
combined with the relatively fast loading time makes maximum force larger.
8. In HyperView click on the add page icon and add another HyperView page.
9. If needed, change the page type from HyperGraph 2D to HyperView using the icon
10. Click on the new empty window and use File > Open > Model and the select the
bottle_nodal1.h3d file and click Apply.
11. Select the contour icon, and contour plot Mass Change (s) which is the (change in
nodal mass) / (original nodal mass).
It is always good to understand where the mass is being added in your model. It can be
important to minimize the amount of mass is added to critical areas of the design.
7. Did the amount of mass added by using a time step of 2.0e-6 cause a large difference in
the results compared to the results from the first simulation with elemental time step?
8. Copy the files to bottle_nodal1_0000.rad and bottle_nodal1_0001.rad files to
bottle_nodal2_0000.rad and bottle_nodal2_0001.rad
12. Determine a time step that adds less mass by editing the bottle_noda11_0000.out
RADIOSS starter output file and searching for the NODAL TIME STEP. Starting with the

smallest time step determine where the time step of the nodes doesnt increase very much
more and then use that as your /DT/NODA/CST time step.
13. Run the model and see how much % mass was added. Experiment until you find a time
step that limits the mass added to 5% (i.e. MAS.ERR 0.05)
14. How much % mass was added ______________.?
15. In same HyperView session that contained the element time step results, switch to the first
page that contained the element time step contour plot by using .
16. Change page to bottle_element.h3d results and change to two windows using this icon,
to
bottle_nodal2.h3d file and click Apply.
19. How does the stress results compare to the first simulation with element time step?
bottle_nodal2T01 file. Uncheck Use report colors and select Overlay under
Mode and click Apply.
21. How does the top load force results compare to the other two simulations?
22. After the solution has finished, look at the end of bottle_nodal2_0001.out for
ELAPSED TIME = ________________ .
23. How much faster does this nodal time step with mass scaling compared first run with
element time step ______________?
Exercise 9d: Run Simulation with Advance Mass Scaling

(AMS)
Purpose: Run the model using the Advanced Mass Scaling (AMS) method to
further reduce run time. The load needs to be applied slower to get a converged
quasi-static maximum top load force and remove vibrations in the force
displacement curve. By using AMS with a higher time step and apply the load
over a longer time, a converged quasi-static maximum top load force can be
calculated.
1. Launch HyperMesh, then select Preferences > User Profile > BRADIOSS Block140
2. From the pull down menu bar, File > Import > Solver Deck

3. Click the icon, navigate to the directory with the starting file and select the initial model
bottle_element_0000.rad
4. Next select Tools > Create Cards > AMS. This option lets you specify a part group AMS
will be applied to. If no part group is specified then AMS is applied to the whole model.
5.
6. Next select Tools > Create Cards > ENGINE KEYWORDS > DT > DT/ Tscale=0.67,
TMIN=1.0E-5
NOTE: The above options will cause RADIOSS to use the Advance Mass Scaling (AMS)
method to increase the time step. With AMS, the added mass does not increase the
translational kinetic energy of the system. See Advanced Mass Scaling (AMS) Guidelines in the
RADIOSS help for more details.
Due to the way AMS changes the mass matrix, high frequencies are damped out of a system.
This makes AMS best used for quasi static or low speed simulation where the high frequency
spectrum is not important to the results.
Experience has shown that a good starting time step for an AMS simulation is 10x the minimum
NODAL TIME STEP from the starter output file or 10x a valid /DT/NODA/CST simulations time
step.
To eliminate the vibrations in the force deflection curve, the load needs applied 10X slower.
9. In Model Browser > Load Collector, click on 3disp and enter scale_x=10. This apply a
scale factor of 10x to the abscissa so the load will be applied from 0 0.3 seconds.
10. In Model Browser > Card click on ENG_ANIM_DT and enter, Tfreq=0.03 to that 10
animation files are created in 0.3 seconds of run time.
11. In Model Browser > Card click on ENG_RUN T_STOP=0.3 so that the simulation ends at
0.3 seconds.
12. Select File > Export > Solver Deck and click enter bottle_ams_0000.rad click
Export
13. As before, start the HyperWorks Solver Run Manager and start running the AMS model
bottle_ams_0000.rad using 4 cores by specifying the option np 4.
14. Compare the total run time to the other simulations.
15. Switch to the first page that contained the element time step contour plot and nodal time
step contour plot change the page to three windows using this icon,
bottle_ams.h3d file and click Apply.
18. How does the stress results compare to the first simulation with element time step?

bottle_amsT01 file. Uncheck Use report colors and select Overlay under Mode
and click Apply.
NOTE: To reduce run solution time, the top load was applied faster than the actual test. To
determine the effect of this faster loading time, a good engineering practice would be to apply
the load slower to converge on a maximum top load force in the simulation.
Using AMS to increase the time step, allows the load to be applied slower and results still be
obtained in a reasonable amount of time.
20. The AMS force deflection curves are smoother then element and nodal results because the
load was applied slower resulting in less dynamic affects. The AMS maximum top load
force is very close to the converged quasi-static force of 205 N.

Capstone Exercises

Capstone: Cell Phone Drop
This capstone project is of a cell phone drop. Many parts of the phone are already connected. Often, this
type of analysis would be done with second order tetrahedral elements. The model supplied is first order
to save computation time.
Your task is to review the model for completeness and finish the model setup using the information below
to get a valid simulation.
Problem Setup
Copy the files: phonedrop_start_0000.rad to a working directory.

Front
cover
Windo
w and Touch
sensor
Gaske
t
Button
s
LCD
module
Carrie
r
PCB
Batter
y
Frame
Screw
s
Back
cover with
logo
Complete Connections and Contact

The screws need to be connected to the front cover.
Assume the parts interact with each other with a friction value of 0.2.
Loading Conditions
The phone drops from a height of 1.5 meters in the Z-direction to a flat floor on the Z plane.
The forces between the phone and the floor need to be recovered.
The total simulation time is 1 millisecond. Animation output requests should include plastic strain for
solids and shells, vonMises stress, tensor of shell membrane stress, and nodal added mass.

Run Analysis and Post-Process
Run the simulation and post-process the results, comparing to the results on the following page. Look
at the force between the phone and the floor as a function of time. Compare with the weight of the
phone at rest.

Displacement and VonMises Stress Results

Capstone: Bumper Impact
This capstone project is of a bumper hitting an offset wall. The parts are completely modeled.
Your task is to review the model for completeness and finish the model setup using the information below
to get a valid simulation.
Front Rail
Crush Box
Bumper Beam
Problem Setup
Copy the files: bumper-start_0000.rad to a working directory.

Property and Material Information
The component thickness and material is shown below:
Part Name Thickness Material
Bumper Beam 2.5 Aluminum
Crush Box 2.5 mm Aluminum
Front Rail 4.2 mm High Strength Steel
Connections
The Crush Box is connected to the Bumper Beam with a MIG Weld along the top and bottom
flanges (4 places). Green box shows one location.
The Crush Box is attached to the Front Rail with bolts of diameter 10 mm (8 places). Red circle
shows one location.
The Truck Frame

The rear part of the truck frame has a value of mass of 1400 kg, with rotational inertias (Ixx, Iyy,
Izz) that can be assumed to be 2.0e6. The masss location is (2000, 0, 170).
Impact Conditions
The bumper impacts a finite sized wall centered at (-503.5, -425, 180) that is 240 mm high
by 560 mm wide. Assume friction of 0.2.
The initial velocity of the frame is 4.5 mm/msec.
Assume all the parts have a friction coefficient of 0.2
The total simulation time is 30 milliseconds

Section forces need to be recovered for the left Front Rail and one for the right at x= -270.
Run Analysis & Post-Process

Run the simulation and post-process the results, comparing to the results on the following page.
Results of interest include:
Deformation
Global Energies Kinetic, Internal, Contact, Total
Vehicle CG deceleration
Rigid Wall forces
Section forces Left and Right Rails

Bumper Results

Appendix A:
Using RADIOSS with HyperStudy
1- HyperStudy
Altair HyperStudy is multi-disciplinary design study software that enables exploration and
optimization of design performance and robustness.
The design of the tool as a wizard makes it very easy to learn and use. It is applicable to
study the different aspects of a design under various conditions, including non-linear behaviors
and multi-disciplinary applications.
The models can be parameterized very easily. Besides the typical definition of solver
input data as design variables, the shape of a finite element model can also be parameterized
with ease.
HyperStudy Post-Processing module contains display, analysis and data mining
capabilities that helps engineers to overcome the challenging task of extracting relevant
information from multi-run studies. With its unique and powerful suite of tools, simulation results
can be analyzed, sorted and studied effectively in HyperStudy.
Specifically developed for design of experiments (DOE), fit (metamodelling), optimization
and stochastic studies, HyperStudy users can:
o Gain insight into the physics of a design
o Assess the robustness of a design for controlled or uncontrolled variations in the
design parameters
o Optimize a design for multi-disciplinary attributes

2- HyperStudy Benefits
9. Provides engineers with an easy way to study effects of design changes for complex
analysis events;
10. Allows engineers to assess the robustness of designs and provides the guidance necessary
to achieve robust designs;
11. Allows engineers to perform multi-disciplinary optimization studies for different attributes of a
design;
12. Allows engineers to perform system identification and correlation studies of designs;
13. Allows engineers to perform validation and evaluation of models and results using the
Evaluation and Rating module;
14. Complements existing CAE software with added functionality and direct interfaces to major
solvers;
15. Minimizes time-to-market by identifying design direction for difficult problems
16. Reads CAE native data files: RADIOSS, MotionSolve, OptiStruct, LS-DYNA, NHTSA ABF,
MADYMO, PAMCRASH, NASTRAN, ABAQUS, ADAMS, DADS, SIMPACK and others.
HyperStudy Interface

HyperStudy Process
HyperStudy process is composed of two major steps: Study Setup and Study
Approaches. In Study setup, the analysis process is automated and in study approaches, this
process is repeated many times depending on the study objectives.
HyperStudy Overview

Study Setup
Study setup compromises of: parameterization, model definition and evaluation,
response extraction.
HyperStudy has two ways of design parameterization. First one, parametrizing an input
deck, is generic but can be involved at times. Second one, working on the HyperMesh model, is
more specific but very easy to use. Any ASCII input deck can be parametrized using
HyperStudys editor. In the case of FEA models, direct linking to Hypermesh provides
HyperStudy direct access to simulation models and to the features such as thickness,
concentrated masses, shape changes which are used as the design variables in DOE,
optimization or stochastic studies. HyperMorph is integrated for shape parameterization.
For response extraction, HyperStudy uses HyperGraph readers and hence any result that
can be read by HyperGraph can also be read by HyperStudy. HyperStudy can also extract any
value from an ASCII output file.

Study Approaches
There are four study approaches in HyperStudy. They are: Design of Experiments (DOE),
fit, optimization and stochastics.
The objective of a DOE, or Design of Experiments, study is to understand how changes
to the parameters of a model influence its performance. In such a study, a model is repeatedly
run through a simulation for various combinations of parameter settings. Effects and interactions
of the design variables of the model can be studied.
From a DOE, mathematical models can be built describing the responses of the model as
an algebraic or numeric function of its parameters. This function is an approximation of the true
response. The algebraic or numeric expression that describes the response of a model as a
function of the parameters is known as a response surface. Once a set of response surfaces have
been generated for a model, those response surfaces can act as a proxy for the model. New
combinations of design variable settings not used in the original design can be plugged into the
response surface equations to quickly estimate the response of the model without actually running
the model through an entire analysis.
Optimization studies are used to find the parameter setting of a model that minimizes or
maximizes a particular objective function subject to a number of design constraints. A special
form of optimization problem, called System Identification, can also be solved in an optimization
study. In this case, the objective function is to minimize the quadratic deviation of a given function
from a target function. Optimization can be applied simultaneously to any one or more analysis
codes and hence can be multi-disciplinary. Size and shape optimizations can be performed. The
optimization can be performed using the analysis solver directly, or using a response surface
created in a DOE study.
Stochastic studies are used to study the influence of statistical distribution in the design
variables on the responses of a design. The stochastic analysis can be performed using the
analysis solver directly, or using a response surface created in a DOE study.

Exercise A1: Material Calibration Using System
Identification
The purpose of this tutorial is to introduce a method for characterizing parameters of a
RADIOSS material law used for modeling elasto-plastic material. The characterization of a
ductile aluminum alloy is studied. A RADIOSS simulation is performed to replicate an
experimental tensile test. The parameters of the material law are determined to fit the
experimental results. A quarter of a standard tensile test specimen is modeled using symmetry
conditions. A traction is applied to a specimen via an imposed velocity at the left-end.
Geometry of the Tensile Specimen (One Quarter of the Specimen is Modeled)
Sections of Node Saved for Time History
The material to be characterized is a 6063 T7 Aluminum: it has an isotropic elasto-plastic behavior which
can be reproduced by a Johnson-Cook model without damage (RADIOSS Block Law2), defined as
follows:

In this study we define, as design variables, the parameters a, b, n, max (maximum
stress) and the Young modulus. The stress-strain curve obtained by the experimental test is
shown in the following image.
Engineering Stress Versus Engineering Strain Curve (Experimental Data)
For the simulation results, engineering strains will be obtained by dividing the
displacement of node 1 by the reference length (75 mm), and engineering stresses will be
obtained by dividing the force in section 1 by its initial surface (12.012 mm2).

Engineering Stress Versus Strain Curve (Simulation Results)
In this tutorial, you will:

Create an input template from a RADIOSS data file using the HyperStudy Template Editor
Set up a study
Run a system identification optimization study
Problem Setup
You will need to copy the files: TENSILE_TEST_0000.rad, TENSILE_TEST_0001.rad, and
exper.xy

Step 1: Create the Base Input Template in HyperStudy
1. Start HyperStudy.
2. From the menu bar, click Tools > Editor. The Parameter Editor opens.
3. In the File field, navigate to your working directory and open the TENSILE_TEST_0000.rad
file.
Tip: RADIOSS uses fixed fields of 20 characters per field for properties.
4. In the Search area, enter /MAT/PLAS_JOHNS/1 and click to run the search..
HyperStudy highlights /MAT/PLAS_JOHNS/1 in the TENSILE_TEST_0000.rad file.
5. Select E, the Youngs Modulus value, by starting at the beginning of row 51 and highlighting the
first 20 fields.
Tip: To assist you in selecting 20-character fields, press CTRL to activate the Selector (set to 20
characters) and then click the value.
6. Right-click on the highlighted fields and select Create Parameter from the context sensitive
menu.
7. In the Parameter Varname_1 dialog, enter E_Young in the Label field.
8. Set the Lower Bound to 50000, the Initial Bound to 60400, and the Upper Bound to 70000.
9. In the Format field, enter %20.5f.

10. Click OK.
11. To define four more variables, repeat steps 1.4 through 1.11 using the information provided in
the table below.
Tip: Some of the initial values are different from the values in the original file.
Variable Label Lower Bound Initial Value Upper Bound Format
a a_PlasticityYieldStress 90 110 120 %20.5f
b b_HardeningCoeff 100 125 160 %20.5f
n n_HardeningExpo 0.1 0.2 0.3 %20.5f
sigmax Sigma_Max 250 280 290 %20.5f
12. Click Save.

13. In the Save Template dialog, navigate to your working directory and save the file as
TENSILE_TEST_0000.tpl.
14. Close the Parameter Editor dialog.
Step 2: Perform the Study Setup
1. To start a new study, click File > New from the menu bar, or click on the toolbar.
2. In the HyperStudy Add dialog, enter a study name, select a location for the study, and click
OK.
3. Go to the Define models step.

4. Add a Parameterized File model.
a. From the Directory, drag-and-drop the TENSILE_TEST_0000.tpl file into the work
area.
b. In the Solver input file column, enter

TENSILE_TEST_0000.rad;TENSILE_TEST_0001.rad. This is the name of the
solver input file HyperStudy writes during any evaluation.
c. In the Solver input file column, select RADIOSS (radioss).
d. In the Solver input arguments column, enter -both at the end of $file.
Tip: This argument runs the Starter, and the Engine of RADIOSS for the crash analysis. It also
prevents the creation of the .h3d result file from animation files. X is the number of CPUs
to use for the simulation.
5. Click Import Variables. Five design variables are imported from the
TENSILE_TEST_0000.tpl resource file.
6. Go to the Define design variables step.
7. Check the design variable's lower and upper bound ranges.
8. Go to the Specifications step.
Step 3: Perform the Nominal Run

1. In the work area, set the Mode to Nominal Run.
2. Click Apply.
3. Go to the Evaluate step.

4. Click Evaluate Tasks.
Tip: An approaches/nom_1/ directory is created inside the study directory. The
approaches/nom_1/run__00001/m_1 directory contains the TENSILE_TESTT01 file,
which stores the time history results of the simulation.
5. Go to the Define response step.
Step 4: Create and Define Responses

Tip: To fit the RADIOSS stress-strain curve to the experimental data in this tutorial,
three specific points per curve will be compared. Since damage is not modeled with this
law, the comparison is not needed after the necking point.
Difference between experimental stress and RADIOSS at Strain equal 0.02 (1)
Difference between experimental strain and RADIOSS at Necking point (2)
Difference between experimental stress and RADIOSS at Necking point (3)
1. Click Add Response.

2. In the HyperStudy - Add dialog, add three responses labeled: Radioss_Strain_0_2,
Radioss_Stress_Necking, and Radioss_Strain_Necking.
3. In the Expression column of the response Radioss_Strain_0_2, click .

4. In the Expression Builder, click the File Sources tab.
5. Click Add File Source.
6. In the HyperStudy - Add dialog, add one Solver output file labeled Disp_sim.
6. In the File column of Disp_sim, click .

7. In the Vector Source dialog, navigate to the approaches/nom_1/run__00001/m_1
directory and open the TENSILE_TESTT01 file.
8. From the Type, Request, and Component fields, select the options indicated in the image
below.
9. Click OK.
10. Repeat steps 4.5 through 4.8 to add a second vector labeled Force_sim.

11. From the Type, Request, and Component fields, select the options indicated in the image
below.
12. Click OK.

13. Click the Function tab.
14. From the list of functions, select lininterp.
15. Click Insert Varname. The function lininterp() appears in the Evaluate Expression field.
16. In the Evaluate Expression field, enter (v_1/75,v_2/12.012,0.02) in the lininterp
function.
Tip: This expression computes the Stress with respect to the Strain, at Strain equals 0.02.
17. Click Evaluate Expression.

18. Click OK.
19. In the Expression column of the response Radioss_Stress_Necking, click .

20. In the Expression Builder, click the Functions tab.
21. From the list of functions, select max.
22. Click Insert Varname. The function max() appears in the Evaluate Expression field.
23. In the Evaluate Expression field, enter
(v_2[subrange(v_1,min(v_1),v_1[indexofmax(v_2)])])/12.012 in the max
function.

Tip: This is the maximum of the force (v_2), which is trimmed between the min strain and the
strain at the max value of Force, divided by 12.012 (surface) to obtain the stress.

25. Click OK.
26. In the Expression column of the response Radioss_Strain_Necking, click .

27. In the Evaluate Expression field, enter
v_1[maxindex(subrange(v_1,min(v_1),v_1[indexofmax(v_2)]))]/75.
Tip: This is the displacement (v_1) at the max value of the force value, divided by 75 to obtain
strain.

29. Click OK.
Step 5: Run an Optimization Study

1. In the Explorer, right-click and select Add Approach from the context menu.
2. In the HyperStudy - Add dialog, select Optimization and click OK.
3. Go to the Select design variables step.
4. Review the design variable's lower and upper bound ranges.
5. Go to the Select responses step.
6. Click Add Objective.
7. In the HyperStudy - Add dialog, add three objectives labeled: Radioss_Strain_0_2,
Radioss_Stress_Necking, Radioss_Strain_Necking.
8. Define the three objectives by selecting the options indicated in the image below from the Type,
Apply On, and Target Value columns.

9. Click Apply.
11. In the work area, set the Mode to Adaptive Response Surface Method (ARSM).
Tip: Only the methods that are valid for the problem formulation are enabled.
12. Click Apply.
14. Click Evaluate Tasks to launch the optimization.
15. Click the Iteration Plot 2D tab.
16. Using the Channel selector, select the three objectives from and the Objective Function Value.
Activate multiplot to see the each channel in its own plot.
Tip: The first three selections are the actual values used in the system identification optimization
problem. Observe their objective history to see that their values indeed approach their
respective target values. The final plot is the scalar objective which is used in the system
identification problem; a normalized sum of the squares difference between the actual and
target objective values. Note that the value of this combined function has been reduced through
the optimization.

HS-4220: Size Optimization Study on an Impact
Simulation Using RADIOSS
This tutorial demonstrates how to perform a size optimization on a finite element model
defined for RADIOSS. The objective is to minimize the mass of the beam under the following
two constraints: the internal energy must be more than 450, and the resulting reaction force
must be less than 75. The design variables are the thicknesses of the four components defined
in the input deck boxbeam1._0000.rad via the /PROP/SHELL entries. They are combined
into two design variables. The thickness should be between 0.5 and 2.0; the initial thickness is
1.0. The optimization type is size.
Figure 1. Boxbeam model, undeformed

Figure 2. Boxbeam model, deformed, t = 2.001.
Problem Setup
You will want to copy the files: boxbeam_0000.rad, boxbeam_0001.rad

Step 1: Create the Base Input Template in HyperStudy
1. Start HyperStudy
2. From the menu bar, click Tools > Editor. The Editor opens.
3. In the File field, navigate to your working directory and open the boxbeam1_0000.rad file.
4. In the Search area, enter /PROP/SHELL/1.
5. Click until you find /PROP/SHELL/1.
6. Highlight the field for the thickness.
Tip: To assist you in selecting 20-character fields, press CTRL to activate the Selector (set to 20
characters) and then click the value. HyperStudy highlights 20 fields.
7. Right-click on the highlighted fields and select Create Parameter from the context menu.
8. In the Parameter - varname_1 dialog, Label field, enter Upper part.
9. Set the Lower bound to 0.5, the Initial value to 1.0, and the Upper bound to 2.0.
10. Set the Format to %20.5f.
11. Click OK.

12. Repeat steps 1.4 through 1.6 for the second component, /PROP/SHELL/2.
13. Assign the same thickness to /PROP/SHELL/2 as /PROP/SHELL/1 by right-clicking on the
highlighted fields and selecting Attach to > varname_1 from the context menu.
14. Repeat steps 1.4 through 1.6 for the third component, /PROP/SHELL/3.
15. Right-click on the highlighted fields and select Create Parameter from the context menu.
16. In the Parameter - varname_2 dialog, Label field, enter Lower part.
17. Set the Lower bound to 0.5, the Initial value to 1.0, and the Upper bound to 2.0.
18. Set the Format to %20.5f.
19. Click OK.

20. Repeat steps 1.4 through 1.6 for the fourth component, /PROP/SHELL/4.
21. Assign the same thickness to /PROP/SHELL/4 as /PROP/SHELL/3 by right-clicking on the
highlighted fields and selecting Attach to > varname_2 from the context menu.
22. Click Save.
23. In the Save Template dialog, navigate to your working directory and save the file as
boxbeam1.tpl.
24. Close the Editor.
Step 2: Optional. View the Base Input Template in TextView
1. Start HyperGraph.
2. On the Client Selector toolbar, select TextView.
3. From the menu bar, click File > Open > Document.
4. In the Open Document dialog, open the boxbeam1.tpl file. The text editor displays the following
design variables that are defined by Templex parameter statements:
{parameter(t1,"Upper part",1.0,0.5,2.0)}
{parameter(t2,"Lower part",1.0,0.5,2.0)}
5. On the Text toolbar, click .
6. In the Find dialog, Find field, enter /PROP/SHELL.
7. Click . The parameterized /PROP/SHELL cards, which reference the design variables,
highlight.

8. On the Text toolbar, click . The text editor evaluates the Templex statements, and replaces
the parameters with their initial values.
9. Repeat steps 2.5 through 2.7, and search for /PROP/SHELL again. You will find:

10. Close HyperGraph; you do not need to save the session.
Step 3: Perform the Study Setup

1. Return to HyperStudy.
2. To start a new study, click File > New from the menu bar, or click on the toolbar.
3. In the HyperStudy Add dialog, enter a study name, select a location for the study, and click
OK.
4. Go to the Define models step.
5. Add a Parameterized File model.
a. From the Directory, drag-and-drop the boxbeam1.tpl file into the work area.

b. In the Solver input file column, enter
boxbeam1_0000.rad;boxbeam1_0001.rad. This is the name of the solver input
file HyperStudy writes during any evaluation.
c. In the Solver execution script column, select RADIOSS (radioss).
6. Click Import Variables. Two design variables are imported from the boxbeam1.tpl resource
file.
7. Go to the Define design variables step.
Step 4: Perform the Nominal Run

1. In the work area, set the Mode to Nominal Run.
2. Click Apply.
4. Click Evaluate Tasks. An approaches/nom_1/ directory is created inside the study directory.
The approaches/nom_1/run__00001/m_1 directory contains the result files.
5. Go to the Define response step.
Step 5: Create and Define Responses

1. Click Add Response.
2. In the HyperStudy - Add dialog, add three responses and label them Energy, Force, and
Mass.
3. In the Expression column of the response Energy, click .

4. In the Expression Builder, click the File Sources tab.
5. Click Add File Source.
6. In the HyperStudy - Add dialog, add one Solver output file.
7. In the File column of Vector 1, click .

8. In the Vector Source dialog, navigate to the approaches/nom_1/run__00001/m_1
directory and open the boxbeam1T01 file.
9. Define Vector 1 as the internal energy of the model by selecting the options indicated in the
image below from the Type, Request, and Component fields.
10. Click OK.

11. Click the Function tabs.
12. From the list of functions, select max.
13. Click Insert Varname. The function max() appears in the Evaluate Expression field.
14. Click the File Sources tab.

15. Click Insert Varname. The expression in the Evaluate Expression field changes to
max(v_1[0]).
16. Remove [0] from the expression; we want the maximum of the entire vector and not just the
first entry.
17. Click OK.

18. Repeat steps 5.3 through 5.8 for the response Force.
19. Define Vector 2 as the resultant reaction force in the Z-direction by selecting the options
indicated in the image below from the Type, Request, and Component fields.
20. Click OK.

21. Wrap the expression in the max function and remove [0]. The expression should read,
max(v_2).
22. Insert the function max(v_2) into the Evaluate Expression field.
23. Click OK.
24. Repeat steps 5.3 through 5.8 for the response Mass.
25. Define Vector 3 as the mass by selecting the options indicated in the image below from the
Type, Request, and Component fields.

26. Click OK.
27. Insert the function v_3[0] into the Evaluate Expression field. In order to extract the initial
mass, do not remove the [0] after v_3.
28. Click OK.
29. Click Evaluate Expressions to extract the response values.
Step 6: Run an Optimization Study

1. In the Explorer, right-click and select Add Approach from the context menu.
2. In the HyperStudy - Add dialog, select Optimization and click OK.
3. Go to the Select design variables step.
5. Go to the Select responses step.
6. Click Add Objective.
7. In the HyperStudy - Add dialog, add one objective.
8. In the Apply On column, select Mass (r_3).
9. Click the Constraint tab.

10. Click Add Constraint.
11. In the HyperStudy - Add dialog, add two constraints.
12. Define the constraints by selecting the options indicated in the image below from the Apply On,
Bound Type, and Bound Value columns.
13. Click Apply.

15. In the work area, set the Mode to Adaptive Response Surface Method (ARSM).
Tip: Only the methods that are valid for the problem formulation are enabled.
16. Click Apply.
18. Click Evaluate Tasks to launch the Optimization.
Step 7: View the Iteration History of an Optimization Study
1. Click the Iteration History tab to display data in a tabluar view. The optimal design is highlighted
green, the infeasible designs are shown with red text, and the violated constraints are indicated
in bold text.
2. Click the Iteration Plot 2D tab to plot the iteration history of the study's objectives, constraints,
and design variables.
3. Using the Channel selector, select Objective 1, Constraint 1, and Constraint 2.
Tip: In the initial design, the design was infeasible as indicated by the large circular marker for
the first iteration. A view of the constraint plots shows that the second constraint was violated
in the initial design. Initially, the optimizer added some weight in order to satisfy the design
constraints. Notice that both constraints are near their bounds in the optimal design.


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Intro to RADIOSS for Impact Analysis

Including Examples using HyperCrash and HyperMesh Desktop

www.altairhyperworks.com | HyperWorks is a division of

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Chapter 3: Running RADIOSS Exercises ................................................................................... 4

Chapter 5: Material Characterization Exercises ....................................................................... 18

Chapter 6: Interface Modeling Exercises ................................................................................... 51

Chapter 7: Kinematic Condition Exercises ............................................................................... 79

Chapter 9: Timestep Control Exercises ................................................................................... 102

Capstone Exercises ................................................................................................................... 116

Appendix A: Using RADIOSS with HyperStudy ...................................................................... 125

HyperWorks 14.0 Intro to RADIOSS for Impact Analysis 3

4 Intro to RADIOSS for Impact Analysis HyperWorks 14.0

HyperWorks 14.0 Intro to RADIOSS for Impact Analysis 5

Speed of sound in steel rail = _________________________

Time for sound to travel length of rail = ______________________________________

# Animation Output Frequency

# NCYCLE IREAD IWRITE

6 Intro to RADIOSS for Impact Analysis HyperWorks 14.0

HyperWorks 14.0 Intro to RADIOSS for Impact Analysis 7

8 Intro to RADIOSS for Impact Analysis HyperWorks 14.0

Step 7: Review the results file FIRST_RUN.h3d with HyperView

button to make the component transparent.

This will contour the velocities at Time=0 to verify initial conditions.

HyperWorks 14.0 Intro to RADIOSS for Impact Analysis 9

10 Intro to RADIOSS for Impact Analysis HyperWorks 14.0

Step 8: Continue the simulation by setting a longer run time

HyperWorks 14.0 Intro to RADIOSS for Impact Analysis 11

# Animation Output Frequency

# NCYCLE IREAD IWRITE

12 Intro to RADIOSS for Impact Analysis HyperWorks 14.0

1. Open a new HyperView session. .

HyperWorks 14.0 Intro to RADIOSS for Impact Analysis 13

5. Click on the top right window to make it current.

Step 10: Plot the Rigid Wall Force as a function of time

14 Intro to RADIOSS for Impact Analysis HyperWorks 14.0

1. Click on the left bottom window to make it current.

16 Intro to RADIOSS for Impact Analysis HyperWorks 14.0

HyperWorks 14.0 Intro to RADIOSS for Impact Analysis 17

18 Intro to RADIOSS for Impact Analysis HyperWorks 14.0

Become familiar with Johnson-Cook Material Law 2

Johnson-Cook Elastic Plastic Material /MAT/PLAS_JOHNS (Aluminum 6063 T7)

HyperWorks 14.0 Intro to RADIOSS for Impact Analysis 19

2. Use the Entity Editor to input the values as shown:

20 Intro to RADIOSS for Impact Analysis HyperWorks 14.0

Step 4: Create boundary conditions for symmetry and general constraint