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Contents
Introduction.............................................................................................2
Installation Instructions: .......................................................................2
Redesign of Aluminum Housing.................................................................3
Description of the Problem ....................................................................3
Design Objectives .................................................................................4
The Analysis Model ...............................................................................5
The Optimization Model.........................................................................6
Results.................................................................................................6
Further Work ........................................................................................6
Summary .............................................................................................8
Frequency Optimization of Vehicle Floor ....................................................9
Description of the Problem ....................................................................9
Design Objectives ............................................................................... 10
The Analysis Model ............................................................................. 10
The Optimization Model....................................................................... 11
Results............................................................................................... 12
Further Work ...................................................................................... 12
Summary ........................................................................................... 13
Shape Optimization of Engine Block ........................................................ 14
Description of the Problem .................................................................. 14
Design Objectives ............................................................................... 14
The Analysis Model ............................................................................. 15
The Optimization Model....................................................................... 16
Results............................................................................................... 17
Further Work ...................................................................................... 17
Summary ........................................................................................... 17
Battery Tray Design ............................................................................... 19
Description of the Problem .................................................................. 19
Design Objectives ............................................................................... 19
The Analysis Model ............................................................................. 20
The Optimization Model....................................................................... 22
Results............................................................................................... 22
Further Work ...................................................................................... 22
Summary ........................................................................................... 22
1
Student Project Summaries CAE and Design Optimization - Basics
Introduction
This material is best used after reading the book CAE And Design
Optimization – Basics.
To make best use of this material you will need a computer with a sound-
card and speakers. Your computer should have a media-player programme
(such as Windows Media Player) and an Internet Browser that supports
JavaScript. The material can be copied to a server and accessed by clients.
Installation Instructions:
1. Copy the folders to your computer or to your server. If you are
working on a server, it is a good idea to set the folders to “read
only” to prevent inadvertent modifications.
2. The videos are best played in full-screen at a resolution of 1024 x
768. You may need to install the CamStudio Codec to view video on
your computer. To do this, right-click on the file camcodec.inf and
choose Install from the popup menu. You may need administrator
privileges to do this.
3. Ensure that JavaScript is enabled on your browser.
4. Each folder contains one HTML file. Double-click on it to open the
instructions.
5. Data files are provided as relevant – IGES files, HM files, etc.
6. In case you need support, contact your distributor or email
edu.support@altair.india.com
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Student Project Summaries CAE and Design Optimization - Basics
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Student Project Summaries CAE and Design Optimization - Basics
Design Objectives
Since we have no information on the variation of the
actual loads with time, we will use an equivalent
static analysis. In this approach, we use a factor of
safety to allow the static design to mimic the
dynamic conditions. Interested students can look up
the MIL-Standard for shock loads to be rigorous.
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Student Project Summaries CAE and Design Optimization - Basics
We then run the optimization with the goal of reducing the stress to less
than that in the baseline analysis, under the same
loads, using steel.
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Student Project Summaries CAE and Design Optimization - Basics
Results
Topology optimization decides an equivalent element
density for each element in the design space. A
density of 1 means material must fill the element,
while a density of 0 means the element needs no
material. For most elements, this value will vary
between 1 and 0. As a designer, you will need to
exercise your judgment. For example, you may decide that you will omit
material from all elements whose density is less than 0.3 (or 30%). Having
made this decision, you will need to take the geometry back to your CAD
modeler, smooth it out (that is, use geometrically regular edges or surfaces,
etc.) and re-evaluate the design for a satisfactory stress.
Further Work
The assignment brings home the advantages of the Optimization-as-an-
integral-part-of-CAE, as well as the advantages of using HyperWorks:
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Student Project Summaries CAE and Design Optimization - Basics
• estimate the change in center-of-gravity, since this affects the forces at the
mounting screws. The center-of-gravity can be a constraint for optimization
• investigate the effect of mesh size on the optimization results
• use shape optimization to choose a fillet radius for the various fillets
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Student Project Summaries CAE and Design Optimization - Basics
Summary
By the end of this assignment, the student will know how to
• import IGES files into HyperMesh
• use the Model Browser
• zoom, pan and rotate
• change colors of entities
• control visibility of geometry
• create collectors for material data, elements, forces and
restraints (SPCs)
• measure distances and the diameter of circles
• find the centers of circles
• use consistent units
• check for different types of element-edges - free, shared, etc.
• fill and stitch surfaces
• create fixed points
• use temp nodes
• create mass elements
• create a load case
• ask for reactions to be output by the solver
• plot stress contours
• view deformed shapes
• use unaveraged stresses to check if the model is adequate
• organize elements in collectors to define the design space
• specify responses that the optimizer needs
• specify stress constraints and deflection constraints
• set the objective
• control the optimizer
• check for convergence and violation of constraints using the text
output files
• check for convergence and violation of constraints using
HyperView
• view density plots in HyperView
• run OS-Smooth to export data back to a CAD modeler
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Student Project Summaries CAE and Design Optimization - Basics
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Student Project Summaries CAE and Design Optimization - Basics
Design Objectives
The design problem involves the specifications, the
methods of addressing these, and the potential for
success. The last point is the most important: in
design, a negative result is also extremely useful. It
is very possible that the floor, with the given
thickness, will not be able to attain the required
characteristics.
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Student Project Summaries CAE and Design Optimization - Basics
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Student Project Summaries CAE and Design Optimization - Basics
Results
Since the solution time for the floor can be quite
substantial, the instructions for this section use a
sample geometry. We study how to check for
convergence and violation of constraints using the
text output files, how to check for convergence and
violation of constraints using HyperView. We also
view bead plots in HyperView and use OsSmooth to
export data back to a CAD modeler
Further Work
The assignment underscores the advantages of
treating Optimization-as-an-integral-part-of-CAE, and
the advantages of using HyperWorks:
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Student Project Summaries CAE and Design Optimization - Basics
Summary
By the end of this assignment, the student will know how to
• import IGES files into HyperMesh
• use the Model Browser
• zoom, pan and rotate
• change colors of entities
• control visibility of geometry
• create material collectors
• create component collectors
• create load collectors
• create loadcases
• measure distances
• use consistent units
• work with different types of edges - free, shared, etc.
• fill and stitch surfaces
• measure the diameter of circles
• find the centers of circles
• use temp nodes
• use autocleanup to do all of the above
• create restraints or SPCs
• specify options for the eigenvalue-solver
• organize elements in collectors to define the design space
• specify responses for the optimizer
• specify topography constraints - i.e., the bead parameters
• use manufacturing constraints
• set the objective
• control the optimizer
• check for convergence and violation of constraints using the text
output files
• check for convergence and violation of constraints using
HyperView
• view bead plots in HyperView
• export data back to a CAD modeler
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Student Project Summaries CAE and Design Optimization - Basics
Design Objectives
Engine design is multi-disciplinary, since heat
transfer and fluid flow (for combustion) are at least
as important as structural design. There are also
forces that the engine experiences because of the
movement of the piston.
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Student Project Summaries CAE and Design Optimization - Basics
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Student Project Summaries CAE and Design Optimization - Basics
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Student Project Summaries CAE and Design Optimization - Basics
Results
Our principal interest is in the shape-variables. We
will want to apply the recommended values to the
FE model. This causes the FE model to be modified
to match the recommendations of the optimizer. We
will then build surfaces from the FE mesh and export
IGES geometry for CAD usage.
Further Work
The advantages of the Optimization-as-an-integral-
part-of-CAE are clear, as are the advantages of
using HyperWorks:
Summary
By the end of this assignment, the student will know
how to
• import IGES files of assemblies into HyperMesh
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Student Project Summaries CAE and Design Optimization - Basics
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Student Project Summaries CAE and Design Optimization - Basics
Design Objectives
The proposed design is made from 2 mm thick
sheet metal, and is designed to assemble with pre-
designed components. It has to carry 2 batteries
that together weight 15 kg.
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Student Project Summaries CAE and Design Optimization - Basics
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Student Project Summaries CAE and Design Optimization - Basics
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Student Project Summaries CAE and Design Optimization - Basics
Results
Our principal interest is in the element
thickness. We will see what OptiStruct has
recommended, and use these to suggest where
ribs should be used under the tray.
Further Work
The advantages of the Optimization-as-an-
integral-part-of-CAE are clear, as are the
advantages of using HyperWorks:
Summary
By the end of this assignment, the student will know how to
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Student Project Summaries CAE and Design Optimization - Basics
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