Van-Rob Kirchhoff - Yimin Zhan.pdf

1. Optimization of a Family
of Supporting Frames
Under Multiple Analysis
Constraints Using
HyperStudy
Yimin Zhan, Ph.D.
Malisha Djokic, M.Sc.Tech., P.Eng.
Van-Rob Kirchhoff Automotive
Aurora, Ontario,
Canada L4G 0A2

2. Contents
• Preface
• Objectives and Description
• Modeling in HyperMesh
• Baseline Analysis using HyperWorks Solvers
• Optimization using HyperStudy
• Validation using HyperWorks Solvers
• Conclusions

3. Preface
• Van-Rob Kirchhoff, based in Aurora Ontario Canada, is a tier-one full
service global supplier of automotive OEMs
• 29 production plants in 12 countries serving both domestic and
overseas customers
• Use of Altair HyperWorks Suite since year 2002 to optimize designs
and improve performance
• Meshing and modeling, linear (static and dynamic) and non-linear

4. Objectives and Description
Long Version
Short Version

5. Modeling in HyperMesh
Long Version
Short Version

6. Baseline Analysis
using HyperWorks Solvers
Analysis Type #1:
Push-test stiffness under boundary condition #1
Z Z
Z
Z Z Z
Z
Z Y Y Z X
Y X
Y Z Y X
Y X X X
Y X
Y X Y X
Y X
Short Version Long Version

7. Baseline Analysis
using HyperWorks Solvers
Analysis Type #2:
Push-test stiffness under boundary condition #2
Short Version Long Version

8. Baseline Analysis
using HyperWorks Solvers
Analysis Type #3:
Modal analysis
Short Version Long Version

9. Baseline Analysis
using HyperWorks Solvers
Analysis Type #4:
Non-linear impact analysis
Short Version Long Version

10. Optimization using HyperStudy
g2
g3
g1
g4
g6L
g6S
g5
Short Version Long Version

11. Optimization using HyperStudy
Morphing variables:
S1S for short version
S1L for long version
Morphing variables:
S2S for short version
S2L for long version

12. Optimization using HyperStudy
Morphing variable: Morphing variable:
S3 S4

13. Optimization using HyperStudy
Create study

14. Optimization using HyperStudy
Create models

15. Optimization using HyperStudy
Create design variables

16. Optimization using HyperStudy
Do nominal run

17. Optimization using HyperStudy
Create responses

18. Optimization using HyperStudy
Link design variables

19. Optimization using HyperStudy
Create optimization study

20. Optimization using HyperStudy
Define design variables

21. Optimization using HyperStudy
Apply constraints

22. Optimization using HyperStudy
Create objective

23. Optimization using HyperStudy
Post processing

24. Optimization using HyperStudy
Post processing

25. Optimization using HyperStudy
Post processing – Visualize…

26. Optimization using HyperStudy
Post processing – Visualize…

27. Optimization using HyperStudy
 
Baseline
Baseline
Optimization
Optimization
 

28. Optimization using HyperStudy
Baseline

Optimization


29. Validation
using HyperWorks Solvers

30. Validation
using HyperWorks Solvers
Analysis Type #1: Push-test stiffness under boundary condition #1
Location 1 Location 1
X
  1 mm   1 mm
Y
  0.1 mm   0.1 mm
Z
  0.2 mm   0.2 mm
Short version Long version

31. Validation
using HyperWorks Solvers
Analysis Type #2: Push-test stiffness under boundary condition #2
Y
  2 mm   2 mm
Short version Long version

32. Validation
using HyperWorks Solvers
Analysis Type #3: Norm mode
  30 Hz   30 Hz
Short version Long version

33. Validation
using HyperWorks Solvers
Analysis Type #4: Non-linear impact
 Target: < 0.5 mm  Target: < 0.5 mm
Short version Long version

34. Conclusions
• HyperStudy is capable to perform simultaneous analysis on multiple FEA
models with multiple types of FEA analysis, design variables and constraints;
• Some components can be shared in different models. This means significant
reduction of processing cost and time;
• All design constraints are achieved and violation level is under 2%;
• Objective is met with mass penalty  0.5 Kg;
• HyperStudy is a quite powerful package for conducting structural optimization;
• Time saving: months versus days or even hours;

35. Conclusions
Wish list:
(a) Topology optimization variables, e.g.
element densities under extrusion
constraints, should be convertible to
become design variables acceptable to
HyperStudy;
(b) Hope to have an “Uncheck” option for the
post-processing panel, so that quick
uncheck of all items and then re-pick of
items needed to display are enabled.
Optionally, a multiple selection of items,
using SHIFT button and left mouse button,
is needed.

36. Thank you