Altair HyperWorks: A Platform for Innovation
Vladimir Obukhov
Technical Consultant
Altair Engineering GmbH
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperWorks Desktop Integration – Typical FEA Process
POST-PROCESSING
Results Visualization
SOLVING
ALTAIR SOLVER EXTERNAL SOLVER
PRE-PROCESSING
1) GEOMETRY2) FINITE
ELEMENT MODEL3) ANALYSIS
IMPORT FROM CAD or CAE World
CAD CAE
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Integration Matters: Flexibility
CAD
ACIS
CATIA V4 / V5
IGES (in)
IGES (out)
JT Precise
Parasolid (in)
Parasolid (out)
Pro/E
SolidWorks
STEP
Tribon
UG/NX
CAE
Adams
Abaqus
Actran
AcuSolve
Ansys
CFD++
Femfat
Fluent
Ls-Dyna
Madymo
Marc
Matlab
Moldflow
Moldex3D
MotionSolve
Nastran
nCode
Permas
Pam-Crash
RADIOSS
OptiStruct
Samcef
Simpack
StarCD
Custom User-defined
InterfacesScripting
Results
Math
Open, adaptable to your environment…
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Modeling and Visualization: Pre-Processing
Pre-Processing
HyperMesh
FEA/CFD Modeling,
Customizable to capture
best practices,
Native CAD Support for
better model quality
MotionView
Multi-body modeling,
Parametric modeling,
Solver-neutral data
model,
Highly customizable
Simlab
CAE Pre-Post Processing
Tools to automate and
reduce the simulation time
without compromising
quality
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Meshing Time Reduction HyperMesh, SimLab
• Superior mesh quality
• Hexaherals
• Tetrahedra
• Shells
• Complete solution
• Geometry cleanup & Meshing
• Loads & boundary conditions
• Morphing
• Broadest set of direct CAD and CAE interfaces
• Abaqus
• Ansys
• Dyna
• Nastran
• Radioss
• …
• Extensive geometry repair functionality
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Modeling and Visualization: Altair SimLab
Simplified Modeling Processes for Complex Problems
Feature based
finite-element
modeling
Create high quality
mesh easily and
rapidly
Knowledge capture
and sharing via
templates
Extremely well-suited
for powertrain
modeling
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Example: Turbine Blade Meshing Strategy at SiemensPresentation European HTC 2011
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Cutting CAE Modeling Time by up to 50% at Dunlop Aerospace
Challenge• Need for complex solid mesh models for
simulation of aircraft braking systems
• Creation of HEXAEDER meshes took
sometimes weeks
Solution• HyperMesh’s HEX mesh capabilities
• “Solid Map” functionality: “intelligent”
extrusion of shell meshes into volumes
• Direct geometry input to eliminate time to
repair surfaces
• Morphing to quickly realize mesh based
design changes
Benefits• Up to 50% reduction in meshing time
• Extremely stable environment
• Easy to learn & use
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Analysis: HyperWorks Solver Technology
Multiphysics Analysis and Optimization
Structural
Analysis
Manufacturing
Simulation
Systems
SimulationFluid
Dynamics
Thermal
Analysis
Crash, Safety,
Impact &
Blast
Electro-
Magnetics
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HyperWorks Solvers
Thermal
and CFD
Highly Non-Linear
Crash
Safety
Forming
Statics
NVH
Thermal
Non-Linear
Multi-body
Dynamics
OptiStruct RADIOSS MotionSolve AcuSolve
Optimization
Smart Multiphysics
FEKO
Electro-
Magnetics
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OptiStruct: Optimization-driven Structural Analysis
Smart Multiphysics
Optimization
Thermal
AnalysisNoise and
Vibrations
Stiffness,
Strength,
Stability
Powertrain
DurabilityKinematics &
Dynamics
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Torque Plate – Design Objectives
Design Problem
• Secure contract for Airbus A380 wheel and
brake systems
• Respond to Airbus demands for lower mass,
reduced package space and lower costs
• Mass under 10kg (from 10.9kg)
Optimization Statement
• Minimize Mass
• Constraints on Displacements and Stress
Methodology
• Topology Optimization followed by Shape
Optimization of the torque plate walls Courtesy of Dunlop Aviation Braking Systems
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Torque Plate – Conventional Design and Analysis Results
• Mass 10% over target of 10 Kg
• Stress 55% over target of 680 MPa
• Project in jeopardy
13 Kg 10.9 Kg
5 weeks
5 weeks of
conventional analysis
work without reaching
mass targets before
optimization Courtesy of Dunlop Aviation Braking Systems
1050 MPa
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• Mass 5% under target
• Stress on target at 680 MPa
10.9Kg 9.5Kg
Courtesy of Dunlop Aviation Braking Systems
680 MPa1050 MPa
Torque Plate – Conventional Design and Analysis Results
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• Final design mass: 9.5 kg
• Final Peak Stress: 680 Mpa
• Financial penalties avoided
• Improved forging performance
• Out-of-plane bending avoided
Courtesy of Dunlop Aviation Braking Systems
Peak Stress
1050 MPa
680 MPa
Mass
13.0 kg
9.5 kg
Torque Plate – Conventional Design and Analysis Results
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Design Exploration: Altair HyperStudy
Multi Disciplinary design exploration, study and optimization software
Perform what-if studies
Calibrate simulation models
to match with test results
Design better performing
products
Increase the reliability of the
designs
Find robust designs that are
less sensitive to variations
Increase the return on CAE
investments
+17% in reliabilityBefore After
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimization and Reliability Analysis of a Mars Lander
•ESA Aurora Exploration Program Launch in 2011 or 2013
•New Lander Design Concept Vented airbag, coming to rest on 2nd bounce Traditional concepts come to rest after 10 to 20 bounces
•Failure modes Roll-over (payload overturns), Dive-through (payload impacts rock) Rupture (fabric tears)
• Full scale terrestrial testing expensive / difficult: virtual design approach
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Reliability Study: Range of Conditions
Controlled/Uncontrolled conditions
Wind speed (Weibull)
Rock Height (Exponential)
Lander pitch attitude (+/- 20 deg)
Lander pitch rate (+/- 30 deg/s) Probability Density Function f(H)
0.0000
1.0000
2.0000
3.0000
4.0000
5.0000
6.0000
7.0000
0.000 0.200 0.400 0.600 0.800 1.000 1.200 1.400 1.600 1.800
Rock Height H (m)
Pro
ba
bil
ity
De
ns
ity
(m
^-1
)
k = 10%
k = 20%
k = 30%
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RADIOSS – The Standard behind Structure Safety
Multiphysics Analysis and Optimization
Crash SafetyDrop &
Impact
Blast &
Hydrodynamic
Impact
Terminal
Ballistic
Fluid
Structure
Interaction
Forming &
Composite
Mapping
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Automotive Crash Simulation
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Improving Helicopter Survivability
• Challenge
• Improve survivability
• Reduce costs and risk of qualification tests
• Solution
• Employ Radioss for impact and crash simulations
• Landing phase analysis
• Impact studies
• Seat behavior analysis
• Results
• Improved survivability
• Reduced number of qualification tests
MotionView
“We appreciate the responsiveness of the development team
to Eurocopter’s specific requirements“
Pierre Prudhomme Lacroix, Manager Structural Analysis
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Structure
Domain 1
FLUID
Domain 2
9,000 shells
dt = 1.4 ms
130,000 bricks (~15x)
dt = 14 ms
Elapsed times ( 8 cores )
Monodomain : 65h50mn
Multi-Domain: 12h18mn
Fluid-structure interaction – Normal Force
AIRBUS-ONERA benchmark airplane ditching
Multi-Domain Approach / ALE v. Lagrange modeling in FSI
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Example 3: Aero Simulation
Helicopter Survivability
Model: Helicopter floor structure
Objective: Improve survivability of cabin
crew under crash landing
Loading: Crash landing Vi= 3-10 m/s
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Example 3: Aero Simulation
Helicopter Sinus Beam
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Impact Simulations
Animation from t=0ms to t=150ms
Front Side
Back Side
Cracks Pattern: opening and closure
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AcuSolve – Better Technology, Better Solution
Multiphysics Analysis and Optimization
Fluid-
Structure
Interaction
Thermal
ManagementComputational
Aero-acoustics
Non-
Newtonian
Flow
Simulation
Electronic
CoolingAerodynamics
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Wind turbine
• Motivation
• Rotor diameter of 10m
• FSI between rotating blades and tower
• Numerical model
• Transient analysis
• DES turbulence model
• 20 structural modes (from Radioss)
• Sliding mesh approach for rotating blades
• Deforming mesh around the blades (boundary layer
mesh deforms with the structure)
• 14Mio cells 48 cores 4h per blade revolution
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MotionSolve - Optimize System Performance
Multiphysics Analysis and Optimization
Kinematics &
DynamicsStatics &
Quasi-staticsLinear and
Vibration
Loads
ExtractionEffort
Estimation
Packaging
Synthesis
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair’s MBS Solution at DaimlerChrysler Consult Graz GmbH
• Challenge
• Generate Load Histories for Durability
Analyses
• Solution
• Modular simulation model to serve multiple
configurations
• Frame and body structure modelled as
flexible bodies
• Results
• Validated vehicle model
• Virtual prototype to assess different
methods for virtual durability testing
"MotionSolve delivers accurate component
loading histories for durability analysis"
Nenad Bozic
Senior Engineering Manager
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Case Study
Virtual Testing at Daimler Chrysler
• Challenge
• Assess and optimize durability performance of body parts
• Static load cases do not correlate with physical tests
• Solution
• Replicate physical test procedure within MotionView
• Combine multibody simulation with fatigue life predictions
• Results
• Simulated critical fatigue locations match physical tests
• Optimized durability performance
baseline optimized
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
FEKO – Leader in High-frequency Electro-Magnetics
Multiphysics Analysis and Optimization
Antenna
Analysis &
Placement
EMC
AnalysisBio-EM
Cable
CouplingRadar Cross
Section
Wave
Guides
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Process Simulation and Design Optimization
Metal
ExtrusionPolymer
ExtrusionForming
Friction Stir
WeldingMetal
Rolling
Altair Manufacturing Solutions
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HyperForm
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperXtrude / HyperStudyOptimization of a Profile Flow
• Velocities of material flow are influenced to a great amount by the friction
length of the tool (called „bearing length)
• Changing the bearing lengths leads to different velocity results,
short bearing = high velocity, longer bearing = slower velocity
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ideation and Conceptual Design: SolidThinking EVOLVE
• 3D industrial design and conceptual modeling tool
• Сreate surface and solid geometry easily, rapidly and cost-effectively
• Create photo-realistic renderings of models
• Geometry
• H3D results
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Construct Build Test
Traditional Development-Process
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InnovationSimulation Inspiration
Simulation Driven Design
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Air Spring Carrier
Original Design:
Inspire Design Proposal
Final Design: - 55% mass!
*Source:. Hoepke, S. Breuer
(Hrsg.),Nutzfahrzeugtechnik, Vieweg+Teubner,
Wiesbaden 2013
*
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Modeling and Visualization: Post-Processing
Post-Processing and Data Analysis
HyperView
Result Visualization,
High performance
architecture,
Advanced reporting
functionality,
Solver independent
HyperGraph
Data analysis with automatic
plot generation
Mathematical library for
advanced analyses
3D Result plotting
HyperMath
General purpose
numerical computing
Allows to easily develop
and perform custom
mathematical operations
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Automated Reporting – Overview
Create / exchange / present simulation result reports frequently
• Applicable when simulations need to be analyzed part / component / group based
• Embedded in HyperView solution loops over all defined groups and load case
and creates a single report page each
Independent of industry, product type, simulation type or simulation
result type
• Analysis is based on given results and load cases, e.g. frequency responses
analysis or eigenforms (NVH)
• Analysts performing Stress analysis, frequency response analysis, durability
calculation, model optimization
Reduce the time to assess the simulation results for 10 components
and 10 loadcases from 6 h to 45 min
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
PBS Works
• PBS Professional is an open workload management solution that
maximizes the efficiency and utilization of high-performance
computing (HPC) resources and improves job turnaround in a number
of industries.
Policy for
resource
allocation
PBS Pro
Projects
Input
Files
Applica-
tionsCPUs
Memory
Disks
Custom
Codes License
Servers
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Value-based Business Model: HyperWorks Licensing
Innovative licensing system to reduce software costs and increase
utilization … translates into immediate cost saving and increased flexibility
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperWorks Unit Chart
Product 1
Product 2 Product 3Nu
mb
er
of
HW
U u
se
d
Leveling
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair Partner Alliance (APA)
Material Library
ManufacturingThermal
Analysis
Durability & Fatigue
NVH
CFD Impact
Additive
Manufacturing
Complexity
Management
Stress
Mathematics
& Analytics
Project Management
Engine
Simulation
EMS
1D
Systems
MBD Rendering
Composites
Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperWorks: Performance Enhancing Software Suite