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![Page 1: Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff](https://reader034.fdocuments.in/reader034/viewer/2022052504/54bd8ca24a7959ca5a8b45f8/html5/thumbnails/1.jpg)
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
![Page 2: Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff](https://reader034.fdocuments.in/reader034/viewer/2022052504/54bd8ca24a7959ca5a8b45f8/html5/thumbnails/2.jpg)
Contents
• Preface
• Objectives and Description
• Modeling in HyperMesh
• Baseline Analysis using HyperWorks Solvers
• Optimization using HyperStudy
• Validation using HyperWorks Solvers
• Conclusions
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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
![Page 4: Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff](https://reader034.fdocuments.in/reader034/viewer/2022052504/54bd8ca24a7959ca5a8b45f8/html5/thumbnails/4.jpg)
Objectives and Description
Short Version
Long Version
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Modeling in HyperMesh
Short Version Long Version
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Baseline Analysis
using HyperWorks Solvers
Short Version Long Version
Analysis Type #1:
Push-test stiffness under boundary condition #1
X Y
Z
X Y
Z
X Y
Z
X Y
Z
X Y
Z X Y
Z
X Y
Z
X Y
Z
X Y
Z
X Y
Z
![Page 7: Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff](https://reader034.fdocuments.in/reader034/viewer/2022052504/54bd8ca24a7959ca5a8b45f8/html5/thumbnails/7.jpg)
Baseline Analysis
using HyperWorks Solvers
Analysis Type #2:
Push-test stiffness under boundary condition #2
Short Version Long Version
![Page 8: Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff](https://reader034.fdocuments.in/reader034/viewer/2022052504/54bd8ca24a7959ca5a8b45f8/html5/thumbnails/8.jpg)
Baseline Analysis
using HyperWorks Solvers
Analysis Type #3:
Modal analysis
Short Version Long Version
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Baseline Analysis
using HyperWorks Solvers
Analysis Type #4:
Non-linear impact analysis
Short Version Long Version
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Optimization using HyperStudy
Short Version Long Version
g3
g4
g1
g5
g2
g6S
g6L
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Optimization using HyperStudy
Morphing variables:
S1S for short version
S1L for long version
Morphing variables:
S2S for short version
S2L for long version
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Optimization using HyperStudy
Morphing variable:
S4
Morphing variable:
S3
![Page 13: Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff](https://reader034.fdocuments.in/reader034/viewer/2022052504/54bd8ca24a7959ca5a8b45f8/html5/thumbnails/13.jpg)
Optimization using HyperStudy
Create study
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Optimization using HyperStudy
Create models
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Optimization using HyperStudy
Create design variables
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Optimization using HyperStudy
Do nominal run
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Optimization using HyperStudy
Create responses
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Optimization using HyperStudy
Link design variables
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Optimization using HyperStudy
Create optimization study
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Optimization using HyperStudy
Define design variables
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Optimization using HyperStudy
Apply constraints
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Optimization using HyperStudy
Create objective
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Optimization using HyperStudy
Post processing
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Optimization using HyperStudy
Post processing
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Optimization using HyperStudy
Post processing – Visualize…
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Optimization using HyperStudy
Post processing – Visualize…
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Optimization using HyperStudy
Optimization
Baseline
Optimization
Baseline
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Optimization using HyperStudy
Optimization
Baseline
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Validation
using HyperWorks Solvers
![Page 30: Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff](https://reader034.fdocuments.in/reader034/viewer/2022052504/54bd8ca24a7959ca5a8b45f8/html5/thumbnails/30.jpg)
Validation
using HyperWorks Solvers
Analysis Type #1: Push-test stiffness under boundary condition #1
X
Y
Z
Short version Long version
Location 1 Location 1
1 mm 1 mm
0.1 mm 0.1 mm
0.2 mm 0.2 mm
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Validation
using HyperWorks Solvers
Analysis Type #2: Push-test stiffness under boundary condition #2
Y
Short version Long version
2 mm 2 mm
![Page 32: Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff](https://reader034.fdocuments.in/reader034/viewer/2022052504/54bd8ca24a7959ca5a8b45f8/html5/thumbnails/32.jpg)
Validation
using HyperWorks Solvers
Analysis Type #3: Norm mode
Short version Long version
30 Hz 30 Hz
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Validation
using HyperWorks Solvers
Analysis Type #4: Non-linear impact
Short version Long version
Target: < 0.5 mm Target: < 0.5 mm
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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;
![Page 35: Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff](https://reader034.fdocuments.in/reader034/viewer/2022052504/54bd8ca24a7959ca5a8b45f8/html5/thumbnails/35.jpg)
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.
![Page 36: Optimization of a Family of Supporting Frames Under Multiple Analysis Constraints Using HyperStudy - Van rob kirchhoff](https://reader034.fdocuments.in/reader034/viewer/2022052504/54bd8ca24a7959ca5a8b45f8/html5/thumbnails/36.jpg)
Thank you