Webinar

Optimizing Sheet Metal Structures

from Designg to Manufacturingg
with
Altair Hyperworks

November 29, 2007

Fatma Kocer,, Pradeep
p Srinivasan,,
Altair Engineering
Agenda:

Challenges: Solutions:
D i off sheet
Design h t metal
t l structures
t t that
th t • Concept Design and Optimization
• meet design requirements, • Formability Analysis and Optimization
• are not overweight, • Mapping Forming Effects to Structural Model
• are manufacturable
f t bl

in an Altair HyperWorks:
• integrated, 9 integrated,
• easy-to-use, 9 easy-to-use,
• robust, 9 robust,
• flexible 9 flexible
• open 9 open
platform

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 2

Hyperworks:
A Platform to Design for Manufacturability

Design Optimization
Altair Optistruct

Formability Simulation
Altair HyperForm
yp

Optimization of Formability
Altair HyperStudy

Mapping Forming Effects to

Structural Model
HyperWorks Results Mapper

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 3

Concept Design and Optimization in HyperWorks for
Sheet Metal Structures

Determination of optimal
p p
principal
p material distribution

Determination of optimal bead patterns for shell structures

Determination of optimal shape of a given design

Determination of optimal model parameters

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 4

Topography Optimization Process

Definition of desired bead

dimensions and optimization OptiStruct proposal of optimized Interpretation of proposed
targets bead pattern bead pattern

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 5

Topography Optimization: Oil Pan

Initial Design Altair OptiStruct Optimized Design

Design Problem:
Increase first mode from 60Hz to
at least 200Hz

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 6

 Cutting Harvester Maintenance Costs at CLAAS

ƒ Challenge
• Design an easy-to-disassemble
easy to disassemble harvester
reel hub
• Goal: bolted, two-component design
• Innovative bead ppattern needed to meet
stiffness requirements

ƒ Solution
• OptiStruct topography optimization to create
optimized bead pattern

ƒ Results
• Time to repair assembly significantly reduced
• Cut in production costs: no welding needed
“OptiStruct’s topography optimization has become an
integral part of our design process to find innovative
bead ppatterns in sheet metal components.”
p
Stephan Diekhaus
CAE Manager CLAAS GmbH, Germany

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 7

Bead Optimization of a Muffler Housing Cap

Design Problem
ƒ Increase Eigenfrequencies of a
housing cap by introducing a bead
pattern
ƒ Target: Mode 1 > 255 Hz
ƒ Baseline: Mode 1 = 63 Hz

Method Used
ƒ Shape optimization to find the
optimum curvature
ƒ Topography optimization to find the
optimum bead pattern
ƒ Combination of both disciplines

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 8

Bead Optimization of a Muffler Housing Cap

Optimized Topography Combined bead and

curvature optimization shape optimization

313 Hz

Target Target Target

217 Hz
184 Hz

Base Base Base

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 9

Topography Optimization Results

Problem Formulation: Baseline Design

Maximize the first 10 frequencies
q
subjected to circular pattern constraints

OptiStruct Proposal

Modes (hz) Baseline Optimum

1 29 50
2 77 196
3 138 265
4 138 267
5 194 313

Optimum Design

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 10

Formability for Initial Manufacturing Feasibility

Initial
Design Model
Modification
From Optimization
for Formability

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 11

Optimizing Formability

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 12

Results

Modes Baseline Optimum Formed Part

(hz)

1 29 50 51
2 77 196 169
3 138 265 233
4 138 267 237
5 194 313 297

The weighted frequency of the first 10 modes has improved by 43%

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 13

What does it take?
HyperWorks Unit Chart

You only need 50 HyperWorks units to optimize

sheet metal structures from design to manufacturing

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 14

Summary

ƒ Optimizing sheet metal structures from design to manufacturing can

entirely be done with HyperWorks

ƒ HyperWorks improves productivity through innovative methods such

as concept design, optimization, and morphing.

ƒ Third party solutions can be easily integrated with HyperWorks

through its powerful interface system.

Copyright © 2006 Altair Engineering, Inc. All rights reserved. 15