Download - SOGETI Altair User Conf Sogeti 20091102
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8/9/2019 SOGETI Altair User Conf Sogeti 20091102
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg
Hyperworks in the Analysis and Optimizationof Composite Structures
Ersteller: Markus Longeru
E-Mail: [email protected]
Datum: 02. November 2009
ALTAIR3rd European HTC Ludwigsburg November 2nd- 4th, 2009
Markus Longeru Volker Grund
Technical Leader Stress Engineer
Abstract
The presentation Hyperworks in the Analysis and Optimization of Composite Structures provides an overview of the use of ALTAIR softwareapplications in engineering supplier tasks.The presentation shows the main fields of activities, where ALTAIR products lead to advantages by means of calculation quality and project
performance. On the exemplary projects, that have been performed by SOGETI HighTech, such as meshing an AIRBUS wing cover, calculatevibration and shock of a ship antenna, optimizing military antenna structures made of GFRP and secondary aircraft structure made of CFRP theapplication for various industries with their specific problems and solutions will be shown.
For the wing cover, a detailed FE model of shell elements is generated, which needed a high grade of automation due to a large model with ahigh amount of elements and special demands. The ship antenna is an interesting example for the postprocessing of shock analysis while the
military antenna structure, made of GFRP has been optimized regarding its weight using topology- as well as composite optimization tools.
Finally, for the secondary structure example, a pilot project from Sogeti HighTech will be discussed where a metallic bracket has beentransformed to CFRP. Within the project the bracket has been sized, manufactured and tested. On this example the whole process fromstructural concept, pre-dimensioning, optimization and test calculation will be shown.
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 2
Introduction
Agenda
Sogeti High Tech
Technical
Advantages
Summary &Conclusions
Introduction
Agenda
Sogeti High Tech
Technical
Workflow and Tools
Pre-processing
SolverPost-processing
Optimization
Advantages
Technical View
Commercial View
Summary & Conclusions
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Introduction -
Agenda
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 3
Introduction -
Sogeti HighTech
Introduction
Agenda
Sogeti High Tech
Technical
Advantages
Summary &Conclusions
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
83.500 Employees
8,7 Billion worldwide
20.000 Employees
15countries,with200+localoffices
Sweden
SwitzerlandSpain
France
Benlux
The Netherlands
U.S.A.
Ireland
Denmark
United Kingdom
India
3.500 Employees
9 Countries
350 Employees
focus on fix priceprojects
8 locations
EN(AS) 9100; DIN
EN ISO 9001:2000
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 4
Introduction
Agenda
Sogeti High Tech
Technical
Advantages
Summary &Conclusions
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Activities
Numerical Simulation
DMU and Simulation
Design and Drafting
Jigs and tools
Quality management
Testing
Introduction -
Sogeti HighTechGeneral Information
Engineering Services focused on theAerospace-, Transportation-, Energy- and
Machinery Industry
Team of more than 350 skilled engineers,designers and draftsmen
Certified EADS E2S-Supplier
Certified Airbus 1.Level-Supplier (BSF006)
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 6
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
Pre-ProcessingPreparation of GeometryBrackets Metallic and Composite
Generation of Midsurfaces
- Advanced tools for midsurface manipulation- Connect Midsurfaces- Convert radii to corners
- Automated property definition- Using the midsurface option
Hypermesh keeps the thickness inmind and can assign it automaticallyto the elements
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions Defeaturing
- Close small holes- Eliminate radii -> Edge / Surf Fillets
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 7
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
Pre-ProcessingMeshing and Property definition
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
Detailed Model of Test Specimen
Skin
Spar
Ribs
Generate Midsurface
Mesh generationrespecting ramps andgeometric contours
Automated PCOMPExtraction from CATIA(1 Prop per Elm)
TCL Scripting forgenerating property sets(delete redundancies)
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 8
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
Pre-ProcessingTCL Scripting Tasks
Generate stringer foot elements Double elements
Duplicate global nodes and renumbering
Offset stringer blade by RBE2 ElementsOffset equal to average thickness ofsurrounding skin elements
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
CFRP Wing Cover
Structure
Idealization
Model Size 33 Ribs 19 Stringer115000 Elements
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 9
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
Pre-ProcessingData Consintency
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
Input / Output- Comments and entries that are not knownby Hypermesh are kepf in the .bdf
- are moved to the end of the file
- .bdf files become very large due toHypermesh comments
- can be swiched off in V10
Components from geometry file
- Components are automatically generated- By Hypermesh comment- By Property- By One component
Sustain file structures
- Include structure can be conserved
Property IDs- Division Hypermesh ID / Solver ID
- may be different- may lead to user errors
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 10
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
Pre-ProcessingPre-Processing Evaluation
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
Quality Performance
Precise Geometry Data
Good Mesh Quality
Less errors due to routines
Fast GUI -> Needs Training
High Level of Adaptivity
Relatively fast Geometryupdate
Low effort for midsurface
modification beforemeshing
Fast thickness definition forisotropic properties orPSHELL idealization
Scripting for repetitive tasks
Fast adaption of geometryupdates with morphingfunction
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 11
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
SolverCompatibility to various solvers
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
Conversion of NASTRAN Models toABAQUS
Solver Independant software package-> Good fit to all types of solvers
Problems HypermeshV9:
NASTRAN RBE3toABAQUS DCOUP3D
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 12
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
Post-ProcessingStatic Analysis
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
Static analysis of CFRP structures are mostly performedusing own Java Tool package due to
- Automation- Number of LC- Individual content of result tables- Easy implementation of arbitrary failure criteria
- etc.
Results for compositeJustification:
Element Forces (Fluxes)- In Material Axes
Element Strains- In Material Axes
Free-Body Forces
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 13
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
Post-ProcessingDynamics
Military Ship Antenna
Weight Optimization at best structural Performance at
Wind Loads Movement of the Ship
Shock
Vibration
Top Load of 50kg
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 14
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
Post-ProcessingDynamics
Military Ship Antenna
10 times deformation scale15 time steps [0s, 0.9s]
0 times deformation scale15 time steps [0s, 0.9s]von Mises stresses
Displacements per Timestep Stresses per Timestep
Shock 120g for 15ms
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 15
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
Post-ProcessingPost-Processing Evaluation
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
Quality Performance
Good result quality forisotropiy materials
(v.Mises, etc)
Impossible to relate resultsto material coord system(Composite Materials)
TCL differs fromHyperMesh
Large result files can behandeled
Interface to partnerProducts (FEMFAT)
Limited Adaptivity for ownjustification criteria
FEMFAT Plot
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 16
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
OptimizationOptimizing Composites
Weight Optimization of Aircraft Primary Structure
Primary Structure made of Foam Sandwich
Model:
Foam and Booster idealized with CHEXA8,
CPENTA, CTETRA Elements
CFRP Covers idealized with CQUAD4 Elements
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 17
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
OptimizationOptimizing Composites
Weight Optimization of Aircraft Primary Structure
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
Booster
Skin
Core
CTETRA
CPENTA
CHEXA
CQUADModel Created by
own Routines
Manual Work(Cleaning) done inHypermesh
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 18
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
OptimizationOptimizing Composites Free-Size
CFRP Foam Sandwich Structures
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
Load:Combined Torsion / Bending
Start plies:3 plies (+ 45; 0; -45)
Constraints:Displacement in Tip
Objective:Minimize Mass
0Plies
45Plies
-45Plies
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 19
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
OptimizationOptimizing Composites Ply Optimization
CFRP Foam Sandwich Structures
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
Initial Sets (Global Ply Ids)
Resultant Thickness per Set
First shot Results for45Plys
Constraint: Design Space:
3500 Skin only
Objective:Minimize Mass
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 20
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
OptimizationOptimization Evaluation
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
Quality Performance
Hints for required fibredirections
Essencial hints for patchdesign
Number of layers neededfor applied loads
Calculation time for thegiven example:
Approx. 4-5 hours
Comfortable GUI
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Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Advantages -
Commercial View
Costs
Lower Costs due to
Time Saving
Quick Geometry Updates
Direct way to good meshquality
Partner Program
Licence System
Price Performance Ratio
Constant use of Units required
to use Hyperworks effectively
Partner Products
Presently in use at Sogeti High Tech:
FEMFAT
Support
Good and Quick Support
Quick & Effective Answers
Licence System
Stacking
Introduction
Technical
Advantages
Technical View
Commercial View
Summary &Conclusions
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Summary & Conclusions
Thank You For Your Attention
Questions?
Suggestions?
Please contact:
Markus Longeru Volker Grund
Technical Leader Stress Engineer
Tel.: +49 (0)40 743 60185 Tel.: +49 (0)40 743 60275
[email protected] [email protected]
Introduction
Technical
Gain in Experience
Advantages
Summary &
Conclusions
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
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Dieses Dokument und alle darin enthaltenen Informationen sind das
alleinige Eigentum von Sogeti High Tech GmbH. Die Zustellung diesesDokumentes oder die Offenlegung seines Inhalts begrnden keine Rechteam geistigen Eigentum. Dieses Dokument darf ohne die ausdrckliche
schriftliche Genehmigung von Sogeti High Tech GmbH nicht vervielfltigtoder einem Dritten gegenber enthllt werden. Dieses Dokument und sein
Inhalt drfen nur zu bestimmungsgemen Zwecken verwendet werden.
Die in diesem Dokument gemachten Aussagen stellen kein Angebot dar.Sie wurden auf der Grundlage der aufgefhrten Annahmen und in gutemGlauben gemacht. Wenn die zugehrigen Begrndungen fr dieseAussagen nicht angegeben sind, ist Sogeti High Tech GmbH gern bereit,
deren Grundlage zu erlutern.
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 24
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
Pre-ProcessingBoundaries & Loads
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions
Stationary Antenna
Definition of Ice and Wind Load
Ice Masses as CONMElements
Wind loads on beamelements as forcevectors
Wind loads onsurfaces as pressuredistributionEquation on sphericalcoordinates
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 25
Markus Longeru
Technical Leader
Analytical &Numerical Simulation
Hyperworks in theAnalysis andOptimization ofCompositeStructures
Technical -
OptimizationOptimizing Composites
Optimization of Stiffener Position
GFRP Radar Dome
Variation of Size and Location ofStiffeners to maximum stiffness
Aim of Optimization:
All Eigenfrequencies >20Hz
Dimensions:
4,5m in Height
3,5m in diameterIntroductionTechnical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary &Conclusions