altair hyperworks - · 2019-08-26 · hyperworks – a platform for innovation • hyperworks...
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Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 11. Dresdner-Probabilistik-Workshop
Altair HyperWorksDriving the Product Development
Process of Turbomachines
Altair Engineering GmbH
Dr. Dominik SchlotzDirector Business Development
Dresden, 09.10.2008
1. Dresdner-Probabilistik-Workshop
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 21. Dresdner-Probabilistik-Workshop
AGENDA
� Company Overview
� HyperWorks – A Platform for Innovation
• HyperWorks Overview
• Altair HyperWorks Morphing Technology
• Design Studies with solver-neutral
Software Altair HyperStudy
� HyperWorks Applications
� Summary
� Q&A
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 31. Dresdner-Probabilistik-Workshop
AGENDA
� Company Overview
� HyperWorks – A Platform for Innovation
• HyperWorks Overview
• Altair HyperWorks Morphing Technology
• Design Studies with solver-neutral
Software Altair HyperStudy
� HyperWorks Applications
� Summary
� Q&A
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 41. Dresdner-Probabilistik-Workshop
Altair – Global CAE Supplier
� Founded 1985 in Detroit, USA
� ~1400 Colleagues
� 30 Offices worldwide
� More than 3,500 Customers
Seattle, USA
Los Angeles, USA
Austin, USA
Dallas, USA
Toronto, Canada
Windsor, Canada
Detroit, USA
Boston, USA
Milwaukee, USA
Atlanta, USA
Sao Paulo, Brazil
Lund, Sweden
Gothenburg, Sweden
Leamington, UK
Manchester, UK
Boeblingen, Germany
Cologne, Germany
Hamburg, Germany
Hannover, Germany
Munich, Germany
Paris, France
Sophia Antipolis, France
Toulouse, France
Torino, Italy
Milan, Italy
Moscow, Russia
Delhi, India
Pune, India
Bangalore, India
Beijing, China
Shanghai, China
Tokyo, Japan
Osaka, Japan
Nagoya, Japan
Seoul, Korea
Melbourne, Australia
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 51. Dresdner-Probabilistik-Workshop
AutomotiveAutomotive AerospaceAerospaceHeavy Heavy
EquipmentEquipmentGovernment / Government /
DefenseDefenseLife Sciences/ Life Sciences/
Earth SciencesEarth SciencesConsumer Goods / Consumer Goods /
Oil & GasOil & Gas
Industry Verticals
Over 3.500 Customers in Various Industries
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 61. Dresdner-Probabilistik-Workshop
Altair Technology Groups
Technology to analyze, optimize and visualize information for decision makers
in business and engineering
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 71. Dresdner-Probabilistik-Workshop
� Market leader for modeling, visualization and optimization of complex mechanical systems
� A Platform for Innovation - Powerful,
open and easy to program design environment for mechanical
engineers in all industries
Computer-aided engineering software suite for product design and manufacturing
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 81. Dresdner-Probabilistik-Workshop
� Market share leader with over 30,000 deployments worldwide
� PBS Professional and OpenPBS
� Proven scalability and reliability on the largest and most complex data centers
� Mature Eco-System partner network ensures seamless integration and ease
of deployment
� It’s EveryWare! - Manages
heterogeneous mix of Unix, Linux and Windows systems
Grid computing technology that maximizes the ROI of enterprise IT assets
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 91. Dresdner-Probabilistik-Workshop
The shortest distance between concept and reality
High value and innovative product design, process mapping
and automation consulting services
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 101. Dresdner-Probabilistik-Workshop
Altair Engineering Inc.
‘94 ‘96 ‘99 ‘03 ‘04 ‘05 ‘06 ‘07‘85 ‘89
Exhibiting Strong Software Growth
Europe 2007: +50%
Total revenue 2007: ~140 M USD
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 111. Dresdner-Probabilistik-Workshop
AGENDA
� Company Overview
� HyperWorks – A Platform for Innovation
• HyperWorks Overview
• Altair HyperWorks Morphing Technology
• Design Studies with solver-neutral
Software Altair HyperStudy
� HyperWorks Applications
� Summary
� Q&A
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 121. Dresdner-Probabilistik-Workshop
Altair HyperWorks - Overview
Modeling &
Visualization
VisualizationVisualizationHyperView
Multi-Body DynamicsMulti-Body DynamicsMotionView
Finite ElementsFinite ElementsRADIOSS
Concept & DesignConcept & DesignOptiStruct
Multi-Body DynamicsMulti-Body Dynamics
MotionSolve
Analysis Optimization Manufacturing
ExtrusionsExtrusionsHyperXtrude
ForgingForgingAltair Forging
MoldingMolding
Altair Molding
Fr. Stir WeldingFr. Stir WeldingAltair Friction Stir Welding
CAE Data ManagementCAE Data ManagementAltair Data Manager
Process AutomationProcess AutomationAltair Process Manager
Sheet MetalSheet MetalHyperForm
Finite Element Finite Element HyperMesh/HyperCrash
Multi-DisciplinaryMulti-DisciplinaryHyperStudy
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 131. Dresdner-Probabilistik-Workshop
Open Architecture for Better Integration into
Enterprise PLM Architectures
� CATIA
� UG
� Pro/E
� IGES
� STEP
� Adams
� Abaqus
� Ansys
� Deform
� Dyna
� Fluent
� Madymo
� Moldflow
� Nastran
� Permas
� PamCrash
� Radioss
� Simpack
� StarCD
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 141. Dresdner-Probabilistik-Workshop
Efficient Preprocessing
� HyperMesh
• Geometry cleanup, automated or manual
• Meshing and assembly for rapid FE model
development
• Advanced Hex-meshing
• State-of-the-art solver interfaces
� BatchMesher
• Automated “Batch” Meshing and Assembly
• Performs geometry cleanup and auto-meshing (in a “batch” mode) for CAD files
• Operates on shell meshes
• Significantly reduce model cleanup and
meshing time
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 151. Dresdner-Probabilistik-Workshop
Morphing Technology
� HyperMorph (embedded in HyperMesh)
What is morphing?
Derive from metamorphose, transformation
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 161. Dresdner-Probabilistik-Workshop
Morphing Existing Models to New Designs
� Description
• Rapidly change geometry of existing FE model
interactively or parametrically
• Adapt existing FE models to new design data
� Benefits
• Dramatic reduction in modeling time
• Enables rapid “What If?” studies
� Application Examples in Gas Turbine Industry
• “System Level Morphing” - HyperMorph is used to
perform morphing of an engine model to allow
rapid assessment of bearing and seal
location/configuration
• “Component Morphing” – Turbine blades morphed
to “in-operation” shape
Example for cyclic morphing
before
after
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 171. Dresdner-Probabilistik-Workshop
Rapid Evaluation of “Concessions”
� Description
• Rapidly assess the usability of out-of-spec high value
components
• FE model is morphed to the “as manufactured”
geometry, loads and boundary conditions are retained
• Assessment usability made within the one week
deadline
• Components on which this has been used include
turbine blades and engine casings
� Benefits
• Significant cost savings by using high value
components that were usually scrapped
• Just one of the concessions saved by this
manufacturer more than covers the price of a HyperWorks license for HyperMesh
Nominal
Out-of-spec
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 181. Dresdner-Probabilistik-Workshop
� HyperView
• Engineering analysis of test data and
simulation results
• Report templates
• Rapid post-processing of design iterations
• Automated report generation
• Publish to HTML and MS/Office
• Results mapping from one analysis to a successive analysis
• Test data correlation and advanced data
analysis
• Comprehensive support of virtually all
commercial solvers, including ANSYS,
NASTRAN and LS-DYNA
• Readers for “in-house” codes can be created
Results overlay
Common Post-Processing Environment
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 191. Dresdner-Probabilistik-Workshop
� Altair Process Manager
• Process management and
authoring environment to capture
best practices for design processes
• Enables integration of diverse
applications (from CAD, to in-house
applications, to HyperWorks) in
organized work flows
� Altair Data Manager
• Product performance data management and decision support
driven by already established
engineering processes
• Manage engineering work-in-process data in the context of
existing PDM system
Process Automation and Data Management
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 201. Dresdner-Probabilistik-Workshop
Today…
Altair…
Altair’s Vision
Optimization is Driver in CAE Driven Design Process
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 211. Dresdner-Probabilistik-Workshop
Optimization & Design Studies
… generic study
tool for arbitrary
solvers, includes
DOE and
Stochastics
… with integrated
FEA solver
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 221. Dresdner-Probabilistik-Workshop
Performing Design Studies
� Altair HyperStudy
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 231. Dresdner-Probabilistik-Workshop
� Solver Neutral
� Direct parameterization: Automatic transfer of modal parameters from e.g. HyperMesh/HyperMorph
� Integrated with HyperWorks thru HyperMesh, MotionView and direct solver interfaces
� Multi-Solver Study: sequential or parallel
� Integration of grid computing software PBS professional
Model
ResultsResultsResultsResultsResults
VariantVariantVariantVariantVariant
SimulationSimulationSimulationSimulationSimulation
Study Results- Optimal Parameters
- Sensitivities
- Model Robustness
- …
Study Results- Optimal Parameters
- Sensitivities
- Model Robustness
- …
Creation
JobManagement
Extraction
Study
Engine
Study
Engine
Design Studies with Altair HyperStudy
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 241. Dresdner-Probabilistik-Workshop
Process Flow in HyperStudy
Setup
DOE
Approximation
Optimization
Stochastic
Process DefinitionProcess Definition
Study DefinitionStudy Definition
Pro
cess
Flo
w
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 251. Dresdner-Probabilistik-Workshop
AGENDA
� Company Overview
� HyperWorks – A Platform for Innovation
• HyperWorks Overview
• Altair HyperWorks Morphing Technology
• Design Studies with solver-neutral
Software Altair HyperStudy
� HyperWorks Applications
� Summary
� Q&A
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 261. Dresdner-Probabilistik-Workshop
Shape Optimization of a Turbine Blade Root
� Objective
Minimize stresses and strains at the root of turbine blade where it attaches to the disc to improve fatigue life
� Software Tools
• FE Model development – HyperMesh
• Solver – ANSYS
• Shape variable definition – HyperMorph
• Optimization setup – HyperStudy
• Optimization – HyperStudy
� Cyclic symmetry boundary conditions
� Two cases – 8500 rpm & 4000 rpm Elements Used: Solid 45, Solid 95 Total No. Elements: 305,524
Total No. Nodes: 304,061
Region of interest
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 271. Dresdner-Probabilistik-Workshop
Shape Optimization of a Turbine Blade Root
� Shape variables definition with HyperMorph
R2
R1
θ
W1
H
VW2
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 281. Dresdner-Probabilistik-Workshop
Shape Optimization of a Turbine Blade Root
� Elastic-Plastic Analysis Optimization Results (8500 RPM)
Baseline DesignMax SEQV = 768 MPa
Max Strain = 0.00808
Optimized DesignMax SEQV = 746 MPa
Max Strain = 0.00603
0
100
200
300
400
500
600
700
800
900
1000
0 0.002 0.004 0.006 0.008 0.01 0.012
Strain
Str
ess
(M
Pa
)
EP
Elastic25%
Baseline Shape
Optimized Shape
Leads to significant improvement in fatigue life
25% reduction in strain
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 291. Dresdner-Probabilistik-Workshop
Engine Compressor Blade Optimization
� Challenge
• Increase pressure ratio of radial compressor
through optimized blade design
� Solution
• CFD optimization using HyperStudy
• Shape optimization with morphing
• Objective: maximize pressure relation between inlet and outlet
� Results
• 5.6% increase in pressure ratio, which leads to
better fuel efficiency and higher engine power
“Including HyperWorks and CFD in the design process cuts development time and enables us to perform automated design and optimization studies.”
Dr. Mario Dittmann, MTU Friedrichshafen GmbH
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 301. Dresdner-Probabilistik-Workshop
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: Therefore virtual design approach
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 311. Dresdner-Probabilistik-Workshop
Optimization and Reliability Analysis of a Mars Lander
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 321. Dresdner-Probabilistik-Workshop
Reliability Study: Range of Conditions
Only rock impact load case considered
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)P
rob
ab
ilit
y D
en
sit
y (
m^
-1)
k = 10%
k = 20%
k = 30%
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 331. Dresdner-Probabilistik-Workshop
Results
Design Variable Change
OptimizedResponses
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 341. Dresdner-Probabilistik-Workshop
Optimization and Reliability Analysis of a Mars Lander
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 351. Dresdner-Probabilistik-Workshop
AGENDA
� Company Overview
� HyperWorks – A Platform for Innovation
• HyperWorks Overview
• Altair HyperWorks Morphing Technology
• Design Studies with solver-neutral
Software Altair HyperStudy
� HyperWorks Applications
� Summary
� Q&A
Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information 361. Dresdner-Probabilistik-Workshop
Summary
� Deep Knowledge of CAE Design Processes
• CAE Process Automation / Integration
• How to Best Exploit CAE Software and Methods
• Provide Mentoring and Best Practices – Comfortable with Technology Transfer
� HyperWorks, Integrated Suite of CAE Tools to Drive Product Innovation
• HyperMesh: Highly Advanced Preprocessor Increasing your Efficiency
• BatchMesher: Fully Automated Geometry Cleanup and Shell Meshing
• HyperMorph: Allowing Rapid Design Changes Resulting in Dramatic Cost Savings
• HyperStudy: DOE, Multi-disciplinary Optimization and Stochastic Simulation Engine
� Altair is a Reliable Business Partner – Exhibiting Strong Growth
• Flexible HyperWorks Licensing Concept Reducing Software Costs
• Passing on Business Benefits to Customer, e.g. HyperWorks Enabled Partner
Program