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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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

    [email protected]

    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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    Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 21

    Markus Longeru

    Technical Leader

    Analytical &Numerical Simulation

    [email protected]

    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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    Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 22

    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

    [email protected]

    Hyperworks in theAnalysis andOptimization ofCompositeStructures

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    Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 23

    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

    [email protected]

    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

    [email protected]

    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