7/16/2014

Engineering Simulation for Design

Simulation Workshop EIMA RACE 2014

Introduction of FEA/FEM
WHAT IS FEA?
Finite Element Analysis (FEA) is a computerized
method for predicting how a real-world object
will react to forces, vibration, heat, and etc. in
terms of whether it will function as planned.


 
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Introduction to HyperMesh
Geometry Clean - Up

Geometry Terminology

Red edge Free edge, no connectivity

Green edge Shared edge, Z surf shared 1 edge connection
Yellow edge T-junction, 3 or more surf shared 1 edge connection & duplicates
Blue edge Suppressed, hidden

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Hypermesh (General Pre-Processing)

1. Open : User Profiles > choose solver (Optistruct/Radioss)
2. Choose display option : Auto
Mixed
3. Opening File >
Open > hm file only
Import > model, solver deck, geometry, connectors
Export > model, solver deck, geometry, connectors

Solver deck = FE (meshing, material, property, BCs)

Geometry = CAD (surface, solid)
Model = hm files

4. Review Component : Model Browser & Check File (Display)

5. Organize
-Rename/Move/Copy to new comps
-Geometry > Organize > Surface
-Create new comp (right click > create > comp)
-delete empty components

6. Geometry, Topology & Surface Clean-up

-edge edit, quick edit, defeature, midsurface
-Surfaces, Solid
-Stitching connecting surface
-Edge Edit (Geometry > edit > surface > edges)
- Quick Edit (F11)

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Geometry > Edit > Surface Edges > Toggle (Stitching/Toggling)

mouse click - left (Red > Green > Blue)
- right (Blue > Green > Red)
a. Clean-up tool
- Gap tolerance
- Equivalence - auto stitch
- surf (displayed)
- stitching (all)
b. To delete/move duplicates surface
1. F2 > delete > surf
2. defeature > duplicates > choose surf > find > del
c. Simplify Geometry > defeature - Remove fillet, pinholes, duplicates, symmetry
Remove pinholes > choose surf > displayed > diameter : 30mm > find > del

Introduction to HyperMesh
Meshing 1D/2D/3D

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Meshing
1. RBE/HyperBeam (1d elements)

2. AutoMesh (2D element only)

Mesh > Create > 2D AutoMesh or F12

3. TetraMesh (Tetra4)
Mesh > Create > Tetra Mesh

AutoMesh (need a surface & elements re-mesh)

Choose surface

Element Size
Mesh Type

Split Surface

> choose mesh type > key in element size > mesh
- density (to control number of elems)
- mesh style (to change element type)
- biasing (to change element side)
- checks ( 1st quality checks)
- Geometry Size
- Analysis Type
- Analysis Type
- Accuracy
F2 = delete
- Solid Mesh
F11 = Quick Edit
F12 = AutoMesh
- Trim for Meshing

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Checking (nodal connectivity & element quality)

Checking/Editing

- Quality Index (2D only)

- Element Check (1D,2D & 3D) > F10
- Edges/Face > Shift+F3 (nodal connectivity)
- Replace > F3

Nodal Connectivity
- Replace > F3 (manually replace node)
- Edge
> choose element > displayed
> tolerance : start with small
> preview Equivalence (to find)
> equivalence (to connect)
> find Edges (to check)
> delete Edges

Element Quality
-Quality Index
- Check elem - warpage
- jacobian
- aspect ratio
- skew
- length
- angle

TetraMesh (3D Mesh/SolidMesh)

Manually

- create/delete 2D Face
- check 2D/3D Quality
- create 3D Element

Auto - create 3D Mesh

- check 3D Quality

Volume Tetra - auto

Tetra Mesh
- manual (need to have 2D elems)
Tetra Remesh - Remesh tetra for better quality
-check elems
1. Tets collapse
> save failed
> mask (choose elems)
> retrieve (reverse)
2. Utility > QA Model > Find Attached
To delete 2D element
F2 > delete > elems > by config > tria3

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Introduction to HyperMesh
Analysis Setup Linear static

Linear
1. Material (SSC)
2. Small deformation
3. Contact > rigid (no contact simulation)
4. Time > small

Create Problem/Test Setup In Software Environment

1. Create - Model Broswer > Create >Component
- Material > update/edit
- Property > update/edit

2. Assign

- assign Material & Property

3. Loadcase - define analysis type

choose load
choose boundary condition

4. Solve

- send to solver

5. Result verification -stress

-displacement

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1. Material & Properties

Edit component
-assign > property -Pbeam, Pbar, Pweld, etc (1D)
-PSolid (3D)
-PShell (2D)
-assign > material -Mat1, Mat4, Mat9, etc
-law1, law2
-isotropic
-Update

2. Assign Boundary (load & constraint)

-create load collector
-assign load/constraint
-Analysis 1. Force > make current
> choose nodes
> choose value (N/KN)
> axis/direction

2. Constraint > make current

> choose nodes
> choose d.o.f (select on fix)

3. LoadStep (setup)
-define type of analysis
-assign boundary collector
4. Solve : OptiStruct (FEM & Result)

5. HyperView

- stress
- displacement
- contour

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Introduction to HyperMesh
Analysis Setup Non Linear Impact

Non Linear
1.Material (SSC)
2.Large deformation
3.Contact
4.Time > large

Create Problem/Test Setup In Software Environment

1. Create

- Component
- Material > update/edit
- Property > update/edit

2. Assign

- assign Material & Property

3. Rigids

Create > Component

1D page > rigids > choose nodes

4. Interfaces

- Analysis page > interfaces > create

5. Rigid Wall

- Tools > Create cards > RWALL > Plane

- choose the node

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6. Boundary condition & velocity

7. Engine File

-Utility > BCs Manager

- create boundary condition & velocity

- Analysis Page > Control Card

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8. Solve

- send to solver

9. Result verification

-stress
-displacement

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