Table of Contents

HyperStudy Introduction
DOE, Approximation, Optimization and Stochastic

Table of Contents ............................................................................................................... II

Chapter 1: Introduction to HyperStudy .................................................................. 1

1 – HyperWorks Overview ............................................................................................... 1

1.1 – HyperWorks Tool Descriptions ............................................................................... 2

1.2 – HyperStudy Integration with HyperWorks ............................................................... 4

1.3 – Class Objectives..................................................................................................... 5

2 – Introduction to HyperStudy ........................................................................................ 6

2.1 – HyperStudy Benefits ............................................................................................... 6

2.2 – HyperStudy Process ............................................................................................... 7

3 – DOE Study ................................................................................................................ 8

4 – Approximations.......................................................................................................... 9

5 – Optimization Study .................................................................................................. 10

6 – Stochastic Study...................................................................................................... 11

7 – Evaluation and Rating ............................................................................................. 12

8 – Configuration Tools ................................................................................................. 13

8.1 – Preference File ..................................................................................................... 13

8.2 – Old Editor ............................................................................................................. 13

8.3 – New Editor............................................................................................................ 14

8.4 – Job Management.................................................................................................. 14

8.5 – Solver Script ......................................................................................................... 15

9 – Parametrization of a FEA model .............................................................................. 16

9.1 – HyperStudy/HM-MV-HF link ................................................................................. 17

Exercise 1.1: Create Design Variables through HyperMesh .......................................... 18

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 9.2 – Parametrization using Create Template GUI ........................................................ 23

9.2.1 – What is Templex? .............................................................................................. 23

9.2.2 – Important Templex Rules................................................................................... 23

9.2.3 – Templex File Description ................................................................................... 24

Exercise 1.2: Create Design Variables using the Create Template GUI ........................ 26

10 – HyperStudy Integration .......................................................................................... 32

10.1 – List of Direct Solvers & Results Access .............................................................. 32

10.2 – Interfacing with Solvers ...................................................................................... 33

10.3 – Integration with Excel ......................................................................................... 34

11 – HyperStudy/HyperMorph Coupling ........................................................................ 35

11.1 – Shape Variable Generation using HyperMorph ................................................... 36

11.1.1 – Exporting Shape Variables .............................................................................. 37

Chapter 2: Design of Experiments (DOE)............................................................. 39

1 – Introduction ............................................................................................................. 39

2 – DOE Concepts and Definitions ................................................................................ 40

3 – DOE Study Types.................................................................................................... 42

4 – DOE Study Types - Applications ............................................................................. 46

4.1 – DOE for Screening ............................................................................................... 46

4.2 – DOE for Factorial Studies ..................................................................................... 46

4.3 – DOE for Response Surface (RSM) Evaluation ...................................................... 46

5 – Typical DOE Assessment Procedure....................................................................... 47

6 – DOE Process .......................................................................................................... 47

Exercise 2.1: DOE Study of a Rail Joint Using RADIOSS.............................................. 48

Exercise 2.2: DOE Study of a Cantilever Beam using Templex ..................................... 58

Exercise 2.3: DOE Study Using MotionView and MotionSolve ...................................... 71

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Chapter 3: Approximation ..................................................................................... 81
1– Introduction .............................................................................................................. 81

1.1 – Why Perform Approximation Study? ..................................................................... 81

1.2 – Least Square Regression ..................................................................................... 82

1.3 – Moving Least Squares .......................................................................................... 83

1.4 – HyperKriging ........................................................................................................ 84

Exercise 3.1: Approximation Study of a Rail Joint Using RADIOSS............................... 85

Exercise 3.2: Least Square Approximation .................................................................... 89

Chapter 4: Structural Optimization ....................................................................... 97

1 – Optimization Problem Statement ............................................................................. 97

1.1 – Optimization Definitions ........................................................................................ 98

2 – Optimization Methods .............................................................................................. 99

2.1 – (ARSM) Adaptive Response Surface Method ....................................................... 99

2.2 – (SQP) Sequential Quadratic programming ......................................................... 101

2.3 – (MFD) Method of Feasible Directions ................................................................. 102

2.4 – (GA) Genetic Algorithm ...................................................................................... 103

2.5 – (SORA) Sequential Optimization and Reliability Analysis ................................... 104

2.6 – (SORA-ARSM) – ARSM based SORA................................................................ 106

2.7 – User Defined – Xopt ........................................................................................... 106

3 – Optimization Problem Example ............................................................................. 107

4 - HyperStudy Optimization Case Studies .................................................................. 108

4.1 - Case Study 1: Rail Optimization .......................................................................... 108

4.2 - Case Study 2: Roof Crush ................................................................................... 110

4.3 - Case Study 3: Airbag .......................................................................................... 111

4.4 - Case Study 4: Knee Bolster Design .................................................................... 113

4.5 - Case Study 5: Exhaust System Design ............................................................... 115

4.6 - Case Study 6: Notch Design ............................................................................... 117

5 – General Discussion ............................................................................................... 121

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 Exercise 4.1: Shape and Size Optimization of a Rail Joint........................................... 122

Exercise 4.2: Size Optimization Study using RADIOSS............................................... 126

Exercise 4.3: Optimization Study Using an Excel Spreadsheet ................................... 133

Exercise 4.4: Shape Optimization Study using HyperForm.......................................... 141

Exercise 4.5: Shape Optimization Study using ABAQUS ............................................ 151

Chapter 5: Stochastic Studies............................................................................. 163

1 – Introduction ........................................................................................................... 163

2 – Random Variables ................................................................................................. 163

2.1 – Example of Random Variables (Uncertainty source)........................................... 164

3 – Statistics and Probability ....................................................................................... 165

3.1 – Probability Density Function ............................................................................... 165

3.1.1 – Normal Distribution .......................................................................................... 165

3.1.2 – Uniform Distribution ......................................................................................... 165

3.1.3 – Triangular Distribution ..................................................................................... 165

3.1.4 – Exponential Distribution ................................................................................... 165

3.1.5 – Weibull Distribution .......................................................................................... 165

3.2 – Cumulative Distribution Function ........................................................................ 169

3.2.1 – Histogram ........................................................................................................ 169

4 – Sampling ............................................................................................................... 169

4.1 – Simple Random Sampling .................................................................................. 169

4.1.1 – Latin HyperCube Sampling .............................................................................. 169

4.1.2 – Hammersley Sampling .................................................................................... 170

4.2 – Correlation.......................................................................................................... 170

4.3 – Interpreting Post-processed Data ....................................................................... 169

4.3.1 – Ant-Hill Plots .................................................................................................... 169

4.3.2 – Histogram, PDF, and CDF ............................................................................... 171

4.3.3 – Statistical Summary ......................................................................................... 172

5 – Robust Design – Stochastic Study......................................................................... 174

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 5.1 - Robustness Definition ......................................................................................... 175

5.2 – Deterministic Optimization Approach .................................................................. 176

5.3 – Robustness Optimization Approach .................................................................... 176

Exercise 5.1: Stochastic Study of a Rail Joint .............................................................. 178

Exercise 5.2: Stochastic Study of a Plate Model.......................................................... 186

Appendix A: Comparison of DOE and Optimization using HyperStudy .......... 183

Appendix B: Solver Scripts ................................................................................. 195

Appendix C: Templex........................................................................................... 199

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