Altair HyperWorks Mechanical Solvers 2019.2

OptiStruct is a proven, modern structural solver with comprehensive, accurate and scalable solutions for linear and nonlinear analyses across statics and dynamics, vibrations, acoustics, fatigue and multiphysics disciplines. It is the industry-leading and most widely used solution for structural design and optimization. Building on a 25-year legacy of providing innovative optimization technology, first-to-market OptiStruct is used by numerous companies worldwide across various industries to supplement their design validation processes through advanced analyses. Furthermore, it is strategically deployed in their design processes to optimize structures for a variety of performance metrics such as weight, strength, stiffness, vibration and fatigue characteristics, to develop innovative, efficient and lightweight designs.

New Features

Stiffness, Strength and Stability

Enhancements to Incremental load step results output control (NLOUT)
New options available for NLOUT Bulk Entry to control the incremental load step results fornonlinear analysis include:
- FREQ: Output frequency
- TIME: Specific time output. Bulk Data SET with TIME will be used to specify the loadstep increment (TIME).
Example:
- NLOUT,ID,FREQ,2: Output is printed for every 2nd increment
- NLOUT,ID,TIME,4 : Output is printed for loads steps at 0.5 and 0.7 -SET,4,TIME,LIST,0.5,0.7
Note: The first and last increments are always output.
In addition, NLOUT is now output request-dependent for STRESS, STRAIN, CONTF and SPCF.This is currently limited to h3d output.
Cohesive Element with Damage Initiation and evolution
Cohesive Response based on Damage Initiation and Evolution has been added.
- Elastic modulus of cohesive elements can be specified with MCHOED Bulk Data.
- Damage Initiation can be defined with Stress or Strain (DMGINI Bulk Data).
.. Damage initiated when the strain in any direction reaches the correspondingmaximum value (MAXE)
.. Damage initiated when the stress/traction in any direction reaches thecorresponding maximum value (MAXS)
.. Damage initiated based on quadratic form of strain (QUADE)
.. Damage initiated based on quadratic form of stress/traction (QUADS)
- Damage Evolution characterized by Displacement or Energy (DMGEVO Bulk Data)
SPCF output while the job is running
NLOUT is supported for SPCF
PARAM,IMPLOUT allows an _impl.h3d to be available while the job is running.
Membranes (PSHELL with MID2/MID3 blank) are supported for Large Displacement NonlinearAnalysis and Nonlinear Elasto-plastic material
Membranes can be used for Large displacement nonlinear analysis and nonlinear analysiswith elasto-plastic materials.
PBUSH1D type SPRING(EQUATN), GENER, DAMPER support for Small Displacement Nonlinear Analysis
PBUSH1D with types SPRING(EQUATN), GENER, DAMPER are now supported for Small
Displacement Nonlinear Analysis.
CGAP(G) force output includes preload
The CGAP(G) force output includes preload (F0 on PGAP).
Overconstraint check for JOINTG
An overconstraint check will be performed if the model has JOINTG. The output is availablein .out file with a list of grids associated with the overconstraint.
Imperfection
An imperfection can be applied to the model.
Note: Only supported for Nonlinear Analysis.
The IMPERF Bulk Data and Subcase Entries can be used to apply an imperfection. Animperfection can be introduced into the model in the following ways:
- TYPE=H3DRES on IMPERF Bulk Data: An h3d file is referenced which containspreviously completed analysis results.
- TYPE=GRID on IMPERF Bulk Data: The perturbation of grids can be directly applied.
Follower Moment
MOMENT1/MOMENT2 Bulk Data Entries are now supported for follower loading.
Rotation base follower force/moment
A new follower force/moment option has been added to FORCE/MOMENT Bulk Data. UnlikeFORCE1/FORCE2 or MOMENT1/MOMENT2 which are vector based follower loads, the new followeroption is based on the rotation of grids. This new optional field is added in the 9th fieldof FORCE/MOMENT and if “ROT” is defined there, the rotation-based follower load will beactivated.
Note: PARAM,FLLWER or FLLWER Bulk Data is required together with “ROT”on the FORCE/MOMENT Bulk Data Entry in order to activate the rotation-basedfollower option.
Nonlinear Explicit Analysis (Beta Release)
This is a newly developed solution type in OptiStruct. It is critical to note that thisfunctionality is different from the existing explicit dynamic analysis through an integrationwith Altair Radioss (ANALYSIS=EXPDYN). This new OptiStruct Explicit solution type(ANALSIS=NLEXPL) has been developed solely in OptiStruct, in the same way as theOptiStruct implicit solution. The input data (elements, material, property, loading, etc.) forthe explicit solution is same as the implicit solution and the output data structure is alsosame as the implicit solution.
- Activation
A Nonlinear Explicit Subcase can be identified via ANALYSIS=NLEXPL. The TTERMSubcase Entry is mandatory to define the termination time. Additionally, a TSTEPESubcase Entry which points to the corresponding TSTEPE Bulk Data Entry is alsoavailable for Nonlinear Explicit Analysis. If TSTEPE Subcase Entry is not defined, then

……….and more

Note: For details on these new features, enhancements and Resolved Issues, refer to the HyperWorksSolvers_2019.2_Release_Notes.pdf

Altair Radioss is a leading structural analysis solver for highly non-linear problems under dynamic loadings. It is used across all industries worldwide to improve the crashworthiness, safety, and manufacturability of structural designs. For over 30 years, Radioss has established itself as a leader and an industry standard for automotive crash, drop & impact analysis, terminal ballistic, blast and explosion effects and high velocity impacts. Automotive, aerospace, electronics, defense companies and R&D centers value the contribution it makes in understanding and predicting design behavior in complex environments, such as automotive crash, airplane ditching or blast effect on vehicles. The tight integration with the HyperWorks environment makes Radioss a powerful design tool. Radioss models are optimization-ready. Transitions to the optimization solver OptiStruct and HyperStudy are easy

New Features

Contact interfaces
A new contact gap option Igap= 4 has been added to the contact interface /INTER/TYPE19 whichenables variable gap for the node to surface contact and constant contact gap, Gapmin, for theedge to edge contact. For self-contact, if element size is less than the gap value, then slavenodes are deactivated for nearby master segments. This is the same as using /INTER/TYPE7,Irem_gap= 2.
Animation output
The plastic work of material LAW12, LAW15, and LAW25 are displayed in /ANIM/ELEM/WPLA and /H3D/ELEM/WPLA output, and are no longer in the plastic strain (EPSP) for those material laws.A new option /H3D/NODA/SKID_LINE displays when the draw bead contact (/INTER/TYPE8) occurson the slave side and when it is sliding.A new user input value is available in FLD failure models (/FAIL/FLD) which defines the marginaldefinition zone display in /ANIM/SHELL/FLDZ and /H3D/SHELL/FLDZ.

Enhancements

/FAIL
Performance improvements have been made for all failure models (/FAIL) that have large tables(/TABLE) or functions (/FUNCT).
/FRICTION
/FRICTION can now be used in //SUBMODEL.
/IMPDISP/FGEO, /IMPVEL/FGEO
These options can now be used with the SPMD and HMPP versions.
/SKEW
Performance improvements have been made for computation in SPMD and HMPP for models witha large number of skews.
/RBE2 and /RBE3
Less information is printed in the starter output by default. This reduces the starter output filesize when a model contains a large number of RBE2 or RBE3 elements. Detailed information canbe output by using Ipri=5 in the card /IOFLAG.

Resolved Issues

/INTER/TYPE25
Numerical issue that caused the Radioss Starter to fail when a slave node was exactly on themaster surface.The initial penetrations warning for /INTER/TYPE25 was not listed in the Starter output filestarting in the 2019.1 release.
/DEFAULT/INTER/TYPE11
Incorrect format input for the card /DEFAULT/INTER/TYPE11. In version 2018.0.1 to 2019.1, anextra blank line was needed at the end of the /DEFAULT/INTER/TYPE11 block.
/DTSDE
To improve stability, the larger time step for pentahedron elements is no longer enabled bydefault.
/FRICTION
Correction of engine failure when /FRICTION is used with Ifric=2.Less information is printed in the starter output file. Only the group of parts is reported instead ofthe full table listing the parts.
/PROP/SOLID
Correction of the SOL2SPH feature in the SPMD version. The Radioss Engine was failing forspecific models that had more than one SPMD domain.A change was made in the default value Icpre (from 1 to 2) with Isolid =18 and elasto-plasticmaterials LAW2 and LAW36.A change was made in the default value IHKT (from 1 to 2) for materials 42, 62, 69, 70, 71, 82,88, 92, and 94.Numerical issue that caused the Starter to fail when imposed motion was applied on the middlenode of a quadratic tetrahedron element defined with Itetra10=2.
/PROP/SHELL
The thickness change flag (with Ithick=1) was not re-activated after a thermal analysis (/DT/THERM).
/FAIL/JOHNSON + XFEM
Memory allocation issue that caused the Engine to fail for models with XFEM in the failure card.
/FAIL/TAB1
The instability strain table (table2_ID) was not being taken into account correctly, and only thevalue for no triaxiality was used.
/INITRUSS/FULL
Input format caused the Starter to fail.
/SUBDOMAIN
Numerical issue for multi-domains (/SUBDOMAIN) and contact interface /INTER/TYPE19 thatcaused the Starter to fail, due to complications with memory allocation.Compilation issue for Open MPI (ompi) version that caused corrupt executables.
/NEGVOL/STOP
A message relative to the FVMBAG was being printed at the same time as a negative volume errormessage in the Engine output file.
/MAT/LAW57 (BARLAT3)
Numerical issue with single Precision version with usage for Barlat material (/MAT/LAW57) andpressure unit defined as "Pa".
/MAT/LAW75 (POROUS)
Numerical issue with the single precision version.
/H3D
Creates an .h3d file from Radioss using /H3D caused the solver to hang at the end of a simulationwhen using new versions of Linux, such as Ubuntu 18.04 and Fedora 28.Computation failed when the stress and strain tensor output in native .h3d files for 2D solidelements (/H3D/QUAD/TENS) was used with the solid property Isolid=17.Numerical issue for native .h3d output with specific models. The Engine failed with segmentationfault as soon as data was written in the .h3d file.
/ANIM/ELEM/SCHLIEREN, /H3D/ELEM/SCHLIEREN
Numerical issue for the Schlieren output in 2D axi-symmetrical analysis.
/IMPVEL/FGEO
Numerical issue when the option /IMPVEL/FGEO was used with the option /PARITH/ON or SPMD.
/LINE
Numerical issue with the /LINE option and domain decomposition in the Starter.
/LOAD/PBLAST
Numerical issue in the Starter when both /LOAD/PBLAST and /INTER/TYPE17 were set in a specificmodel. The Starter failed with a memory allocation error.
/MONVOL/FVMBAG1
Numerical instability in the volume computation for a specific airbag meshed with pyramid andtetrahedron elements. The model failed during the first cycle.Starter initialization correction for a finite volume mesh created with pyramid and tetrahedronelements.Radioss Starter was taking too much time to create the restart files.
/PROP/TYPE9(SH_ORTH)
With Ishell=24, membrane damping (Dm) was not set to the correct value for triangle shellelements (/SH3N) and material law /MAT/LAW19. The value was Dm=0.015, instead of Dm=0.25.

Altair Multiscale Designer is an efficient tool for development and simulation of multiscale material models of continuous, woven, and/or chopped fiber composites, honeycomb cores, reinforced concrete, soil, bones, and various other heterogeneous materials. Applications include multiscale material modeling for design, ultimate failure, statistical-based material allowables, fatigue, fracture, impact, crash, environmental degradation, and multiphysics simulations and provides plugins to commercial FEA solvers Optistruct, RADIOSS, LS-DYNA, and Abaqus.

New Features

User Experience

- Real-time assistant unit cell calculations are now automatically calculated and guide meshinput parameters. In addition, real-time assistant unit cell calculations have been verified foraccuracy to the actual exported unit cell.
- Auto selection of Step 1: Unit Cell model mesh algorithm (direct or adaptive) including autocalculation of mesh element size based on unit cell model selection.
- Auto populate Laminate definition default layers for general laminates (orientation = 0,thickness = 1.0) and injection molding laminates (orientation = 0, thickness = 1, fiberorientation tensor = {0.9, 0.1, 0.0, 0.0, 0.0, 0.0.}).
- Added Step 3: Nonlinear Material Characterization summary plot which plots all simulationson one chart as a summary in addition to the individual plots for each simulation.
- Changed Step 3: Nonlinear Material Characterization simulation data from “strain rate” to“test time” which is more consistent with standard macro solvers (that is OptiStruct, Abaqus,and so on) that defines default time for implicit solutions. In addition, default “test time” isset to 1 sec, which is the standard default for macro solvers.

Constituent Material Database

- The Constituent Material Database has been enhanced to include separately continuousmaterial product forms and injection molding material product forms. The proper constituentmaterial (continuous or injection molding) should be selected based on the product formbeing simulated.
- Added Tow material class and corresponding Aramid/Carbon/Glass material subclass to theconstituent material database which enables the constituent material database to be used forwoven materials.

Step 1: Unit Cell Definition

- Support for external unit cells with quadratic elements from OptiStruct (*.fem) and Abaqus(*.inp).
- Added both geometric and manufacturing parametric input for Fibrous > Discontinuous Fiberparametric unit cells.

Resolved Issues

- Added default license file location checkout for EDU package/install.
- Fixed incorrect macro strain calculations with Step 4: Material Nonlinear Characterization dogbonesimulation models.
- Simulation models for injection molding with fiber orientation tensor results no longer requireelement IDs to start at ID=1. Element IDs can now be numbered starting at any number and donot have to be continuously numbered. As such, the mdsFiberOri.dat file now has the headerinput *Max_ElementID instead of *Total number of elements.
- Simulation models for injection molding with fiber orientation tensor results no longer require themodel to be built completely within the global X-Y plane. Simulation models for injection moldingwith fiber orientation tensor results can now be built in ANY 3D XYZ coordinate system, and localelement material orientations are automatically calculated from the local element fiber orientationtensor at every element. Prior versions required the model to be built completely within the globalXY plane (that is Fiber Orientation Tensor results A33 ~ 0.0). With this change, v2019.2 completelysupports A33 >> 0.0.
- The performance of simulation models for injection molding with fiber orientation tensor resultswith explicit solvers (that is, Radioss, Abaqus-explicit, LS-Dyna, and so on) has been significantlyimproved.

Altair Manufacturing Solver is a state of the art solver suite for manufacturing applications. It is built on Kratos Multiphysics, which is a framework for building parallel, multi-disciplinary simulation software that aimsat modularity, extensibility, and high performance. The current version of Manufacturing Solver includes a castingsolver and an injection molding solver. This casting solver is used under Altair Inspire Cast and themolding solver has an interface in Altair SimLab.

Casting Simulation: Supported Features

Metal casting is a widely used manufacturing process used to mold metal into a desired shape. Thisis achieved by pouring a liquid metal into a mold and cooling it to solidify the part. There are manyvarieties of casting processes that depend on how the molten metal is delivered into the mold, the typeof material used to make the mold, and the cooling techniques. The casting solversupportsthe following features:

Supported common casting techniques

- High pressure die casting
- Low pressure die casting
- Investment casting
- Gravity sand and die casting
- Gravity tilt pouring
- Gravity tilt pouring with crucible
- Gravity with constant liquid level on the sprue
- High pressure die casting with shot sleeve
- Cycling

Supported standard casting components

The solver supports the modeling of standard casting components, such as:

- Core
- Chiller
- Riser
- Isothermal and exothermal sleeves
- Overflow- Mold
- Cooler
- Filte
r- Shot sleeve
- Crucible

Supported computed results

- Flow Front
- Velocity

- Pressure
- Temperature
- Cold Shuts
- Air Entrapment
- Flow length
- Mold Erosion
- Solid Fraction evolution
- Shrinkage porosity
- Pipe shrinkage
- Solidification Modulus
- Niyama
- Microporosity
- Solidification time

Modeling Simulation: Supported Features

Injection molding is one of the most common processes used for the production of polymer parts. Thisis a cyclic process and often used with thermoplastic polymers. A polymer in the form of pellets is mixedwith other additives, then heated to a melt state, and finally pressurized in a single screw extruder.This pressurized polymer melt is injected into the mold at a high flow rate to fill the mold cavities.These cavities are made in the form of the final part accounting for the shrinkage, and then the mold iscooled and the part is ejected from the mold as soon as it is stable enough for ejection. This is a cyclicprocess and this sequence repeats. Altair Manufacturing Solver is used for simulating the injection molding process.The following features are supported:

Supported solution sequences

- Filling
- Filling + Cooling
- Filling + Cooling + Warpage
- Cooling
- Cooling + Warpage
- Filling + Packing
- Filling + Packing + Cooling
- Filling + Packing + Cooling + Warpage

Support for fiber orientation analysis

Fiber orientation analysis is supported and can be optionally turned on.

Filling solution module

The filling solution module supports:

- Velocity driven filling
- Velocity/pressure (VP) switch over
- Final pressure driven filling
- Gates can be timed with table data

Supported packing stage phases

The packing stage includes both packing and holding phases.

Model support

The solver can support models that contain:

- Complete or partial runner system
- Single or multi-cavity molds
- Analysis with or without mold plates and mold inserts
- Analysis with or without part inserts
- Symmetry conditionsSupported computed results
- Air traps
- Density
- Fill time
- Pressure
- Temperature
- Velocity
- Maximum velocity
- Strain rate
- Weld surface
- Viscosity
- Sink marks
- Fiber orientation tensor
- Warpage - displacement
- Warpage - stresses

Operating System: Windows 7even (64bit) or Windows 10 (64bit),
RAM: 4 GB (higher recommended)
Graphics Hardware: OpenGL 3D graphics accelerator compatible with OpenGL 3.2 or higher, True color (24-bit) support, 2 GB or higher dedicated RAM, Only AMD and NVIDIA GPUs supported (Intel chipsets are not supported)