Composite optimization of a skateboard using
Altair HyperMesh™ and Altair OptiStruct™ 2019
This tutorial should help students and young engineers to get an easy access and to gain first experiences in composite modelling, analysis and optimization. Chapter 1 covers basic aspects of composites, continuing chapter 2 covering the modelling process of composites using Altair HyperMesh™. Geometry preparation, FE (Finite element)-model generation and post-processing are carried out in chapter 3. Chapter 4 covers the optimization process and the tutorial ends with a summary table in chapter 5.
More specifically, for the monocoque suspension mass optimization, CAD geometry was initially imported into HyperMesh and a meshed model was created. After assigning composite material properties to the primary monocoque structure and aluminum properties to the bonded end cap, design and non-design regions of the model were specified. Loads were also input, and the maximum monocoque displacement was constrained to a maximum allowed value. A three-step OptiStruct optimization process for composite structures was then applied to minimize the monocoque volume. After analyzing the optimized results in HyperView, the team created a manufacturable geometry, which was subsequently evaluated using linear finite element analysis to ensure that all design requirements were met.
As part of a senior design project – the design and analysis of a coaxial rotor craft – Christopher Van Damme, at the time of the project senior undergraduate student within the department of Engineering Mechanics at the University of Wisconsin-Madison, had to analyze a composite made helicopter rotor blade. In his analysis he had to employ Computer-Aided Engineering tools to cover the required studies regarding static, modal, frequency response, and dynamic analysis of the rotor. The CAE tools of choice were Altair‘s HyperWorks suite, mainly HyperMesh, the pre-processor of the suite, and Altair‘s FE-solver and optimization tool OptiStruct.
• Construct, manufacture and market the Formula Student Race Car „PX215“
• Student team of the University of Paderborn
• 50 team members of different faculties
• Compete with about 500 teams in international events
Automotive and aeronautics industries look for more and more lightweight structures.
3D Composites seems a promising material to achieve.
Is it possible to manufacture a 3D Fabrics with optimal properties according to each requirement?
Need of a decision making tool to design and place the correct composite material in the correct place