Manufacturing Solutions 11.0 HyperForm Tutorials

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(1)Manufacturing Solutions 11.0 HyperFormTutorials.

(2) Altair Engineering Contact Information Web site. www.altair.com. FTP site. Address: ftp.altair.com or ftp2.altair.com or http://ftp.altair.com/ftp Login: ftp Password: <your e-mail address>. Location. Telephone. e-mail. North America. 248.614.2425. [email protected]. China. 86.400.619.6186.. [email protected]. France. 33.1.4133.0992. [email protected]. Germany. 49.7031.6208.22. [email protected]. India. 91.80.6629.4500 1800.425.0234 (toll free). [email protected]. Italy. 39.800.905.595. [email protected]. Japan. 81.3.5396.2881. [email protected]. Korea. 82.70.4050.9200. [email protected]. Scandinavia. 46.46.286.2052. [email protected]. United Kingdom. 01926 .468.600. [email protected]. Brazil. 55.11.3384.0414. [email protected]. Australia. 61.3.9016.9042. [email protected]. New Zealand. 64.9.413.7981. [email protected]. The following countries have distributors for Altair Engineering: Asia Pacific: Indonesia, Malaysia, Singapore, Taiwan, Thailand Europe: Czech Republic, Hungary, Poland, Romania, Spain, Turkey. © 2011 Altair Engineering, Inc. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated to another language without the written permission of Altair Engineering, Inc. To obtain this permission, write to the attention Altair Engineering legal department at: 1820 E. Big Beaver, Troy, Michigan, USA, or call +1-248-614-2400. ® HyperWorks 11.0 Release Notes. Trademark and Registered Trademark Acknowledgments. Listed below are Altair® HyperWorks® applications. Copyright© Altair Engineering Inc., All Rights Reserved for: HyperMesh® 1990-2011; HyperCrash™ 2001-2011; OptiStruct® 1996-2011; RADIOSS® 1986-2011; HyperView® ® ® ® ® 1999-2011; HyperView Player 2001-2011; HyperStudy 1999-2011; HyperGraph 1995-2011; MotionView 1993® ® ® 2011; MotionSolve 2002-2011; HyperForm 1998-2011; HyperXtrude 1999-2011; Process Manager™ 2003-2011; Templex™ 1990-2011; Data Manager™ 2005-2011; MediaView™ 1999-2011; BatchMesher™ 2003-2011; TextView™ 1996-2011; HyperMath™ 2007-2011; ScriptView™ 2007-2011; Manufacturing Solutions™ 2005-2011; HyperWeld™ 2009-2011; HyperMold™ 2009-2011; solidThinking™ 1993-2011; solidThinking Inspired™ 2009-2011; Durability Director™ 2009-2011; Suspension Director™ 2009-2011; AcuSolve™ 1997-2011; and AcuConsole™ 2006-2011. In addition to HyperWorks® trademarks noted above, GridWorks™, PBS™ Gridworks®, PBS™ Professional®, PBS™ and Portable Batch System® are trademarks of ALTAIR ENGINEERING INC., as is patent # 6,859,792. All are protected under U.S. and international laws and treaties. All other marks are the property of their respective owners..

(3) Manufacturing Solutions 11.0 Tutorials - HyperForm. HyperForm ........................................................................................................................................... 1 Introduction................................................................................................................................... to HyperForm 3 Introduction................................................................................................................................... to HF Macros - HF-0010 5 Introduction to HyperBlank Macros HF-0010 ................................................................................................................................... 11 HF-0100: ................................................................................................................................... General Introduction 13 Radioss One Step ................................................................................................................................... 33 HF-0150: ........................................................................................................................................ Quick Setup 35 HF-0200: ........................................................................................................................................ Geometry Cleanup 49 HF-0300: ........................................................................................................................................ Automeshing 65 HF-0400: ........................................................................................................................................ Mesh Quality 81 HF-0500: ........................................................................................................................................ Model Preparation - Undercut Check and Autotipping 89 HF-1000: ........................................................................................................................................ One-Step Stamping Simulation 95 ........................................................................................................................................ HF-1010: Increasing Blankholder Pressures 105 ........................................................................................................................................ HF-1020: Applying Drawbeads and Performing Circle Grid Analysis 109 ........................................................................................................................................ HF-1030: Transferring Forming Results to Crash Analysis 115 ........................................................................................................................................ HF-1040: Laser Weld 123 ........................................................................................................................................ HF-1050: Trim Line Layout 127 Incremental Analysis ................................................................................................................................... 133 ........................................................................................................................................ HF-3000: Introduction to Incremental_Radioss and Incremental_Dyna 135 ........................................................................................................................................ HF-3001: Auto Process 143 ........................................................................................................................................ HF-3002: User Process 159 ........................................................................................................................................ HF-3003: Setting Up a Multi Stage Simulation from the User Process 175 ........................................................................................................................................ HF-3010: Simple Draw Forming 181 ........................................................................................................................................ HF-3020: Combined Binderwrap and Draw Forming Analysis 191 ........................................................................................................................................ HF-3030: Drawbead 203 ........................................................................................................................................ HF-3040: Springback 213 ........................................................................................................................................ HF-3050: Trimming 219 ........................................................................................................................................ HF-3060: Gravity 225 ........................................................................................................................................ HF-3070: Redraw 227 ........................................................................................................................................ HF-3080: Multi-stage Manager 237 ........................................................................................................................................ HF-3090: Tube Bending 247 ........................................................................................................................................ HF-3100: HydroForming 255 ........................................................................................................................................ HF-3110: Blank Optimizer 265 Die Module ................................................................................................................................... 273 ........................................................................................................................................ HF-2005: Basic Addendum Creation Using Die Process 275 ........................................................................................................................................ HF-2010: Basic Addendum Creation 281. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. i.

(4) ........................................................................................................................................ HF-2020: Designing a Parametric Addendum 287 ........................................................................................................................................ HF-2030: Modifying a Parametric Addendum 307 HF-2040: Parameterization of External Binder and Addendum Section Using Section Editor ........................................................................................................................................ 317 Optimization ................................................................................................................................... 327 ........................................................................................................................................ HF-4010: Mesh Morphing 329 ........................................................................................................................................ HF-4020: Optimization 1-Step 337 Result Mapping ................................................................................................................................... 347 ........................................................................................................................................ HF-5000: Using Result Mapper in HyperCrash 349 ........................................................................................................................................ HF-5100: Result Mapping Using Process Manager 357 HF-6000:................................................................................................................................... Die Structure Optimization 367. ii. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(5) HyperForm Introduction HF-0010: Introduction to HF Macros HF-0100: General Introduction. Radioss One Step Analysis HF-0150: Quick Setup HF-0200: Geometry Cleanup HF-0300: Automeshing HF-0400: Mesh Quality HF-0500: Model Preparation - Undercut Check and Autotipping HF-1000: One Step Stamping Simulation HF-1010: Increasing Blankholder Pressures HF-1020: Applying Drawbeads to a Model HF-1030: Transferring Forming Results to Crash Analysis HF-1040: Laser Weld HF-1050: Trim Line Layout. Incremental Analysis HF-3000: Introduction to Incremental HF-3001: Auto Process HF-3002: User Process HF-3003: Setting Up a Multi Stage Simulation from the User Process HF-3010: Simple Draw Forming HF-3020: Combined Binderwrap and Draw Forming Analysis HF-3030: Drawbead HF-3040: Springback HF-3050: Trimming HF-3060: Gravity HF-3070: Redraw HF-3080: Multi-stage Manager HF-3090: Tube Bending HF-3100: HydroForming HF-3110: Blank Optimizer. Die Module. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 1.

(6) HF-2005: Basic Addendum Creation Using Die Process HF-2010: Basic Addendum Creation HF-2020: Designing a Parametric Addendum HF-2030: Modifying a Parametric Addendum HF-2040: Parameterization of External Binder and Addendum Section Using Section Editor. Optimization Study HF-4010: Mesh Morphing HF-4020: Optimization 1-Step. Result Mapping HF-5000: Using Result Mapper in HyperCrash HF-5100: Result Mapping Using Process Manager. HF-6000: Die Structure Optimization. 2. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(7) Introduction to HyperForm The following introductory tutorials are available:. HF-0010: Introduction to HF Macros HF-0100: General Introduction. HF-0010: Introduction to HyperBlank Macros HF-0100: General Introduction to HyperBlank. Radioss One Step Analysis HF-0200: Geometry Cleanup HF-0300: Automeshing HF-0400: Mesh Quality HF-0500: Model Preparation - Undercut Check and Autotipping HF-1000: One-Step Stamping Simulation HF-1010: Increasing Blankholder Pressures HF-1020: Applying Drawbeads to a Model HF-1030: Transferring Forming Results to Crash Analysis HF-1040: Laser Weld HF-1050: Trim Line Layout. Incremental Analysis HF-3001: Auto Process HF-3002: User Process HF-3010: Simple Draw Forming HF-3020: Combined Binderwrap and Draw Forming Analysis HF-3030: Drawbead HF-3040: Springback HF-3050: Trimming HF-3060: Gravity HF-3070: Redraw HF-3080: Multiple Stage Manager HF-3090: Tube Bending HF-3100: HydroForming HF-3110: Blank Optimizer. Die Design. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 3.

(8) HF-2010: Basic Addendum Creating HF-2020: Designing a Parametric Addendum HF-2030: Modifying a Parametric Addendum HF-2040: Parameterization of External Binder and Addendum Section using Section Editor. Optimization Study HF-4010: Mesh Morphing HF-4020: Optimization 1-Step. Result Mapping HF-5000: Result Mapper Using HyperCrash HF-5100: Result Mapping Using Process Manager. HF-6000: Die Structure Optimization. 4. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(9) Introduction to HF Macros - HF-0010 Radioss One Step process macros This is the interface for HyperForm with the Radioss One Step macro active. You will see the active browser for Radioss One Step on the left side of the interface. See the online help for information about the specific macros that are available.. HyperForm interface w ith One Step tab active. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 5.

(10) HyperBlank interface w ith the OneStep tab active. All the Radioss One Step macros are located on the 1Step page of the Utility Menu. These macros allow you to quickly set up an analysis for one step simulation. The Radioss One Step macros are divided into the following three sections.. 6. Model. Allows you to import, cleanup, and mesh the model.. Setup. Allows you to setup the model for simulation using Radioss One Step.. Results. Allows you to do post-processing once the analysis is done.. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(11) Radioss One Step Utility menu. Incremental process macros The following image shows the Utility Menu of the HyperForm interface with Incremental_Radioss user profile:. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 7.

(12) Incremental_Radioss Utility Menu. All of the macros are located in the Radioss page of the macro area. The incremental process macros allow you to more easily setup different application types. The following application types are available under Application.. 8. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(13) Form - 1st forming operation setup. Bend - Tube bending setup. Hydro - Hydroforming setup. Blank Opti - Blank Optimizer TL Opti - Trim Line Optimizer Die Compensation - Die Compensation macroDepending on the application type chosen, the setup process contains different macros. The organization of the buttons within the Utility Menu is topdown, guiding you through each step of the specific application type. Further explanation of each application type is provided in the subsequent tutorials.. Return to HyperForm Tutorials. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 9.

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(15) Introduction to HyperBlank Macros - HF-0010 HyperBlank process macros This is the interface for HyperBlank with the OneStep tab active. This is the default setting when HyperBlank is started. The various macros that are available for HyperBlank are available on the Utility Menu, which is also on the left side of the interface. See the HyperBlank online help for information about the specific macros that are available.. HyperBlank interface w ith the OneStep tab active. All the macros are located on the Utility Menu. These macros allow you to quickly set up an analysis for one step simulation. The macros are divided into the following three sections. Model. Allows you to import, cleanup, and mesh the model.. Setup. Allows you to setup the model for simulation.. Results. Allows you to do post-processing once the analysis is done.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 11.

(16) HyperBlank Utility Menu. Further explanation of each application type is provided in the subsequent tutorials.. Return to HyperForm Tutorials. 12. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(17) HF-0100: General Introduction HyperForm, a subset of Manufacturing Solutions, is a finite element based pre- and post-processor for sheet metal forming. It combines an extremely fast one-step solver and incremental forming solution using Radioss as the solver. It also integrates well with the LS-DYNA solver for incremental forming simulation. With the customized geometry manipulation and mesh generation capabilities, HyperForm enables you to build metal forming related finite element models, view their results, and perform data analysis. HyperForm integrates the functionality of HyperMesh and provides engineers at any stage of product design with quick, valuable, reliable information, reducing the overall product cycle. HyperForm's die module enables engineers to create and analyze conceptual die designs in order to generate an optimized die. Die concepts can then be read into any CAD system as a starting block for the actual die build. Integrated with HyperView, HyperForm can export data in the .h3d format allowing results to be visualized using HyperView Player with any web browser. This tutorial introduces HyperForm, as well as many basic concepts and tasks that are needed to get started with HyperForm, and which serve as pre-requisites for most other HyperForm tutorials. In this tutorial, you will be introduced to HyperForm from the one-step analysis point of view. The HyperForm interface for incremental analysis will be described in later tutorials. This tutorial covers: Session 1: Fundamental HyperForm user interface o. User Profiles. o. Graphics Area. o. Using the mouse. o. Tool bar menu. o. Main menu. o. Toggles and switches. o. Utility Menu. o. The pull-down menus. Session 2: Using the online help Session 3: File input and output Session 4: The concept of collector Session 5: Secondary menus o. Menu items. o. Entity selector. o. Direction selector. o. Input fields. o. Pop-up menus. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 13.

(18) o. Function buttons. Session 6: Default HyperForm files. Exercises: Three exercises are provided in this chapter: Exercise 1: Opening a database file and using the tool bar Exercise 2: Understanding Collectors and using online help Exercise 3: Translating elements. Session 1: Fundamental HyperForm user interface The HyperForm window consists of these main areas: the graphics area, the User Process tab, the header bar, the main menu, Utility Menu, and the drop-down menu as shown below. You can access secondary menus either through their main panel or by using keyboard function keys.. User profiles The HyperForm user interface includes the following analysis configurations: Radioss One Step: Setup, run, and review of a one-step analysis Incremental_Radioss: Setup and run an incremental analysis using RADIOSS Solver. 14. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(19) Die Module: Create and edit binders and addendums Incremental_LsDyna: Setup and run an incremental analysis using the LS-DYNA solver After starting HyperForm, the following dialog appears.. In the Applications: field, select Manufacturing Solutions and then select one of the modules - Radioss One Step, Incremental_Radioss, Incremental_LsDyna, or Die Module - before performing any further operations. The selected configuration can include loading a specific template, loading a specific Utility Menu, renaming panels, removing unused panels or subpanels, and removing, moving, or renaming panel options. The selected configuration can change the appearance of a panel, but they do not affect the internal behavior of each function.. Graphics Area The graphics area displays geometry, models, and XY plots.. Status Bar. The status bar is located at the bottom of the HyperForm window, just below the user profile switches on the Utility Menu. It displays the name of the current panel and user profile, and model status information. Messages also appear on the message bar, temporarily overriding the title and status information.. Using the Mouse The mouse attached to your system is integral to HyperForm and can be used in almost every aspect of user. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 15.

(20) input. A two- or three-button mouse can be used with HyperForm. The mouse buttons have these functions: Left mouse button. Performs selection operations.. Right mouse button. De-selects entities in the graphics area. Aborts graphics operations.. Middle mouse button. In the rotate (r) and arc dynamic motion (a) modes, selects a new center of rotation when you pick a node in the model.. CTRL + left mouse button. Dynamically rotates the model. CTRL + the middle mouse button. Zooms into an area of the model. CTRL + the right mouse button. Pans the model. Toolbars Collectors toolbar. Visualization toolbar:. Display toolbar:. The toolbars enable you to manipulate the view of the model, control which collectors are displayed in the graphics area, set global modeling parameters, and edit solver-specific data. The functions of some of the toolbar menu icons are described below: Panel. 16. Icon. Description. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(21) Files. Load, save, or import files.. Card edit. Edit solver-specific data in card format. Wireframe Elements. Draws model geometry as a wire-frame. Shaded Elements & Mesh Lines. Draws model geometry in shaded mode. Wireframe geometry. Draws model geometry as a wire-frame. Click the downward arrow to choose between excluding and including surface lines.. Shaded Geometry & Surface Edges. Draws model geometry in shaded mode. Click the downward arrow for options: with edges or without them.. Visualization. Show or hide different types of topology, connector, or morphing entities. A sub-menu is enabled when this panel is selected.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 17.

(22) The following viewing icons are available: Item. Icon. Description. Plot Refresh. Refreshes the graphics area by re-plotting the model. Previous View. Returns to the previous view. Fit View. Resizes the model view to fit the model to the graphics area. Modal Zoom. Circle zoom (left click) / Dynamic zoom (right click). Left-clicking activates the circle zoom feature. Circle zoom deactivates after zooming once, or when you click either button while the pointer is in the graphics area.. 18. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(23) Right-clicking activates the dynamic zoom feature. Once active, right-click and drag in the graphics area to zoom in/out. Left-click to deactivate. Incremental Zoom. Zoom incrementally; left-click to zoom in, right-click to zoom out. Rotate Mode. Rotate modes: this functions in one of two different ways: Left-click to activate dynamic rotate mode. Once active, clickand-drag in the graphics area to rotate the model. Right-click to deactivate. Right-click to activate dynamic spin mode. Once active, rightclick in the graphics area and hold the mouse button down to make the model spin. Left-click to deactivate.. Pan modes. Pan modes: this functions in one of two different ways:· Left-click to activate pan mode. Once active, click-anddrag in the graphics area to pan the model view. Right-click to deactivate· Right-click to activate center mode. Once active, right-click in the graphics area to change the graphics area center. Left-click to deactivate.. Rotate (left/ right). Click the left mouse button to rotate the model leftward, and the right button to rotate it rightward. Rotate (up/ down). Click the left mouse button to rotate the model upward, and the right button to rotate it downward. Spherical clipping. Use spherical clipping to isolate portions of the model regardless of component or collector. User View / True view. Open a pop-up menu used to save and retrieve user-defined or standard views.. True View. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 19.

(24) Exercise 1: Opening a database file and using the toolbar Step 1: Load the HyperForm Radioss One Step environment file 1.. Start HyperMesh.. 2.. On the Preferences menu, click User Profiles….. 3.. For Application, select Manufacturing Solutions. Verify that HyperForm and Radioss One Step are selected.. 4.. Click OK.. Step 2: Load the model file 1.. From the File menu, select Open.. 2.. In the Open File dialog, change the Files of type: field to All files.. 3.. Navigate to the 1Step folder, click on the file Die_Mesh.hm and click Open.. Step 3: Change the visualization of the model 1.. In the Model Browser, expand the Master Model folder, and then Component folder.. 2.. Right-click on the Binder component and select Hide. Notice the Binder mesh is no longer displayed in the graphics area. Right-click on it again and select Show.. 3.. From the toolbar, click the Shaded Elements & Mesh Lines icon shaded mode.. 20. to re-draw the model geometry in. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(25) 4.. From the toolbar, click the Wireframe Elements icon mode.. to re-draw the model geometry in wireframe. 5.. From the toolbar, click the Element Color Mode icon. and select By Mat from the selection list.. Notice that the Binder and Addendum components become a gray color. This indicates the two components share the same material. 6.. Repeat step 5 and change the setting back to By Comp.. 7.. From the Preferences menu, click Colors.. 8.. The graphics area is displayed as a gradient color. You can change both the lighter and darker colors. Click the color box next to Background 1 and Background 2 and select other color options. This changes the background color to your selection.. 9.. Click Reset to restore the default settings.. 10. Click Close to close the dialog. 11. From the toolbar, right-click Pan modes. .. 12. Move the mouse cursor to graphics area, keep on holding the right mouse button and pan the model graphically. Move the mouse cursor back to toolbar menu to release the panning action. Note: Pan action can also be achieved by holding Ctrl keyboard + right mouse button. 13. From the toolbar, left click Rotate Mode icon. to enter dynamic rotate mode.. 14. Click and drag in the graphics area to rotate the model. 15. From the toolbar, left click Incremental Zoom icon 16. From the toolbar, click Fit View icon. to zoom in on the model.. to fit the model on the screen.. 17. From the toolbar, left click User View / True view icon. to open the user view panel. 18. Click the left button to review the model from the XZ plane.. Main Menu From the main menu you can access to a variety of panels grouped by the selected user profile.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 21.

(26) The main menu w ith the Radioss One Step user profile loaded. Toggles and Switches Toggles and switches allow you to select and specify options that need to be determined before you complete the function. Click a toggle to alternate between two options.. Click a switch to display a list of options in a pop-up menu.. Reset button. This removes selection and back to empty value. Utility Menu The Utility Menu is located on the left side of the graphics region and can be relocated by clicking on View and selecting Tab Area. When Manufacturing Solutions and HyperForm working environments are loaded, the Utility Menu is automatically switched to the HyperForm working environment. It provides tools for defining/reviewing/editing a model. The Model tab option enables the Model Browser functionality The user profile selection buttons are at the bottom of the menu.. 22. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(27) 1Step Quick access/switch to the Radioss One Step user profile Radioss Quick access/switch to the Incremental_Radioss user profile Die Quick access/switch to the Die Module user profile Disp Tools for visualization purpose Util Utilities to perform operations at geometry level. User User-created macros only Dyna Quick access/switch to Incremental_LsDyna user profile To hide the Utility Menu: From the View pull-down menu, uncheck the Utility Menu. To display the Utility menu: From the View pull-down menu, check the Utility Menu.. The menu bar The menu bar, located just beneath the title bar, enable access to many types of functionality. Most menu options access panels, but some options perform other tasks such as configuring the layout of the. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 23.

(28) HyperForm environment.. When the HyperForm environment is loaded, the menu bar also enables you to access to the fundamental menus regardless of the customization of the HyperForm interface.. Session 2: Using the online help HyperForm includes a help system to provide information about using the interface. There are several methods of accessing and using the online help system.. Method 1: Start online help from the pull-down menu This method provides access to all information. 1.. Stay in the main menu; do not click any panel.. 2.. From the Help menu, select HyperForm. The HyperForm online help is launched. This book contains all information including Release Notes, User’s Guide, Reference Guide, Tutorials, etc.. Method 2: Start context-sensitive help This method allows you to search information specifically for individual panels. 1.. Click any panel from the main menu, for example, the Sections panel, and stay in the selected panel.. 2.. From the keyboard, click the H key. This directly enters the help function for the selected panel. The information for the Sections panel is displayed on screen.. Method 3: Finding information using the tabs You can also search information by typing any keyword(s). 1.. Stay in the main menu; do not click any panel.. 2.. From the Help menu, select HyperForm.. 3.. Click on the Index or Find tab, and type in the desired keyword(s). A list of related topics is displayed.. Session 3: File input and output File input and output is performed through the File menu.. 24. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(29) File - Open/ Saves and retrieves HyperForm binary database files. Save/ Save As There are no restrictions placed on HyperForm database file extension names other than those imposed by the operating system. To load a HyperForm database file on top of another HyperForm database file (*.hf ), use the import option. File - Import. Loads CAD generated geometry or finite element model information. It is possible to import a CAD generated geometry or a finite element model information file into a HyperForm database file. HF PARM translator is used to import one step analysis ASCII input file. File - Export. Writes an ASCII file in a format specific to the selected analysis code.. Load. Load a the template file used to format the HyperForm database for a specific analysis code, or load a Results file, or a Macro file. Run. Run a command file or a TCL script. Session 4: The concept of a collector Collectors store entities, grouping together all the data pertaining to an entity and allowing you to handle the data as a group. Collectors in HyperForm consist of the Components, Materials and Sections (for Incremental_Radioss and Incremental_LsDyna analysis) panels. The component and material collectors in HyperForm have specific data associated with them. In one-step analysis, the component collector contains thickness data while the material collector holds the Young’s Modulus of Elasticity value and other constants. All entities in a HyperForm database are stored in collectors. Based on the analysis type, each collector may use a dictionary or card image to define the attributes assigned to the collector. The Collectors panel allows you to create and update collectors and assign and edit card images or dictionaries. Before you build a model, create a component collector for storing or organizing different data.. Exercise 2: Understanding collectors and using online help The Die_Mesh.hm file from Exercise 1 should still be loaded in HyperForm. In steps 1 through 6, you will practice changing the visualization of component collectors. 1.. In the Model Browser, click on the Mesh icon next to the Part component to turn off the display of the mesh for that component. Notice the mesh of the Part component is no longer displayed in the graphics area. The surface of the Part component is still visible.. 2.. Click the Mesh icon to turn the mesh display back on.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 25.

(30) 3.. Similarly, click the Geometry icon next to the various components to turn their display on and off. When finished, right click on the Components folder and click Show to display all of the components completely. In steps 4 though 11, you will review card images, assign a new material to the Part component, and use the online help.. 4.. From the Application menu, select Incremental_Radioss.. 5.. From the main menu, click the Components panel.. 6.. Double-click component: and select Part. The associated material is displayed. Notice material = Rigid_material.. 7.. Click edit card to review the card image in solver definition.. 8.. Click return to go back to the Components panel.. 9.. Click material: and select CRDQ Steel material.. 10. Click update. Notice the associated material is now changed to CRDQ Steel. 11. Press the H key to start the online help. The online help is launched, displaying the help topic for the panel. Review information for the Components panel. Return to the main menu when finished.. Session 5: Secondary Menu The secondary menu contains several stand-alone functions, like calculating the distance between two points. Accessing the secondary menu interrupts the active main panel and allows you to perform a function from the secondary panel and then return to the main panel. For example, a user can access the secondary menu by pressing the function keys, F1 through F12, Shift F1 through shift F12, and more.. Menu Items The menu items on each panel allow you to specify settings and enter information that is needed to perform the panel’s function. Panels can contain subpanels, function buttons, toggles, switches, entity selectors, direction selectors, data entry fields, input fields, and pop-up menus.. 26. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(31) In the following discussion of menu items, you will be using the Translate panel. Access it from the Geometry menu.. Entity Selector The entity selector allows you to choose the type of entity to be modified when performing a function. The entity selector may or may not have a switch ; some panels perform a function on only one type of entity. The entity selector button is yellow; when it is surrounded by a blue box, the collector is active and ready for you to select or pick the entities to be processed. You can click on the switch to change the entity selector type.. Direction Selector The direction selector allows you to define a plane or vector by using the global x, y, or z axis, or by selecting a vector, or by selecting nodes in the database.. Direction selector pop-up menu x-, y-, and z-axis Specify a direction along any one of the global axes. vector. Use a pre-existing vector entity (something you can create using the vector panel) to define a direction.. N1, N2, N3. Create a user-defined direction. Selecting two nodes, N1 and N2, allows you to define a vector direction with base point at N1 toward N2. Selecting three nodes, N1, N2, and N3, allows you to define a plane with base point at N1 (unless otherwise specified). The vector is normal to the plane and its direction is determined by the right hand rule.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 27.

(32) Direction vectors for 2 point and 3 point definitions. Clears the node selections.. Reset. Input Fields Input fields are used to enter text or numerical values. A description of the type of input precedes the field.. For numeric input fields, you can use the keyboard to enter the value or double-click the input field and use the pop-up calculator to enter the value.. An example to input values and operations is as below: "0.0 (default) + 6" will need to be inputted as 0.0(default), 6, +, enter. Pop-up Menus Pop-up menus display when there are several options from which to choose. For example, the extended entity selection menu (shown below) allows you to specify alternate methods for selecting entities of the current data type. To use the extended entity selection menu, click the yellow data type button of the entity selector. The menu automatically closes when you have made your selection. Notice the grayed-out options within the pop-up menu indicates that the function is disabled in the selected entity selection menu.. 28. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(33) Function Buttons The color of the menu button corresponds to its purpose: Green. Carries out a function or a command.. Red. Exits a panel or aborts a command.. Exercise 3: Translating Elements The Die_Mesh.hm file from the previous exercise should still be loaded in HyperForm.. Access the Translate panel by hot keys 1.. From the Geometry menu, select Translate.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 29.

(34) All selections under the Translate option are displayed. SHIFT + F4 is the hot key for the Translate function. 2.. Press SHIFT + F4 to access the Translate panel directly.. Select the elements to translate 1.. Click the entity selector switch. .. A pop-up menu is displayed, listing all the entity types that can be modified with the Translate panel. The mouse cursor is located at the center of the pop-up menu. 2.. Select elems to specify "elements" as the entity type you want to translate. After you select elems, the pop-up menu automatically closes. The yellow entity selector button displays "elems" and the button has a blue border to indicate that it is active.. 3.. Click elems. The extended entity selection menu displays, with the mouse cursor in the center.. 4.. Select by collector to indicate you want to select the elements by component collector. After you select by collector, a list of component collectors is displayed.. 5.. In the graphics area, pick a cyan element by clicking near its element handle (the dot in the center of the element). Selecting this element also selects the component collector containing the element, Part in this case. The element picked is momentarily highlighted white. The check box preceding Part has a white check mark in it.. 6.. Click select to select all the elements in the component collector, Part, as the elements to be modified when you use the translate function. The Translate panel again displays and all of the elements in the Part component are highlighted.. Specify a direction to translate the selected elements 1.. Click the direction selector switch. A menu is displayed with a list of plane and vector options for translating the selected entities. The mouse cursor is located at the center of the pop-up menu.. 2.. Click N1 N2 N3 to select the N1, N2, N3 method. After you select N1, N2, N3, the pop-up menu automatically closes.. 3.. Click N1. The blue border around N1 indicates it is active. The selected elements in the graphics area are now gray because the entity selector is not active.. 4.. In the graphics area, pick a node. A green circle displays in the graphics area at the node that was picked. The N1 button no longer has a blue border, but the N2 button does. N2 is currently active.. 30. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(35) 5.. In the graphics area, pick any other node. A blue circle displays in the graphics area at the node you specified. The N2 button no longer has a blue border, but the N3 button does. N3 is currently active, but in this case, a node for N3 will not be specified.. 6.. In the graphics area, right click the blue circle to deselect the node N2. The blue node N2 is not displayed in the graphics area. The N2 button now has a blue border.. 7.. In the graphics area, pick a different node. This new node is the new N2 node. A blue circle displays in the graphics area at the node you specified.. Specify a distance to translate the selected elements 1.. Double-click magnitude =. The calculator pop-up menu appears.. 2.. Input 50.0, click enter and click exit to leave the calculator.. 3.. Click translate +. The highlighted elements move 50 units in the positive N1-N2 vector direction with N1 being the vector’s base node and the vector passing through N2.. 4.. Click reject to reject the translation action.. 5.. Click f on the permanent menu. The model is resized to fit the screen.. Session 6: Default HyperForm Files HyperForm includes or automatically creates several default files. These include: hm.cfg. configuration file. hmmenu.set user interface settings command. cmf. command file. hm.cfg The hm.cfg file is a default configuration file read on start-up. The hm.cfg file controls many aspects of how HyperForm runs at your particular site. You can edit the commands in the hm.cfg file to your own preferences. command.cmf The command.cmf file is a standard ASCII file that HyperForm reads and writes. Command files allow you to retrieve a work session in case of a system crash or program a series of procedures. You can use a command file in applications that contain repetitive steps or you can create demonstrations. All commands executed by the HyperForm command processor are written to this file. This file is. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 31.

(36) automatically created in the directory in which you started HyperForm. If the file already exists, new commands are appended to the existing file. For more information about the command.cmf file, please see the HyperForm online help topic HyperForm Commands. hmmenu.set The hmmenu.set file is a binary file that HyperForm updates when you exit HyperForm. Your personal hmmenu.set file stores many global parameters and is located in the directory from which you started HyperForm. If the file already exists, it is overwritten after you run a new session. The most recent global parameter values in the current HyperForm session are written to this file when you exit. The next time you start HyperForm, it has the values recorded in the hmmenu.set file. If the file does not exist when HyperForm is invoked, the global parameter values are default values.. Return to HyperForm Tutorials. 32. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(37) Radioss One Step The following Radioss One Step tutorials are available:. HF-0150: Quick Setup HF-0200: Geometry Cleanup HF-0300: Automeshing HF-0400: Mesh Quality HF-0500: Model Preparation - Undercut Check and Autotipping HF-1000: One Step Stamping Simulation HF-1010: Increasing Blankholder Pressures HF-1020: Applying Drawbeads to a Model HF-1030: Transferring Forming Results to Crash Analysis HF-1040: Laser Weld HF-1050: Trim Line Layout. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 33.

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(39) HF-0150: Quick Setup This tutorial describes the steps required for modeling and running one step analysis that can be performed in HyperForm within the Radioss One Step user profile. The following steps are involved in one step analysis: 1.. Geometry cleanup and meshing. 2.. Assigning materials and thickness. 3.. Defining symmetry. 4.. Defining blankholders. 5.. Defining drawbeads. 6.. Setting the stamping direction either by tipping the part or by using the existing part orientation as the forming axis. 7.. Checking for undercuts. 8.. Running the analysis. Exercise 1: Geometry Cleanup and Meshing This exercise uses the model file Part1a.igs. The following image shows the program with the Radioss One Step user profile and model file loaded:. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 35.

(40) Step 1: Load the model file 1.. Click File > Import..... 2.. Click the Import Geometry icon. 3.. Click the Select Files icon and browse to the file <installation_directory>\tutorials\mfs\hf\1Step\part1a.igs.. 4.. Click Import and then click Close.. 36. .. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(41) Step 2: Geometry cleanup 1.. In the OneStep tab, right-click on Parts > New > Pick... as shown in the image below:. Note: The component name is recognized automatically as Part once the model is loaded into the session. 2.. Pick the part from the screen.. 3.. Click on proceed. Note: The material CRDQ steel and a thickness of 1 mm is assigned to the part by default.. 4.. Right-click on the part lvl1 and select Geometry > Remove Holes.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 37.

(42) 5.. In the diameter< field, enter 40.. 6.. Click on the yellow surfs button to highlight it. Click again and select displayed from the extended entity selection menu. This selects all the entities on the screen.. 7.. Click find. All pinholes found are highlighted with xP.. 8.. Click delete to close the hole.. 9.. Click return to close the panel.. Step 3: Meshing the part 1.. Right-click on the part lvl1 and select Mesh > R-Mesh.. 2.. Enter the values as shown below:. 3.. Click on Mesh..... 4.. Click surfs and select displayed from the extended entity selection menu. This selects all the surfaces displayed on the screen.. 5.. Click proceed.. 6.. Click Close.. Exercise 2: Setting up One Step Analysis. 38. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(43) Step 1: Assigning the material and thickness to the part 1.. Right-click on CRDQ Steel > Database... to change the material selection. Note: A user-defined material can also be added to the database by editing the material file hf.dat.. 2.. When finished viewing/changing the material selection, click Close to close the dialog.. 3.. Highlight Thickness:1 by clicking on it once. Double-click on the digit 1 to make it editable and change the value to 1.5.. Step 2: Setting symmetry conditions 1.. In the OneStep tab, right-click on Symmetry:No > Edit.. 2.. Click on the yellow nodes button and select on plane from the extended entity selection menu.. 3.. Click the toggle switch to x axis.. 4.. Pick a point on the symmetric plane, as shown below.. 5.. Click select entities.. 6.. Under Constraint Type, click the X radio button.. 7.. Click size = and enter 10.. 8.. Click update.. 9.. Click return.. constraints along the symmetric edge. Step 3: Setting the stamping direction. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 39.

(44) 1.. Right click on Stamping Direction:X and select Z. Note: Stamping can also be done in any of the three principal axes or an arbitrary axis in space by using Stamping Direction in the Autotip panel. Use the stamping direction subpanel to specify the stamping in an arbitrary direction. –. In the Autotip panel, use the vector selector switch to assign a direction. If the stamping direction of the part is not one of the principal axes, use N1, N2, N3 option and select 2 nodes on the model to define a direction.. –. Click set.. Step 4: Selecting the blankholder Blankholders can be defined as the upper and lower holding surfaces that control metal flow around a shape to be formed in a draw operation. They supply a restraining force on the material during the pressing process. HyperForm allows you to define the blankholder force in two ways: on element and on edge. The correlation between the magnitude and level of the applied forces is always available. Edge blankholder force application allows you to restrain an edge by enabling automatic selection of all nodes between two user-defined nodes along a free edge of a part. You can define the blankholder force in two ways: tonnage force or pressure level (high, medium and low). Note. The pressure level is proportional to the area of blank under the blankholder as well as thickness. A pressure level of 2MPa, 5MPa and 10MPa for a 1mm blank has been chosen as a reference for Low, Medium, and High (based on practical experience). The tonnage (metric ton unit) is equivalent to the pressure times the blankholder area normalized/scaled by the thickness (1 metric ton = 9810N).. 1.. In the OneStep tab, right click on Blankholders > New. If desired, you can double click on Blankholder1 to change the name.. 2.. Right click on Blankholder1 > Elements…. 3.. Click elems and select on plane.. 4.. Select z-axis and pick a node on the binder (flat region) for B (base node).. 5.. Click proceed.. 6.. Friction, Tonnage and Pressure level appears below Blankholder1. Double click on the values for Friction and Tonnage to change the values.. 7.. Right click on Pressure Level: and select Medium. Notice that the Tonnage changes according to the selected pressure level.. Step 5: Creating drawbeads Modeling the exact drawbead geometry requires a large number of elements, which increases CPU time dramatically. A practical approach is to use an equivalent drawbead model by representing the drawbead analytically and providing a constant drawbead restraining force and closure force.. 40. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(45) Use the calculate subpanel to determine the closure and restraining force based on drawbead dimensions. The restraining force is the value of the force (per unit length) applied by the bead in the plane of the blank surface. The closure force is the force (per unit length) required in the perpendicular direction to keep the drawbead closed.. 1.. From the OneStep tab, right-click on Drawbeads > New > Restrain….. 2.. Pick two nodes on the part as indicated in the image below to define the drawbeads.. 3.. Click create. Notice a message shows "The drawbead set has been created." A line representing drawbeads is created.. 4.. Notice that Drawbead1 is created with a default Restraint Force and Pressure Level. Double click Drawbead1 to rename it.. 5.. Right click on Pressure Level > Medium. Notice that Restraint Force changes based on the Pressure Level selection.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 41.

(46) Step 6: Tipping 1.. Right click on the OneStep tab anywhere in the red box as shown below and select Autotip.. 2.. Select the autotip radio button.. 3.. Verify the entity selector is set to comps and select the lvl1 component.. 4.. Verify the toggle is set to full model and keep the rest of the options as default.. 5.. Click calc autotip. Notice the angle to be tilted is displayed on the header bar on the left hand bottom corner and the magnitude is displayed in the angle field. 6.. Click autotip.. 7.. This action will tilt the part by an angle calculated by HyperForm to reduce draw depth during forming.. 8.. Click return.. Step 7: Checking for undercuts 1.. 42. Right click on the OneStep tab anywhere in the red box as shown above and select Undercut Check.. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(47) 2.. Click on the yellow comps button to highlight it.. 3.. Pick the part from the screen.. 4.. Click on check undercut. Notice the message “0 elements with undercut detected”. If there are undercuts in the model then the failed elements are highlighted on the screen.. 5.. Click return.. Step 8: Checking the model and running the analysis 1.. Right click on the OneStep tab anywhere in the red box as shown above and select Check Model. A message is displayed on the message bar, stating “Model checked.”. 2.. Right click on the OneStep tab and select Run.. 3.. Enter a name for the run. The feasibility solver launches, as shown below: Note: It is advised to run the analysis into a separate folder.. Exercise 3: Post processing After the successful completion of the run, right click on the white space of the OneStep tab to see the Blank Shape, %thinning and Formability options, which were not available before running the analysis.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 43.

(48) Right click and select the desired result type for post processing.. Step 1: Blank Shape 1.. Right click on the OneStep tab anywhere in the white space and select Blank Shape.. 2.. Under Blank Shape Profile: click on the Initial radio button. Notice that the initial blank shape is displayed on the screen, as shown below.. 3.. Click on export to write out an iges boundary of the predicted blank shape to the folder where feasibility analysis was run. The file will be named as <filename>_blank.iges.. Exercise 4: Blank Fit. 44. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(49) Step 1: Fitting the initial blank shape into different configurations 1.. From the Tools menu, click on Blank Fit. This will bring up the blank fit utility, as shown below:. 2.. Use the Part drop down menu to select the component on which the one step analysis was run.. 3.. Keep the default values for Density and Cost per Kg.. 4.. Under PLOT OPTIONS, click on the checkbox next to %Thinning and Formability. Notice that % Thinning and Formability buttons becomes active.. 5.. Rotate the model to a desired direction and click on %Thinning. This contours the model with % Thinning result type.. 6.. Left click to capture the image to include it in the report. A right click will abort the function and return to the Blank Fit macro. This is indicated by the image on the right hand bottom corner of the graphics area .. 7.. Under BLANK SHAPES, check all the boxes.. 8.. Click on Blank Fit. This will fit the blank into the selected shapes.. 9.. Click on Publish Report. This will open a HTML report with hyperlinks to blank shapes and results, as shown below.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 45.

(50) 11. Click Close.. Exercise 5: Blank Nest Step 1: Nesting the initial blank shape on coil or sheet 1.. Click Tools > Blank Nesting.. 2.. Click on elems and select displayed from the extended entity selector menu.. 3.. Click on the nesting button. A new window called Blank Nesting opens which allows you to nest the blank in different configurations.. 46. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(51) 4.. Right click any where on the blank shape and select Duplicate. This will create a duplicate of the existing blank shape.. 5.. Right click anywhere on the blue screen and select Auto nesting from the menu. This will make the best fit of the 2 shapes of the blank on a sheet.. 6.. Click on File > Export.. 7.. Enter a name and click on Save. This saves an .iges boundary of the nested sheet.. 8.. Select File > Exit to close Blank Nesting, Note: There is a detailed explanation of all the options in Blank Nesting in the HyperForm online help.. Exercise 6: Report Generation Step 1: Publishing a report of the feasibility analysis results 1.. Click Tools > Report Generator. The Report Generator opens up as shown below:. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 47.

(52) 2.. Click on the Result File: file browser icon and select <filename>.res in the folder where you have run the feasibility analysis. Note: You must run feasibility analysis in a separate folder with no spaces in the path and in the folder name.. 3.. Click on the Report Name: file browser icon and type a name for the report. Note: The folder and report name must not have any spaces in the folder name or file name.. 4.. Check all the boxes under Result Types.. 5.. Under Export Mode, select HTML.. 6.. Under Export Options, select JPEG.. 7.. Click on Generate. This creates a report in the folder selected in the Report Name field. It includes a folder called <filename>_data_dir and <filename>.hml.. 8.. Open the folder that was selected for Report Name. Open the file <filename>.html in Internet Explorer or Firefox. This opens a html page with hyperlinks to the selected result types and the corresponding image with contour, as shown below:. 9.. Click Close to close the panel.. Return to Radioss One Step Tutorials. 48. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(53) HF-0200: Geometry Cleanup When designers create CAD geometry, their priorities are different from those of analysts trying to use the data. A single smooth surface is typically split into smaller patches, each a separate mathematical face. The juncture between two surfaces often contains gaps, overlaps, or other misalignments. To make the geometry more appropriate for meshing, analysts need to combine a number of faces into a single smooth surface. A single, smooth surface not only allows the elements to be created on the entire region at once, but also prevents unnecessary artificial or accidental edges from being present in the final mesh. Sometimes, the gaps, overlaps, and misalignments present when surface data is imported can affect the mesh quality. By eliminating misalignments and holes, and suppressing boundaries between adjacent surfaces and unnecessary details, you can automesh across larger, more logical regions of the model and improve the overall meshing speed and quality. In this tutorial, you will use a variety of tools to prepare surface geometry for meshing. Exercise 1: Reviewing Geometric Problems Exercise 2: Fixing Geometric Problems. Tools Auto Cleanup panel The Auto Cleanup panel performs automatic geometry cleanup. Quick Edit panel (F11 hotkey) This panel combines many tools for rapid editing of model geometry.. Exercise 1: Reviewing geometric problems In this exercise, you will first review a variety of common geometric problems after reading a CAD file. The. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 49.

(54) solutions are discussed in Exercise 2. This exercise uses the model file Bpillar_cleanup.hf.. Step 1: Load the model file 1.. Click File > Open..... 2.. Browse to the location <Installation Folder>\tutorials\mfs\hf\1Step and select the Bpillar_cleanup.hf file.. 3.. Click Open.. Step 2: Review the model in Topology color mode 1.. Click View > Toolbars > Visualization to display the Visualization toolbar. The Visualization toolbar will need the panels displayed also in the View menu.. 2.. From the toolbar, select Geometry Color Mode. and change to By Topo.. Notice the color of the model is changed and topology definitions are displayed on screen. 3.. From the toolbar, click Shaded Geometry & Surface Edges. icon to shade the surfaces on screen.. The model comes in with several geometric problems after importing. You will first review the problems to have a better understanding of the nature of the model. In Topology color mode, each color represents different topological modes: Free edge (Red color): The edge is owned by one surface. On a clean model, free edges appear only along the outer perimeter of the part and internal holes. Free edges that appear between two adjacent surfaces indicate the existence of a gap between the two surfaces. Shared edge (Green color): The edge is owned by two adjacent surfaces. When the edges between two adjacent surfaces are shared (green), there is no gap or overlap between the two surfaces, and they are geometrically continuous. The automesh utility always places seed nodes along their length and will. 50. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(55) produce a continuous mesh without any gaps along that edge. The automesh utility will not construct any individual elements that cross over a shared edge. Suppressed edge (Blue color): The edge is owned and shared by two adjacent surfaces but it is ignored by the automesh utility. They are blue dotted lines by default. Like a shared edge, a suppressed edge indicates geometric continuity between two surfaces but, unlike a shared edge, the automesh utility will mesh across a suppressed edge as if were not even there. The automesh utility does not place seed nodes along their length and, consequently, individual elements will span across it. By suppressing undesirable edges you are effectively combining surfaces into larger logical meshable regions. Non-manifold edge (Yellow color): The edge is owned by three or more surfaces. They typically occur at "T" intersections between surfaces or when 2 or more duplicate surfaces exist. The automesh utility always places seed nodes along their length and will produce a continuous mesh without any gaps along that edge. The automesh utility will not construct any individual elements that cross over a nonmanifold edge. These edges cannot be suppressed and can sometimes be indication for duplicated geometry.. Step 3: Review and measure the largest pinhole diameter 1.. From the toolbar, select the Visualization icon. 2.. From the Visualization tab, select the Topology icon Non-manifold check boxes.. . and clear the Shared, Suppressed and. Only the red free edges display. 3.. Click Close to close the Visualization tab.. 4.. Press T on your keyboard and input thetax = -101.154, thetay = -59.845 and thetaz = 109.363.. 5.. Click set angles to set the true view.. 6.. Notice several pinholes as shown in image below.. Notice the biggest pinhole as indicated in the left side of the image is considered as a part of the feature and will be kept. The smaller holes on the flange area are considered removable. 7.. Press F4 on the keyboard to go to the Distance panel.. 8.. Hold the Ctrl key and middle mouse button to draw a circle to zoom in the center bigger pinhole on the flange as indicated in the image below.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 51.

(56) 9.. In the Distance panel, select the two nodes option. Notice a halo is surrounding N1.. 10. Hold the left mouse button and move the mouse cursor to the N1 location on top of the hole (location A in the image) until the hole is highlighted. Release the left mouse button and click again to create a temp green node created on top of the hole. 11. Repeat the same procedure for N2 to create a second blue temp node as shown as location B in the image. 12. Notice the diameter of the hole (value next to distance = ) is about 3.2. The approximate diameter of the largest hole is about 3.2. Remember this value so you can apply it when you remove pinholes later. 13. Press F on the keyboard to fit the model to the screen. 14. Click return to close the panel.. Step 4: Review free edges 1.. From the toolbar, select the Wireframe Geometry icon. 2.. Notice several red lines as shown as in the image below. An example can be found as indicated where an arrow is pointing.. .. Free edges that appear between two adjacent surfaces indicate the existence of a gap between the two surfaces.. 52. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(57) Step 5: Review a missing surface 1.. From the toolbar, select Shaded geometry and surface edges. .. The surfaces are shaded on the screen. 2.. From the toolbar, select the Visualization icon. 3.. From the Visualization tab, select the Topology icon manifold to turn on the display of all definitions.. 4.. Click v on the keyboard to open the dialog with saved views.. 5.. Click restore 1 to display the previously saved missing surf view.. 6.. Notice the missing surface as shown in the image below.. . and check Shared, Suppressed and Non-. Step 6: Review the distorted surface 1.. Click v on the keyboard to open the dialog with saved views.. 2.. Click restore 2 to display the previously saved distorted surf view. Notice the dark shadow on top of the surface as indicated in the image below.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 53.

(58) You will use the Automesh panel to verify the quality of the surface in the following procedures. 3.. Click Mesh > Auto Mesh.. 4.. Click surfs and select only the surface with dark shadow. Notice two surfaces are selected as shown in the image below. This is a first indication of distorted surface.. 5.. Click element size = and input 0.5.. 6.. Click mesh. Notice the mesh pattern has poor quality and higher node density at the center area (along the center shared edge). This is a second indication of the distorted surface.. 54. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(59) 7.. Click abort to abort the meshing operation.. 8.. Click return to close the panel.. Step 7: Review the duplicated surface In this model, you have duplicated surfaces existing in this model. 1.. Click v on the keyboard to open the dialog with saved views.. 2.. Click front to review the front view. Notice the yellow lines surrounding the surface as indicated by an arrow below:. 3.. Click Geometry > Defeature and then select the duplicates subpanel.. 4.. Click the switch and change to faces.. 5.. Click find. Notice the two surfaces are highlighted and identified.. Step 8: Review deviated trim line 1.. Click v on the keyboard to open the dialog with saved views.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 55.

(60) 2.. Click restore 3 to display the previously saved improve share view. Notice the deviation of one trim line as circled in the image below. The deviation of the trim lines could cause poor mesh quality. An ideal trim line will look like the dash line on the right hand side of the image below. You will correct this problem later.. Step 9: Review incorrect fixed point definition 1.. Click v on the keyboard to open the dialog with saved views.. 2.. Click restore 4 to display the previously saved fixed point view. Notice the incorrect definition for the free boundary. This is due to the incorrect definition of the fixed point as indicated in the image below.. Exercise 2: Fixing geometric problems In this exercise, you will use a variety of tools to fix the geometric problems.. Step 10: Remove pinholes using the Auto Cleanup panel. 56. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(61) 1.. From the Geometry menu, select Auto Cleanup.. 2.. Click edit parameters… to launch the Parameters File editor to modify Auto Cleanup settings.. 3.. In the Parameters File editor, clear all settings under Other options:. 4.. Click the. 5.. Repeat the steps above and disable all options EXCEPT Geometry cleanup and Surface hole recognition.. 6.. Click. 7.. In the first row under Surface hole recognition, input 4.0 under R< and check the Remove option. The final result should look like the image below. Since the largest diameter of the holes on the flange is about 3.2, using the value 4.0 can make sure all the holes on the flange will be removed.. 8.. Change Target element size: to 3.0.. next to Other options and change to . This disables the other options.. (Delete line) to delete the second row under Surface hole recognition.. The target element size is the desired mesh size after geometry cleanup.. 9.. Click Apply and Ok to return to the Auto Cleanup panel.. 10. Click surfs and select all from the pop-up window. 11. Click autocleanup. Notice the cleanup process is launched. A message is displayed "There is a conflict between the user requested element size of 3 and the quality criteria ideal element size 0.5 used in the optimization, How do you wish to proceed?". Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 57.

(62) 12. Click Continue. When the cleanup process is finished, a message "Geometry cleanup process is finished" is displayed in message bar. After the auto cleanup process, notice that: The four holes on the flange are removed. The number of free edges (red edges) is reduced as shown in the image below. If you wish to see only the free edge definitions, select the Visualization definitions EXCEPT Free edges.. icon and deactivate all topologic. Duplicate surfaces are removed.. 13. Click return to close the Auto Cleanup panel.. Step 11: Fix the missing surface using the Quick Edit panel In this step, you will manually clean up geometry using Quick edit panel. 1.. From the toolbar, select the Visualization. 2.. From the toolbar, click the Shaded Geometry & Surface edges icon. 3.. Click v on the keyboard to open the dialog with saved views.. 4.. Click restore 1 to withdraw previously saved missing surf view.. 5.. Click F11 to access the Quick Edit panel.. 6.. Click the line(s) button right next to filler surf:.. icon and activate all topologic definitions. to shade surfaces.. A blue halo appears and surrounds the line button. 7.. Click any red edge of the missing rectangular surface. A surface is created to fill the missing surface. Notice the previous four free edges are now changed to a green shared edge.. 8.. Click return to close the panel.. 58. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

(63) Step 12: (optional) Delete the distorted surface and recreate it Using the Auto Cleanup function, most of the time, distorted surfaces are removed automatically. If you don't see distorted surfaces after the Auto Cleanup operation, skip this step. 1.. Click v on the keyboard to open the dialog with saved views.. 2.. Click restore 2 to display the previously saved distorted surf view.. 3.. Press F2 on the keyboard to go to the delete panel.. 4.. Click the entity selector and change it to surfs.. 5.. Click surfs and select the distorted surface (the surface with dark shadow) from the screen.. 6.. Click delete entity. This action deletes the distorted surface.. 7.. From the menu bar, click Geometry > Create > Surfaces > Ruled.. 8.. If necessary, click the switch to set the selection to line list. Click the upper line list selector and select the three red edges as shown in the image below.. 9.. Click the lower line list selector and select the one red edge as shown in the image below.. 10. Verify that auto reverse is activated. 11. Click create. 12. Click return.. Notice a new surface is created at the same location. The new surface has three shared (green) edges and one free (red) edge as indicated in the image below.. Altair Engineering. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. 59.

(64) 13. Press the F11 key to open the quick edit panel. 14. Click the line(s) button right next to toggle edge:. 15. Change the tolerance to be 0.1. This is the geometric cleanup tolerance. 16. Use the left mouse button to click the red free edge to turn it into a shared green edge. 17. Click return to close the panel.. Step 13: (optional) Delete the duplicated surfaces Using the Auto Cleanup function, most of the time, duplicated surfaces are removed automatically. This step is optional if you wish to remove duplicated surfaces manually without Auto Cleanup. If you don’t see duplicated surfaces after the Auto Cleanup operation, skip this step. 1.. Click Geometry > Defeature.. 2.. Select the duplicates subpanel.. 3.. Change the entity selector from surfs to faces.. 4.. Click faces and select all from the pop-up window.. 5.. Click find. Notice two duplicated surfaces are highlighted and identified.. 6.. Click delete to remove the duplicated surfaces.. 7.. From the toolbar, select the Visualization icon. 8.. From the Visualization tab, select the Topology icon and uncheck Shared, Suppressed and Nonmanifold to turn off the display of all definitions EXCEPT free edge (red line).. 9.. From the toolbar, select the Wireframe Geometry icon. .. .. Notice a red circular line indicating free edge. Since there is no hole existing, it indicates a problem with redundant surface.. 60. Manufacturing Solutions 11.0 Tutorials - HyperForm Proprietary Inform ation of Altair Engineering. Altair Engineering.

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