There are a myriad of ways to mathematically quantify “variation of a part surface.” As introduced in Variation as a Measure of Producibility, HyperXpert offers two methods for quantifying Design Variation across a part. Both are explained in the proceeding sections.
Important
As of HyperX Version 2024.1.8, Run Sets can only be plotted with respect to # of Constants (a.k.a Unlinked Variables). Variability Scoring can be shown for each Point on the Plot by enabling the "Show Design Variability" Plot Option.
The first algorithm quantifies variation by determining the total number of variables within a part.
A Constant dimension is a cross-sectional dimension that is same across all Zones in the part. The thickness in Design #1of the Simple Example given in the previous article is an example. Variables, then, are the opposite - dimensions that are not the same across Zones. The more Constant cross-sectional dimensions, the less Design Variation there is across a part, and the more producible it becomes.
To mirror previously explained trends, this data is plotted in terms of Design Variability (# of Variables). So, the more Design Variability along a part surface, the harder it is to manufacture - thus ensuring that the lightest weight design with the most variation is found in the bottom right of the plot. In the example Design Property below, there are 3 Variables (indicated by the black boxes). All other inputs are Constants (i.e. all Zones will have the same dimensions for these values).
HyperXpert runs full factorial design of experiments (DOE) of all possible ways design variables and their prescribed values can be forced constant across a part surface. For each solution to the DOE, the number of Constants vs. Variables are stored. The weight of each solution is then plotted with respect to the total number of Variables in the design. See the example plot below.
Using the tree on the left, each Data Point can be identified if it is a design that is held constant at the selected dimension. For example, all red points in the image above represent designs in which all Zones have a stiffener height of 0.7in. For more information on identifying points and operating the plot interface, see The HyperXpert Viewer.
Further explaining the example above:
Starting on the right where #variables = all* - This one datapoint has maximum variability. This represents the typical HyperX Sizing result that allow every dimension and every Material/Laminate to be different throughout the Structure, across all Zones. This one data point is the lightest design from the lightest Sizing result of every Zone.
Moving to the left, the axis with #variables = all* - 1 - Represent designs that have one constant input across all Zones. Such as H=1.2” or Spacing = 7”. Only the lightest design of each unique variable is displayed.
Moving furthest left where #variables= 0 - These datapoints have all Constant input values. These are designs that have every dimension and every Material/Laminate the same across all Zones. As such, these designs have to carry the highest load of any Zone and are the heaviest.
Note
The less Design Variation there is across a part, and the more producible it becomes.