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  3. Training Module #1: The Design Workflow

Training Module #1: Design Workflow (Click-Along)

Video

Summary

You are the engineer in charge of design sizing this wing – all the way through PDR.

00_ProblemDescription.png

Using HyperX:

  • Optimize wing skins, spars, and ribs to external loads applied in the FEM.

  • Enforce manufacturing constraints and understand the effect they have on design results.

  • Visually interrogate and verify Sizing results.

  • Export a Stress Report to support design review documentation.

Part 1: Setup and Run First Sizing

This portion of the training example largely follows the HyperX Basics, found in the Getting Started help category. We recommend referencing those articles for more information as you are walking through this example!

Open Database and Project

A Database is the center of all operations in HyperX. When working in HyperX, you are working in a Database. Within a Database, there are Projects. This particular training Database has only 1 Project. To understand more about HyperX file organization, see File Organization Overview.

Path: C:\HyperX\Training\[Version#]\

Database: Training Module #1 - Design Workflow_[Version#]

Project: Design Workflow - UAM Wing

01_DBFileBrowser.png

Note

If prompted in Project Options, select Design Workflow – UAM Wing and select Open Project.

Import Finite Element Model

  1. From the Model tab of the Ribbon, select ‘FEM Import’.

    femImport_fromRibbon.png

  2. Click "Add". Then, use the browser to navigate to: C:\HyperX\Models\Wing UAM\ folder and select WingUAM_01a.dat.

    FEMImportFormTraining

  3. Open the Units window.

  4. Change the ‘FEM units’ section to match the SI units system used in the FEA.

  5. Click ‘Apply’ to import the FEM.

Note

For more information on the FEM Import process, as well as the different element and load case types supported by HyperX, see: FEM Import and corresponding reference documentation linked throughout that page.

The model will populate the Viewport behind the FEM Import form.

Tip

If you don't immediately see the model after clicking "Apply," try resetting the Viewport. Do this by clicking one of the sides on the View Cube (upper right corner of the screen) to center the model about the corresponding perspective.

image5.png

Setup Design Load Cases

Design Load Cases correspond to FEM Subcases. These are the load scenarios that will be evaluated in HyperX Sizing and Analysis routines. To understand more, see Design Load Cases.

  1. Open the Design Loads form.

  2. Change the Analysis Temperature to 120F for all cases (as shown below).

  3. Change the Ultimate Safety Factor to 1.5 for all cases (as shown below).

  4. Click ‘Apply’ and close all forms.

Note

Both options for Step 2 and 3 are available if you: Use ctrl+a to select all rows and Right-click to reveal a menu of options.

04_DesignLoads.png

Organize Model into Structures

After importing the FEM, FEM properties must be moved into Structures in order to become HyperX Zones. See Transitioning from FEM to HyperX to understand more.

For this model, we'd like to create Zones by organizing them into Structures based on part type:

055_StructureOverview.png

Create Upper Skin Structure - Using the Ribbon and Viewport

  1. From the Structures tab of the Ribbon, select ‘Create Structure’.

  2. Name the Structure.

  3. Use the Viewport to select the Upper Skin FEM property.

  4. Click ‘Create’.

05_StructureCreation-fromRibbon.png

Tip

You can hide the Upper Skin Structure to have direct access to Substructure Properties in the Viewport.

Create Rib Structure – Using the FEM Tree

  1. In the FEM tree, Type ‘Rib’ into the search bar to isolate all FEM Properties with the word ‘Rib’ in the title.

  2. Use Ctrl to select all Rib Properties.

  3. Right-click and select ‘Create Structure’ from the resulting menu.

  4. Name the Structure.

  5. Click ‘Create’.

06_StructureCreation-fromTree.png

Create Remaining Structures Using Tools of your Choice.

Compare the resulting Structure and FEM Trees with the images below to verify your Structure creation.

Tut4_6.png

Organize Model into Sets

Sets are a user-defined group of Zones - created for user convenience in terms of viewing, assigning Properties, and isolating certain portions of the model. For this example, group the lower and upper skins into a "Skins" Set. Do the same for the ribs and spars in an "Internal Substructure" Set.

Create Sets

  1. From the Structures tab of the Ribbon, select ‘Create Set’.

  2. Name the set and select Zones to be assigned.

  3. Click ‘Create’.

  4. Repeat using spars and ribs to create an internal substructure Set.

07_SetCreation-Skins.png

Note

Sets that have been created appear in the Structure Tree under the "Sets" node.

Verify Set Creation

To double-check assignment:

  • Right-click on the node of a Set and select ‘Show Only’ - OR -

  • On the View tab of the Ribbon, select Color Mode > Set to color the Zones by Set assignment.

08_VerifySetCreation.png

Assign Panel Properties

Recall: In order to Size or Analyze a Zone, it must be assigned a:

Each Property was pre-defined in the Database Template. Find them in the Property Tree. Double-click on any given Property to understand its definition.

09_PanelProperties.png

Review Properties

The images below summarize the Properties used to define panel Zone sizing.

10_ReviewProperties.png

Assign Properties

11_AssignProperties.png

To assign a Property to a Zone:

  1. Use the Viewport to select the 2D Zones.

    Tip

    Use the Structure Tree to hide the 1D beams to make shell selection easier.

  2. Drag the desired Property from the Property Tree onto the selected Zone.

    Note

    The color of the selected Zone will flash to confirm that the Properties were successfully assigned.

  3. Repeat for each Property to fully define the Zone

Assign Beam Designs

12_ReviewBeamProperties.png

Apply the following Properties to all beam Zones:

Design: Caps – Solid Laminate

Load: Peak – All

Analysis: Caps

13_AssignBeamProperties.png

Size Wing

  1. Select the entire wing.

  2. Navigate to the Run tab of the Ribbon.

  3. Click ‘Size’.

14_SizeWing.png

Tip

The ‘Size’ button also comes prepopulated in the Custom Ribbon (left-side of image) for quick access.

Review Sizing Results

Open the Legend and start plotting results directly on the model. Turn on the Weights option in the Structure Tree.

15_Legend_Weight.png

  • Review ply counts per panel.

16_PlyCounts.png

  • Review beam thicknesses.

17_BeamThickness.png

Part 2: Split Up Zones and Re-Run Sizing

Understand What is Driving Sizing

Open the Analysis Watch Window to review margins of safety per Zone. Let’s focus on the upper skin, as it is the heaviest

18_AnalysisWW.png

Sizing is driven by analytical panel buckling. What goes in to this calculation?

  1. Right-Click>Criterion Documentation to open the Help System page for the controlling metric.

image27.png

Knowing that, how do we visualize the buckling lengths for the upper skin Zone?

  1. Open the ‘View’ tab of the Ribbon.

  2. Click ‘Indicators’.

  3. Select ‘Buckling Spans’.

19_BucklingSpan.png

Evoke Engineering Judgement

image6.png

  • Based on engineering knowledge, we know that the greater the buckling length, the smaller the critical buckling load (i.e. the more buckling critical a structure is).

  • Buckling lengths are calculated per Zone based on the number of elements, size of elements, etc. Since the upper skin is all one Zone, the buckling lengths span the entire skin.

  • However, the model contains ribs and spars that will serve as ‘panel breakers’ in the physical world – thereby breaking up the buckling mode shape.

∴ The model should be updated to have a Zone within each panel breaker section. This will reduce the model to more reasonable buckling lengths and result in a realistic representation of the Structure.

Run Zone Splitter Utility

  1. Open the Structures tab of the Ribbon.

  2. Select ‘Split Up Zones’.

  3. Select the entire model.

  4. Choose to split on Orthogonal Members and Beam Intersections.

  5. Click ‘Commit’.

image29.png

A new Zone has now been created at each orthogonal boundary. Notice that:

  • Design, Load, and Analysis Property definitions are inherited from the parent Zone.

  • Buckling Lengths have been recalculated accordingly.

image30.png

Re-Run Sizing and Review Results

image31.png

Now that the Zones have been split:

  • Each Zone has its own cross-section and MS result

  • Lighter weight

  • More accurate buckling margin calculations

Show only the skins

image32.png

Analysis Results:

  • Min. Margin: 0.030

  • Controlling Criterion: Analytical Buckling

Note

The upper skin is still controlled by analytical buckling. Perhaps changing the design to something more buckling efficient would lead to lighter results.

Part 3: Size Upper Skin as Honeycomb Sandwich

Create a Sandwich Design Property

Sandwiches are more efficient in buckling-driven structures. Let’s try a sandwich design.

  1. Navigate to the Design tab of the Ribbon.

  2. In the ‘Panel Designs’ section, select the ‘Sandwich’ rise-up.

  3. Select ‘Honeycomb Sandwich’ from the resulting menu.

image33.png

Define Design Property

On the Design Property form…

  1. Name the Design Property.

  2. Select ‘Laminate’ as the Material System.

  3. Select ‘Detailed Sizing’ as the Sizing Mode.

    image34.png

  4. Apply the Laminate Family “LamFam_CollierThinPly_Symmetric” as the Material selection to the top facesheet.

    Note

    Detailed Sizing = Parametric Sizing Optimization meaning the user is responsible for selecting the Sizing bounds and Material inputs for each object.

    1. Right-click in the Material selection field.

    2. Choose ‘Select Laminate Family’.

    3. Select “LamFam_CollierThinPly_Symmetric”.

    4. Repeat for the bottom face.

    image35.png

  5. Select honeycomb Materials and define Sizing bounds for the core object.

    1. Material Selection

      • ECA-1/8-1.8 (1.5)

      • ECK-1/8-2.5 (1.4) Typical

      • Hexcel 3.1 pcf 1/8-5052-.0007

    2. Bounds

      • Min= 0.125in

      • Max = 0.75in

      • Step = 0.125in

    image36.png

Create Sandwich Analysis Property

  1. Create a new Panel Analysis Property.

  2. Name the Analysis Property.

  3. Use the "..." buttons to add existing Failure Modes to the Analysis Property, as shown.

  4. Click 'Apply' to save to the Database.

image37.png

Assign Sandwich Properties to Upper Skin

Use mechanisms defined earlier (drag-and-drop) to assign new sandwich design and analysis property to the upper skin. The load property can remain the same as before.

21_SandwichAssign00.png

Size Upper Skin and Review Results

  1. Select the skins.

  2. Click ‘Size’.

  3. Note the drastic change in weight. Open the Legend to start reviewing specifics.

    21_SandwichResults01.png

  • View Ply Counts per Facesheet - Sizing Results > Laminates > Total Ply Count.

    22_SandwichResults02.png

  • View Selected Core Material per Zone - Sizing Results > Materials > Honeycomb.

    23_SandwichResults03.png

Part 4: Design Upper Skin for Producibility

Update Sandwich Design to One Core Material

Perhaps you have just found out from your machine shop that they have Kevlar core readily accessible. The sizing should be updated to only allow for that material in the core.

  1. Open existing Design Property.

  2. In the Core object: Right-Click > Select Materials.

  3. Select only ECK-1/8-2.5 (1.4).

  4. Click ‘Apply’.

SandwichDP.png

Run HyperFEA to Converge Loads

Tip

HyperFEA will automatically run Sizing for all Zones organized into Structures. Assign new sandwich Design Property to Lower Skin to get more realistic results (but we won't focus on those results in this example).

Now that the Sizing has changed, the stiffness has changed. Use automated FEA Iteration tool (HyperFEA) to get updated load paths.

image42.png

After five iterations, the loads should be converged. This is evidenced by the similarities in mass value in the last two Sizings. The iterated loads will be used for Sizing from here on out.

image43.png

Use Dimension Overrides to Implement Core Taper

By default, HyperX chose the weight-optimum core height per Zone – but this is not the most manufacturable solution

  1. Use the Legend to plot the core thickness resulting from the last Sizing in the upper skin.

image44.png

Enforcing a core height taper down the wing, as shown below, will result in a more producible result. Within each tapered section, all Zones should inherit the maximum core height.

image45.png
image46.png

  1. Select the first section of Zones.

  2. Design > Dimension Overrides > Sizing Overrides.

  3. 0.5in for all Zones.

  4. Click ‘Apply’ to save changes.

image47.png

Repeat for remaining two sections. Re-Size to verify results.

image48.png

Note

The Design Property now indicates that Dimension Overrides exist for assigned Zones.

image49.png

Sequence Facesheet Laminates into Global Plies

Translate results per Zone into a Structure-level Ply layup scheme.

  1. Select the Upper Skin Structure.

  2. Go to the Composite tab of the Ribbon.

  3. Select the Sequencing Rise-Up.

  4. Choose “Top Face/Skin”.

image50.png

Sequencing table lays Zone-level solutions into global Plies.

  1. Choose ‘Sequence’ to generate top face Plies.

  2. Click ‘Apply’.

  3. Review Plies created in Structure Tree.

image51.png

Repeat for bottom face and core and notice all entities now have nodes in the Structure Tree. If you see a warning about "dirty" analysis results, close the Sequencing form, re-run Analysis, and try Sequencing again.

image52.png

View Global Plies on Model

You can visualize the results by:

  1. Enable Ply Visualization by pressing the "Plies" button on the Structures Tree.

  2. Choose the Ply Visualization Mode. We can use the "Exploded" view here.

  3. Optionally, use the "Ply View Options" to alter visualization settings.

end_plydisplay.png

Tip

Global Plies can be used to communicate the design to CAD.

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