3 Geometry Import-Altair Flux

ALTAIR FLUX 2019
CH3 - GEOMETRY AND IMPORT

© 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair Flux, v2019
CHAPTER 3 - GEOMETRY AND IMPORT

3. Geometry and Import
• Modeling strategy
• Geometry building
• 2D/Skew
• Sketcher
• Overlay
• 3D
• Modeler
• Overlay
• Import
• Importing 3D models
• Best practices and geometry healing
• Exercises 3A, 3B, 3C, 3D, 3E, 3F
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CONTENTS
Geometry building • 2D, 3D and Skew modeling
• General concepts
Mesh generation • Sketcher/Modeler
• Overlay
• Import from CAD files
Physical properties
Solving process
Results post-processing
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MODELING STRATEGY
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MODELING STRATEGY
First step: domain’s dimensions
• 2D plane study
• device supposed infinitely long in one y
y
direction x
x
z
real object 2D plane geometry
• 2D axisymmetric study
• device having a revolution symmetry around
an axis
y
Z
x
R
z
real object 2D axisymmetric geometry
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MODELING STRATEGY
First step: domain’s dimensions
• Skew study (2 ½ D)
• 2D geometry with several superposed layers “skewed”
• Specially suitable in cable and machine applications
• 3D study
• Any device
• Less assumptions and higher accuracy
• More time consuming
The study dimension should be carefully chosen as
! function of the device and desired accuracy. Geometry

building greatly depends on this choice
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GEOMETRY BUILDING
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GEOMETRY BUILDING
GEOMETRY
Domain Tools
Infinite box, symmetry , periodicity Coordinate system, parameters, functions
2D/Skew 3D Import
Sketcher Modeler From 2D CAD
Overlay Overlay From 3D CAD
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DOMAIN
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STUDY DOMAIN
• Study domain (S.D.): definition
• device model (where the equations are solved)

• limited by boundaries on which boundary conditions are imposed
• Study domain limits:
• Limitation of the S.D. by truncation or infinite box

• Reduction of the S.D. in presence of:
• repetitive patterns (periodicities)
• symmetry planes
• Domain options available for all dimensions: 2D, 3D and skew
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DOMAIN: INFINITE BOX

• Main features
• Just one infinity box per domain

• Centered in (0,0,0)
• Boundary conditions automatically attached
• Dimensions defined by the user
• Enough separation with the device required (i.e., low fields in the boundary)
• A distance of twice the device radius advised
• Definition steps
• Build the geometry

• Define symmetries/periodicities (if needed)
• Define infinity box (dimensions)
• Complete infinity box
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DOMAIN: INFINITE BOX DEFINITION 2D

• Type of infinite box: Disc
y
INFINITE
R min
R min
R max x
R max
Classical study
domain
Remember: It is necessary to complete infinity box after

! its definition.
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DOMAIN: INFINITE BOX DEFINITION 3D

• Type of infinite box
• Parallelepiped
• Cylinder
Remember: It is necessary to complete infinity box after

! its definition.
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DOMAIN: PERIODICITY AND SIMMETRY

• Reduction of the study domain (Periodicity/Symmetry)
• Take advantage of known patterns
• Save computation time
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DOMAIN: PERIODICITY DEFINITION

• 2D: Types of periodicity
• Rotation about Z-axis
• Translation along X
• Translation along Y
• 3D: Types of periodicity

• Rotation about X-axis
• Rotation about Y-axis
• Rotation about Z-axis
• Translation along X
• Translation along Y
• Translation along Z
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DOMAIN: SYMMETRY DEFINITION

• 2D: Types of symmetry
• Versus X-axis
• Versus Y-axis
• Defined by offset angle about Z-axis
• 3D: Types of symmetry

• Versus XY plane
• Versus YZ plane
• Versus ZX plane
• Defined by offset angle about X-axis
• Defined by offset angle about Y-axis
• Defined by offset angle about Z-axis
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GEOMETRIC TOOLS
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GEOMETRIC TOOLS
• Used to define
• geometric parameters
• local coordinate systems
• Example
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GEOMETRIC TOOLS: PARAMETERS

• Algebraic expression
• Constants
• Mathematic operators
• Arithmetic functions
• Parameters (defined before)
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GEOMETRIC TOOLS: COORDINATE SYSTEM

• Type of coordinate system:
• Cartesian
• Cylindrical
• Defined with respect:

• to the global coordinate system
• to the local coordinate system
• Parametrized definition possible

• Constants
• Mathematic operators
• Arithmetic functions
• Parameters
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GEOMETRIC TOOLS: FUNCTIONS

• Used not only in the geometry but also for pre and post-processing
• Arithmetic operators
Operator Description
+ add two values
- subtract two values
* multiply two values
/ divide two values
**or^ raise the left operand to the power specified by the right
hand operand
• Several mathematical functions available

• Logarithm and exponential functions
• Trigonometric functions
• Many others: Absolute value, steps and stair functions, etc.
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GEOMETRIC TOOLS: FUNCTIONS

• Mathematical functions Function Description
Sqrt(x) Square root of the expression x

• Square function and absolute value
Abs(x) Absolute value of the expression x
• Logarithm and exponential functions
Exp(x) Exponential function of the expression x
• Trigonometric functions
• Many others Log(x) Natural logarithm of the expression x
Sin(x) Sine of the angle x expressed in radians
Cos(x) Cosine of the angle x expressed in radians
Tan(x) Tangent of the angle x expressed in radians
Sinh(x) Hyperbolic sine of the expression x
if x1≤x<x2 VALID(x,x1,x2) = 1
Valid(x,x1,x2)
else VALID(x,x1,x2) = 0
Int(x) Integral part of the expression x
Modulo(x,x1) Remainder of the division of x by x1
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2D/SKEW GEOMETRY
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BUILDING A GEOMETRY IN 2D/SKEW

• Building module – Sketcher
• Automatically opened when new 2D/skew project is created
• Creation tools (basic geometries)
• Construction tools (geometric operations)
• Correction and simplification tools
• Overlay
• Automatic creation of geometry through templates
• Geometric and configuration information provided by user
• Several machine topologies included
• Import from external file
• From a 2D CAD file
• Several CAD formats read
• Checking and healing functions
• From a 3D project
• Imported section selected from a cut plane
• Detailed explanation in import section
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SKETCHER
• Sketcher: easy and fast way to enter geometries
• First step: Draw polylines, elementary shapes (circles, rectangles, …).
• Second step: Select, move, delete, duplicate entities in a few clicks
• Third step: Heal your geometry
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SKETCHER: MAIN TOOLS

Each step has its own set of dedicated tools
• Creation tools
• Polylines
• Arcs
• Rectangles
• Circles
• Construction tools
• Symmetry
• Linear / circular repetition
• Chamfer / fillet
• Translation / rotation of a selection
• Adjust intersections
• Fractionate a line / merge superimposed lines
• Simplify lines
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SKETCHER: SOME REMARKS

• Forbidden intersections
• Crosses or superimposed lines are forbidden
• They should be healed to assure a proper geometry
• Sketcher allows parametrized entities and operations
• The geometry of skew projects is a 2D geometry

• Skew projects geometry can be defined using the sketcher
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EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

STEPS 1-7
File Name and Location
…\STUDENT-EXERCISE\2D\A_Translation_motion\buildGeomesh.py
Objectives - Flux 2D Project Building

Methods to create devices:
• Method 1:
• Open Flux 2D
• Open a new 2D project
• Create a new symmetry versus Y axis
• Create 2 new geometric parameters
• Create 2 new coordinate systems
• Change the working coordinate system
• Create the shape of the part using the tool “create segment”
• Create the infinite box
• Method 2:
• Python to automatize previous operations
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STEPS 1-7
• Objectives - Flux 2D Project Building … continue
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STEPS 1-7
METHOD 1: Step 1
a) Open a new 2D project from the supervisor
b) Create a new symmetry versus Y axis
c) Geometry>Symmetry>New
d) Create 2 new geometric parameters

• DIST=0mm
• THICK=8mm
e) Create 2 new coordinate systems
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STEPS 1-7
METHOD 1: Step 2
a) Change the working coordinate system to FIXED
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STEPS 1-7
METHOD 1: Step 3
(15; 23+THICK) (32; 23+THICK)
a) Create approximately the shape of the fixed part
using the tool “create segment” (15; 23) (32; 23)
(32-THICK/2; 23)
b) If necessary, use correction tools to correct
intersections.
c) Edit points (by a double click on a point) to set the (14,5; -11)
exact coordinates to each point.
(32-THICK/2; -11)
(5; -20,5)
(3; -20,5)
(32; -24)
(14,5; -24)
(3; -31) (32; -31)
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STEPS 1-7
METHOD 1: Step 3
d) Create approximately the shape of the coil using the tool

“create rectangle by two points defining the diagonal” (25; 22)
(17; 22)
e) Edit points (by a double click on a point) to set the exact
coordinates to each point of the rectangle
(17; -23)
(25; -23)
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STEPS 1-7
METHOD 1: Step 4
a) Change the working coordinate system to MOBILE
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STEPS 1-7
METHOD 1: Step 5 (8; 46,5)
(0; 46,5) (14,5; 46,5)
a) Create approximately the shape of the moving part using the
tool “create segment”
(8; 31,5)
b) If necessary, use correction tools to correct intersections.
(3; 26)
c) Edit points (by a double click on a point) to set the exact

coordinates to each point.
(3; -13,5)
(14,5; -4)
(0; -13,5) (5; -13,5)
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STEPS 1-7
METHOD 1: Step 6
a) Create the infinite box Domain>Infinite box>new
b) Add two lines to close the domain, using the tool “create segment”
c) Close the sketcher context
METHOD 1: Step 7
a) Save the project as: 3A_Geometry.FLU
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METHOD 2 (Alternative 1):
Step 1
a) Starting from the supervisor, choose:
2D application > Python script
Step 2
a) Navigate to file:
…\STUDENT-EXERCISE\2D\
Translation_motion\buildGeomesh.py
b) Run the selected script
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Step 1
a) Start a new 2D project and exit from
the sketcher.
b) Click on Run a python file with

reduced GUI refresh (faster)
c) Navigate to file
Translation_motion\buildGeomesh.py
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OVERLAY 2D
• Overlay
• Template to generate the geometry
automatically
• Several certified overlays provided
(machine application)
• Using an overlay
• Load the overlay
• Introduce geometry / configuration
variables
• Run the overlay
• No previous geometry should exist to run
an overlay
• Results The geometry is ready to be used !
• Geometry with mesh information No further steps needed!
• Overlay inputs can be updated in any
moment
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EXERCISE 3B: EMBEDDED MAGNETS MOTOR GEOMETRY CREATION

STEPS 1-7
…\STUDENT-EXERCISE\2D\B_2D_machines\buildGeomesh.py
• Objectives - Flux 2D Project Building

Methods to create devices:
• Method 1:
• Open Flux 2D
• Open a new Overlay project
• Create a new Brushless Permanent Magnet Motor
• Set the general, Airgap and Winding parameters
• Set the geometry and the parameters for Rotor and Stator
• Edit Mesh Point
• Method 2:
• Python to automatize previous operations
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STEPS 1-7
• Objectives - Flux 2D Project Building … continue
• Motor Prius 2 (for hybrid electrical vehicule)
• Ratings
• Max bus voltage : 500 V
• Peak torque : 400 Nm
• Max speed : 6000 rpm
• Peak power rating : 50 kW at 1200-1500 rpm
• Motor characteristics
• 48 stator slots
• 3 phases wye connected
• 8 poles
• NdFeB magnet
• Lamination type M270-35A
• Outer diameter: 242 mm
• Stack length : 75 mm
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STEPS 1-7
METHOD 1:
Step 1
a) Open a new Flux 2D project from Supervisor
b) Load the Overlay “Brushless Permanent Magnet Motor”
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STEPS 1-7
METHOD 1:
Step 2
a) General Information
Do not click on the OK button before the end of the process

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STEPS 1-7
METHOD 1:
Step 3
a) Airgap specifications
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STEPS 1-7
METHOD 1:
Step 4
a) Rotor
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STEPS 1-7
METHOD 1:
Step 4
b) Rotor
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STEPS 1-7
METHOD 1:
Step 4
c) Rotor
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STEPS 1-7
METHOD 1:
Step 4
d) Rotor
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STEPS 1-7
METHOD 1:
Step 5
a) Stator
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STEPS 1-7
METHOD 1:
Step 5
b) Stator
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STEPS 1-7
METHOD 1:
Step 6
a) Winding
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STEPS 1-7
METHOD 1:
Step 7
a) Save project as: 3B_Geometry.FLU
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Step 1
a) Starting from the supervisor, choose:
2D application > Python script
Step 2
a) Navigate to file:
…\STUDENT-EXERCISE\2D\2D_machines\
buildGeomesh.py
b) Run the selected script
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Step 1
a) Start a new 2D project and exit from the
sketcher.
b) Click on Run a python file with reduced GUI

refresh (faster)
c) Navigate to file
2D_machines\buildGeomesh.py
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EXERCISE 3C: EMBEDDED MAGNETS MOTOR WITH SKEW

STEPS 1-7 old

Start from a new 3D project

• Open Flux Skew
• Set the general, Airgap and Winding parameters
• Set the geometry and the parameters for Rotor and Stator
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STEPS 1-7 old
Objectives - Flux 2D Project Building … continue

• Ratings
• Peak power rating: 50 kW at 1200-1500 rpm
• 48 stator slots
• 8 poles
• NdFeB magnet
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STEPS 1-7 new
File Name and Location Characteristics

Start from a new 3D project Motor Prius 2 (for hybrid electrical vehicule)
• Ratings
Objectives - Flux 2D Project Building • Max bus voltage : 500 V
• Open Flux Skew • Peak torque : 400 Nm
• Open a new Overlay project • Max speed : 6000 rpm
• Create a new Brushless Permanent Magnet Motor • Peak power rating : 50 kW at 1200-1500 rpm
• Set the general, Airgap and Winding parameters • Motor characteristics
• Set the geometry and the parameters for Rotor and Stator • 48 stator slots
• 8 poles
• NdFeB magnet
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STEPS 1-7
Step 1
a) Open a new Flux 2D project from Supervisor
b) Load the Overlay “Brushless Permanent Magnet Motor”
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STEPS 1-7
Step 2
a) General Information
59 Do not click on the OK button before the end of the process

Altair Flux, v2019

STEPS 1-7
Step 3
a) Airgap specifications
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STEPS 1-7
Step 4
a) Rotor
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STEPS 1-7
Step 4
b) Rotor
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STEPS 1-7
Step 4
c) Rotor
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STEPS 1-7
Step 4
d) Rotor
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STEPS 1-7
Step 5
a) Stator
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STEPS 1-7
Step 5
b) Stator
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STEPS 1-7
Step 6
a) Winding
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STEPS 1-7
Step 7
Save project as: 3C_Geometry.FLU
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3D GEOMETRY
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BUILDING A GEOMETRY IN 3D
• Building module – Modeler
• Automatically opened when new 3D project is created
• Creation tools (basic geometries: block, cylinder cone)
• Boolean operations
• Geometric functionalities (cuts, symmetries, repetitions…)
• Import module
• Overlay
• Automatic creation of geometry through templates
• Geometric and configuration information provided by user
• Several machine topologies included
• Import from external file
• From a 2D CAD (sketch)
• From a 3D project
• Detailed explanation in import section
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MODELER FEATURES
• Efficient tool to build 3D geometry
• Based on the geometrical Kernel ACIS 3D developed by SPATIAL Technology
• Lots of functionalities to create 3D objects
• Parametrizable geometry definition
• 2D sketch used to defined surfaces to be extruded
• Compatible with CAD import
• Includes correction and simplification tools
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MODELER STRATEGIES
• Strategy 1: Through 3D objects
• Primitives
• Fillets / chamfers ..
• Strategy 2: Through 2D Sketch extrusion

• Draw a 2D sketch (use the 2D Sketcher)
• Apply extrusion operations (linear, circular…)
• The modeler is able to combine these 2 methods

• Objects combined through boolean operations
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MODELER TOOLS
• Modeler tools
• Primitive objects
• Geometry operations
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MODELER TOOLS
• Primitive objects
• Block
• Cylinder
• Cone
• Union
• Intersection
• Subtraction
• Assembly
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MODELER TOOLS
• Union
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MODELER TOOLS
• Intersection
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MODELER TOOLS
• Subtraction
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MODELER TOOLS
• Assembly
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MODELER TOOLS
• Fillet / Chamfer
• Fillet
• Chamfer on edge
• Chamfer on vertex
• Symmetry / repetition
• Symmetry
• Circular repetition
• Linear repetition
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MODELER TOOLS
• Displacement operations
• Translation
• Rotation
• Create object from sketch

• Sketch
• Extrusion
• Linear
• Circular
• Helicoidal
Once out of the modeler the sketches are in
! NO_EXISTS mode (they have no physical relevance)
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MODELER TOOLS
• Other operations
• Defeaturing
(Remove Fillets/Chamfers/Holes)
• Cut objects
• Clean faces
• Remove volumes
• Separate volumes from objects
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MODELER: GEOMETRY HEALING

• Forbidden intersections
• Line-line, line-face and face-face intersections
• To avoid interference boolean operations should be used
• Healing and simplification options are also provided by the modeler
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MODELER: SOME REMARKS

• Modeler can be combined with import
• Modeler objects are not available in Flux

normal context
• They are translated into volumes
• It is possible to go back to the Modeler

from Flux normal context
• The geometry must be unmeshed
• Infinite box not allowed
• It is advisable to check the geometry once

in Flux normal context
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EXERCISE 3D: SENSOR WHEEL GEOMETRY CREATION

STEPS 1-14
WHEEL
Objectives - Flux 3D Project Building COIL 1
MAGNET 1
PROBE 1
• Open Flux 3D COIL 2

PROBE 2
• Create wheel sketch MAGNET 2
• Create geometric parameters

• Create Coordinate Systems
• Make extrusion
• Create an Infinite Box
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STEPS 1-14
• Studied device
• a variable reluctance speed sensor
• Functionality
• The rotation of the target wheel near the tip of the sensor changes the magnetic flux, creating an analog
voltage signal that can be recovered in probes.
• The device consists of WHEEL
• one cogged wheel with three teeth

• two probes with a magnet and a coil around
COIL 1
PROBE 1
MAGNET 1
COIL 2
PROBE 2
MAGNET 2
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STEPS 1-14
Geometry done with Modeler
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STEPS 1-14
Step 1
WHEEL_R
a) Start a new Flux 3D project from the supervisor
ALPHA
Step 2 TOOTH_IR
a) Create geometric parameters
Name Comment Expression
TOOTH_OR
TOOTH_IR Tooth inner radius 12.5
TOOTH_OR Tooth outer radius 21.5
WHEEL_R Wheel radius 10
ALPHA Wheel angle 0
WHEEL_TH Wheel thickness 6
WHEEL_TH
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STEPS 1-14
Step 2: Create a Coordinate System
b) Create a Coordinate System: WHEEL_CS with the following
criterias
• Construction → Coordinate System → New
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STEPS 1-14
Step 3: Create wheel sketch
a) In the Modeler Context, create a sketch in the XY plane
• Tools → Sketch → New
b) Create a first circle defined by the center and the radius with the
following characteristics:
• Construction → Circle → Circle center+radius
• Center point: (0; 0)
• Radius: WHEEL_R = 10mm
c) Create a Second circle defined by the center and the radius with the
following characteristics:
• Construction → Circle → Circle center+radius
• Radius: TOOTH_IR = 12.5mm
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STEPS 1-14
Step 4: Create the first teeth
a) Create an arc center end two points defined by two points as in the
figure
• Construction → Line → Arc two point with center
• Radius: TOOTH_OR = 21.5mm
• Angle: 15°
b) Create a reference line on X axis

• Construction → Reference → Reference line Line 5
c) Create a symmetry transformation in order to propagate line 5:

• Tools → Symmetry
• Line to propagate: line 5
• Symmetry axis: reference line
• Connect to origin: No
Reference
line
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STEPS 1-14
d) Simplify the geometry Point 6
• Delete the Reference Line
• Simplify geometry in order to delete point 6

• Tools → Heal and simplify all geometry
Reference line
Point 7
Point 1
e) Create two lines (yellow lines) from point 1 to point 7 and 8 Point 8
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STEPS 1-14
f) Fractionate both lines with the external circle and delete the yellow line Tools → Fractionate
New points
• Delete Line 5 and 7 (yellow line)
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STEPS 1-14
g) Simplify Lines 4 and 11
• Tools → Simplify all lines
Before simplify all lines After simplify all lines
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STEPS 1-14
Step 5: Create the cogged wheel sketch
a) Create a circular repetition of the tooth with the following characteristics:
• Tools → circular repetition
• Graphic selection: lines 10; 8; 6; 5
• Pivot point: 1
• Angle between repetition: 120
• Number of repetition: 2
• Connect to origin: yes
Tools >> simplify all lines
• Simplify lines 19 and 3
Point 1
Lines 10,8,5 and 6
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STEPS 1-14
b) Create line from point 1 to point 3
Point 1
Point 3
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STEPS 1-14
c) Create a circular repetition of this line with the following characteristics:
• Graphic selection: lines 3
• Pivot point: 1
• Angle between repetition: 120
• Connect to origin: yes
Line 3
Point 1
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STEPS 1-14 Select lines, right click edit array
Step 6: Sketch parametrization

a) Tools >> simplify all lines
Line 2,21 and 23
WHEEL_R
Line 9,17 and 18

TOOTH_IR
Line 5 and 6
b) Parameterize the following lines: Angle: 30 deg
• Lines 2, 21, 23 radius: WHEEL_R
• Lines 9,17,18 radius: TOOTH_IR
• Line 6 radius: TOOTH_OR
• Line 5, 6: Angle: 30 deg
Line 6
c) Close the sketch and return to the modeler context TOOTH_OR
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STEPS 1-14
Step 7: Make the extrusion
a) Extrude the faces with the following
characteristics:
• Tools → Extrusion → New
• Sketch containing faces to extrude: Sketch_1
• Faces: ALL
• Extrusion type: along a vector
• Coord. system: COORDSYS_XY_PLANE
• Formula: (0,0,1)
• Length: WHEEL_TH
• Offset of origin plane: -WHEEL_TH/2
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STEPS 1-14
ALPHA
Step 7: Make the extrusion
b) Rotate the device with the following characteristics:
• Tools → Rotation → New
• OBJ_EXTRUDE_1
• Rotation axis: 64
• Angle: ALPHA
Line 64
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STEPS 1-14
Step 8: Create parameters
Name Comment Expression
COIL_IR Coil inner radius 2.8
COIL_OR Coil outer radius 3.5
COIL_H Coil height 16 ANGLE
ANGLE Angle of the probe 30

position
MAG_R Magnet radius 2.5
MAG_H Magnet height 20 32 mm

MAG_H/2
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STEPS 1-14
Step 8: Create parameters
b) Create a Coordinate System with following criterias
• Construction → Coordinate System → New
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STEPS 1-14
Step 9: Create the First probe
a) Select first the coordinate system
b) Create a three cylinders with the following characteristics:
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STEPS 1-14
Step 9: Create the First probe
a) Assemble the 3 cylinders
• Tools → Assembly → New
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STEPS 1-14
Step 10: Create the Second probe
a) Create a circular repetition with the following characteristics:
• Tools → Circular repetition → New
• Object: OBJ_CYLINDER_1 Line 64
• Axis line: 64
• Angle between repetition: ANGLE
ANGLE
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STEPS 1-14
Step 10: Create the Second probe
b) Create cut for both Probe
• Correction&Simplification → Cut Objects → Object cut
• Object: OBJ_CYLINDER_1
• Object: OBJ_CIRCULAR_1_1
• Cut reference Plane: XY_PLANE
• List of cut section: SECTION 1 & SECTION 2
c) Assemble the 4 parts of probe (1_1 with 1_2 and 1_3 with 1_4)
d) Close the modeler context.

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STEPS 1-14
Step 11: Create the infinity box Infinite
Box Parallelepiped infinite box
X inner size, ½ length X outer size, ½ length Y inner size, ½ length Y outer size, ½ length Z inner size, ½ length Z outer size, ½ length
50 60 50 60 30 40
Step 12: Complete the Infinite Box
Step 13: Change the value of Alpha

(Alpha=75)
Step 14: Save the project as:

3D_Geometry.FLU
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OVERLAY 3D
• Overlay
• Template to generate the geometry automatically
• Several certified overlays provided (machine
application)
• Using an overlay
• Load the overlay
• Introduce geometry / configuration variables
• Run the overlay
• No previous geometry should exist to run an
overlay
• Results
• Geometry with mesh information
• Overlay inputs can be updated in any moment
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EXERCISE 3E: EMBEDDED MAGNETS MOTOR GEOMETRY CREATION

STEPS 1-6
File Name and Location ol

• Open Flux 3D
• Set the general, Airgap and z dimensions parameters
• Set the geometry and the parameters for the Rotor
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STEPS 1-6
Objectives - Flux 3D Project Building … continue ol
• Ratings
• 48 stator slots
• 8 poles
• NdFeB magnet
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STEPS 1-6
File Name and Location Characteristics
Start from a new 3D project Motor Prius 2 (for hybrid electrical vehicule)
• Ratings
Objectives - Flux 3D Project Building • Max bus voltage : 500 V
• Open Flux 3D • Peak torque : 400 Nm
• Open a new Overlay project • Max speed : 6000 rpm
• Set the general, Airgap and z dimensions • Motor characteristics
parameters • 48 stator slots
• Set the geometry and the parameters for the Rotor • 3 phases wye connected
• 8 poles
• NdFeB magnet
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STEPS 1-6
Step 1
a) Start a new Flux 3D project from the supervisor
b) Leave the modeler context
Leave the modeler context
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STEPS 1-6
Step 2
a) Load the Overlay “Brushless Permanent Magnet Motor”
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STEPS 1-6
Step 3
a) General overwiew of the Overlay “Brushless
Permanent Magnet Motor”
Do not click on the OK button before the

end of the process
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STEPS 1-6
Step 4: Rotor
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STEPS 1-6
Step 5: Stator
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STEPS 1-6
Step 6: Save the project as: 3E_Geometry.FLU
Leave the 3D overlay

Save the project as: 3E_Geometry.FLU
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IMPORT
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GEOMETRY CAD IMPORT

• From a 2D or 3D Flux project
• From a CAD file
• From a 2D or 3D Flux project
• From a 2D CAD file
• Good practices
• Geometry healing
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IMPORTING 3D MODELS
• CAD files are imported from the Modeler
• Able to read a great number of different CAD files
• Same import process no matter the file type
• Flux project are imported from the normal context

• From both, 2D and 3D projects
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IMPORTING 3D MODELS – FROM A FLUX PROJECT

• From 2D and 3D projects
• Only geometry is exported, not mesh or physical information, if any
• Avoid symmetries, periodicities and infinite box definition in the original project
• In case of 2D projects its geometry is imported into the reference plane Z=0
• It is possible to import the geometry from several different projects

• Be careful with possible collisions! Union and assembly operations maybe required!
Just pick up the project and get its

geometry imported
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IMPORTING 3D MODELS – FROM A CAD FILE

• Same import process for all file types
CAD Flux
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CAD Flux
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Small edges, faces, gaps will be removed

! according with project’s tolerance
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• Import process
• Two critical steps: read solids and imprinting solids
Read Solids
Imprinting Solids
New points, lines and faces created

! Model
Bothinvalid for FEM computation
steps automatically performed
during the import
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IMPORTING 3D MODELS – IMPORT REPORT

• Import process: Example with an assembly operation
CAD file Import Report

Entities analysing
- Solid body: 2.
- Wire body: 0.
- Unknown body: 0.
Assembly operations
- Successful number of operations: 1.
- Failed number of operations: 0.
- Initial number of solids: 2.
- End number of solids: 1.
Number of Solid Body : 2 Entities conversion

- Points created: 12.
- Lines created: 20.
- Faces created: 11.
- Volumes created: 2.
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IMPORTING 2D MODELS
• CAD files and Flux projects are imported from the normal context
• Able to import directly other Flux 2D projects
• Import of a great number of different CAD files
• Same import process no matter the file type
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IMPORTING 2D MODELS – FROM A FLUX PROJECT 2D

• From 2D projects
• Only geometry is exported, not mesh or physical information, if any
• Avoid symmetries, periodicities and infinite box definition in the original project
• It is possible to import the geometry from several different projects

• Be careful with possible collisions! Healing operations maybe required!
Just pick up the project and get its

geometry imported
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Altair Flux, v2019
IMPORTING 2D MODELS – FROM A FLUX PROJECT 3D

• Generate a 2D CAD file from the 3D project:
• Go into the modeler
• Define a reference plane containing the 2D geometry

to export
• Go to menu project – 2D CAD export and select the

CAD type
• Select the cut plane and the object to export
• Import the 2D CAD file into a 2D Flux project:
• See next section
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IMPORTING 2D MODELS – FROM A 2D CAD FILE

• Same import process than in 3D
In case of import from 3D project:

! Import free faces and lines instead
of solids !
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IMPORT GOOD PRACTICES

• Good use of CAD import in Flux
• Import format
• The use of native files is preferred
• ProE
• Catia
• SolidWorks
• Inventor
• Than common format ones
• IGES
• Step
• Prefer the import of solids rather than faces

• With Faces import there is one more step during the import (faces stitching)
• However, to import 2D CAD generated by 3D Flux projects face import is necessary !
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• Always simplify the geometry before the import
• Delete useless parts for the finite elements computation
• Avoid tangent faces
• It can be difficult to mesh
• Modify the shape in the CAD software
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• Avoid collisions between solids
• Collisions between solids can generate small volumes difficult to mesh
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GEOMETRY HEALING – ENSURE GEOMETRICAL CORRECTION

• Main goal: Ensure geometrical correction
• « Automatic Repair » option activated at the import

• Detect the defects specific to ACIS
• Correct all the defects
• « Automatic Repair » option non activated at the import
• Defects list is filled
• Possible to correct each defect or all
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GEOMETRY HEALING – SIMPLIFY THE GEOMETRY

• Second goal: Simplify the geometry to make the mesh process easier
• Small lines, faces, volumes

• Detected by maximum ratio
• Simplified by merging with a nearby entity
• Tangency problems
• Detected with maximum angle
• Simplified through modeler tools
• Modeler defeaturing allows to correct:

• Fillets (with maximum radius)
• Chamfers (with maximum distance)
• Holes (with maximum diameter)
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EXERCISE 3F: AXIAL FLUX MOTOR GEOMETRY CREATION

STEPS 1-10
File Name and Location old

• Import step file
• Create a cylindrical coordinate system (CYL for instance)
• Run ModifyCoordinateSytemForPoints macro for all points
• Create parameters
• GAP: airgap length (1.5)
• HR_1: heigth of magnet (5)
• HR_2: heigth of rotor (10)
• ANGLE: opening angle of magnet (35)
• Modify points coordinate to use parameters

(Magnet1: 22.5±ANGLE/2)
(Magnet2: 67.5±ANGLE/2)
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STEPS 1-10
Objectives - Flux 2D Project Building … continue old
• Characteristics
• External diameter: 100 mm
• Length: 38.5 mm
• Power rating: 1 kW
• Operating speed: 1000 rpm
• Rated torque: 1.1 N.m
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STEPS 1-10
File Name and Location Characteristics new
Start from a new 3D project • External diameter: 100 mm
• Length: 38.5 mm
• Power rating: 1 kW
Objectives - Flux 2D Project Building • Operating speed: 1000 rpm
• Import step file • Rated torque: 1.1 N.m
• Create a cylindrical coordinate system (CYL for
instance)
• Run ModifyCoordinateSytemForPoints macro for
all points
• Create parameters
• GAP: airgap length (1.5)
• HR_1: heigth of magnet (5)
• HR_2: heigth of rotor (10)
• ANGLE: opening angle of magnet (35)
• Modify points coordinate to use parameters
• (Magnet1: 22.5±ANGLE/2)
• (Magnet2: 67.5±ANGLE/2)
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Altair Flux, v2019

STEPS 1-10
Step 1
a) Open new Flux 3D project
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Altair Flux, v2019

STEPS 1-10
Step 2
a) Import STEP file Select the STEP file
Leave the modeler context
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STEPS 1-10
Step 3
a) Create coordinate system
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STEPS 1-10
Step 4
a) Import macro
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STEPS 1-10
Step 4
b) Run macro
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STEPS 1-10
Step 5
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STEPS 1-10
Step 6
a) Modify points coordinate to use parameters
• Import the python file: « Modify_Coordinate_Points.py »
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STEPS 1-10
Step 7: Create sliding cylinder
a) Create a new geomtric parameter
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Altair Flux, v2019

STEPS 1-10
b) Create new points
Do the same thing with other points

First Second Third coordinate
coordinate coordinate
Point_1 20-L_1 0 Gap/2
Point_2 20-L_1 0 Gap/2+HR_1+HR_2+L_1
Point_3 50+L_1 0 Gap/2+HR_1+HR_2+L_1
Point_4 50+L_1 0 Gap/2
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STEPS 1-10
c) Create segment between points created before
Line number Starting and end points

of the segment
S_1 (P1, P2)
S_2 (P1, P4)

Select the points defining the S_3 (P4, P3)
segment
S_4 (P3, P2)
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STEPS 1-10
d) Create transformation
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STEPS 1-10
e) Extrude segments
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STEPS 1-10
f) Build faces and volumes
1 2
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STEPS 1-10
Step 8: Create infinite box
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STEPS 1-10
Step 9: Create the periodicity
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STEPS 1-10
Step 10: Complete infinite box
a) Save the project as: 3F_Geometry.FLU
154
ANNEX: REGIONS
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REGIONS
• A region is…
• … a set of geometric entities of the same type
(points, lines, faces or volumes) …
• … having the same physical properties
• Not part of the geometry but of the problem physical description
• Examples of use
Region Region Is used to describe… Examples

(in 2D) (in 3D)
Point Line filiform parts of thin section thin magnetic bars
Line Face planar parts of small thickness magnetic sheets, air gap
current sheet
specific boundary conditions
Face Volume parts of any shape
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Altair Flux, v2019
ASSIGN REGIONS
• Assign regions to:
• points
• lines
• faces
• volumes
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QUESTIONS & ANSWERS
158

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ALTAIR FLUX 2019

CH3 - GEOMETRY AND IMPORT

CHAPTER 3 - GEOMETRY AND IMPORT

Geometry building • 2D, 3D and Skew modeling

real object 2D axisymmetric geometry

The study dimension should be carefully chosen as

! function of the device and desired accuracy. Geometry

Sketcher Modeler From 2D CAD

Overlay Overlay From 3D CAD

• device model (where the equations are solved)

• Study domain limits:

• Limitation of the S.D. by truncation or infinite box

• Domain options available for all dimensions: 2D, 3D and skew

DOMAIN: INFINITE BOX

• Just one infinity box per domain

• Build the geometry

DOMAIN: INFINITE BOX DEFINITION 2D

Remember: It is necessary to complete infinity box after

DOMAIN: INFINITE BOX DEFINITION 3D

Remember: It is necessary to complete infinity box after

DOMAIN: PERIODICITY AND SIMMETRY

DOMAIN: PERIODICITY DEFINITION

• 3D: Types of periodicity

DOMAIN: SYMMETRY DEFINITION

• 3D: Types of symmetry

GEOMETRIC TOOLS: PARAMETERS

GEOMETRIC TOOLS: COORDINATE SYSTEM

• Defined with respect:

• Parametrized definition possible

GEOMETRIC TOOLS: FUNCTIONS

• Several mathematical functions available

GEOMETRIC TOOLS: FUNCTIONS

Sqrt(x) Square root of the expression x

Cos(x) Cosine of the angle x expressed in radians

Tan(x) Tangent of the angle x expressed in radians

Sinh(x) Hyperbolic sine of the expression x

BUILDING A GEOMETRY IN 2D/SKEW

SKETCHER: MAIN TOOLS

SKETCHER: SOME REMARKS

• Sketcher allows parametrized entities and operations

• The geometry of skew projects is a 2D geometry

EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

Objectives - Flux 2D Project Building

EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

a) Open a new 2D project from the supervisor

b) Create a new symmetry versus Y axis

d) Create 2 new geometric parameters

e) Create 2 new coordinate systems

EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

d) Create approximately the shape of the coil using the tool

EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

a) Change the working coordinate system to MOBILE

EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

c) Edit points (by a double click on a point) to set the exact

(0; -13,5) (5; -13,5)

EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

b) Run the selected script

EXERCISE 3A: CYLINDRICAL ELECTROMAGNET OF AN ELECTRO-VALVE

b) Click on Run a python file with