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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Chapter 4: Solids and Hexas


Creating and Editing Solid Geometry

Creating a Hexahedral Mesh using the


Solid Map Function
Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Solid Geometry: What is it?

A solid is:
• A geometric entity that define a 3-dimensional volume
• Same as solids used in most CAD programs

Used in functions where defining a volume is required


• Hexa meshing (3D : solid map : volume sub-panel)
• Tetra meshing (3D : tetramesh : volume tetra sub-panel)

Especially helpful when dividing a part into multiple volumes


• A part can be divided into multiple, connected solids
• The connection between adjacent solids (topology) can maintain the
connectivity of mesh
• Aids visualization when dividing a part into simple, mappable regions
(used in hexa meshing)
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Solid Geometry: 3D Topology

Example: 2 connected solids in topology display

Solid faces Edges


• Selectable as surfaces • Selectable as lines

• Bounding Faces
• Shared Edges
• Green
• Green
• Belong to 1 solid
• Belong to 2 adjacent
faces of 1 solid
• Partition Faces
• Yellow
• Shared between • Non-manifold Edges
connected solids • Yellow
• Belong to:
• A partition face
- OR -
Fixed Points • 2 solid faces
• Selectable as points and 1+ surfaces
• Lie at the ends of edges
Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Solid Geometry: Tools for Creating Solids

Import
• Pull-down menus – File > Import > Geometry
• Toolbar > > Geometry
• HyperMesh will import solid geometry from file types that support solid data

Solids panel
• Bounding Surfs – Select surfaces that enclose a volume
• Drag – “Extrude" a cross section along a linear path
• Spin – “Extrude” a cross section via a circular path

Primitives panel
• Creates solid geometry of basic shapes:
• Square / Block
• Cylinder / Cone
• Sphere
• Torus
Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Solid Geometry: Tools for Editing Solids

Surfaces panel
• Creates surfaces using various methods
• Can be used to split a solid
• Edges of the surface must be equivalenced to edges on the solid

Solid Edit panel


• Trim with… – splits a solid into 2+ solids using:
• Nodes
• Lines
• Planes
• Surfaces
• Merge – combine 2+ adjacent solids into a single solid entity
• Detach – disconnects connected solids
• Boolean – advanced trim & merge operations
• Union (Solid A + Solid B) – same as merge
• Intersection (Solid A x Solid B) – keeps overlapping portions of 2 solids
• Removal (Solid A – Solid B) – deletes the volume of one solid from another
• Cut (Cut Solid A with Solid B) – trims one solid with another solid
• keeps both solids, but they no longer overlap
Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Solid Geometry: Tools for Viewing Solids

On the toolbar:

• Geometry Color – color geometry by component color or by


topology
• Wireframe Geometry – set geometry to wireframe mode
• Shaded Geometry – set geometry to shaded surfaces mode
• Visualization Panel – Controls:
• visibility of edges & faces based on topology
• transparency of surface shading
• visibility of fixed points
Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Solid Map: What is it?

• Location:
• 3D (page) > solid map (panel)
- OR -
• Mesh (drop down menu) > create > Solid Map

• What it does:
• Creates hexa-penta mesh in 1 or more volumes
• Each volume is defined by selecting a solid
geometry entity
• Easy to define shape for the mesh since only one
entity is selected
• Each volume must be a “mappable shape”
Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Solid Map Volume: Mappable Shapes

• Solid Map requires solid geometry of mappable shapes


• Mappable shapes are defined as:
• 2 opposing faces (called “source” and “destination” faces)
• 1 or more faces that directly connect the source and destination
• These enclose the volume between the source and destination
• Called “along faces”
• “Drag direction”: the vector from the source face to the destination face
• A volume might be mappable in more than 1 direction

Destination
Along
Face
Faces

Source Drag
Face Direction
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Solid Map One Volume: Process

• Basic process of using solid map: one volume is:

1. Create solid geometry 2. Split the solid geometry into


mappable regions

3. Use solid map to create hex mesh on each solid entity


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Solid Map Volume: Tips and Requirements

• Source and destination faces


• Source face can be made of multiple surfaces
• Edges can be suppressed to make a single surface (if possible)
• Destination face must be a single surface

• Solid map will mesh the rectangular • Solid map will fail
region • Both sides have multiple
• Only 1 side has multiple surfaces (connection to the
surfaces (connection to the cylindrical regions)
meshed cylindrical region)
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Solid Map Volume: Tips and Requirements

• Edges and fixed points on along faces


• Hexa mesh will follow shared edges parallel to the drag direction
• Shared edges perpendicular to the drag direction cause solid map : volume to
fail
• Suppress these edges
• Hexa meshes will ‘ignore’ fixed points along drag direction

Drag
Direction

Edges perpendicular to Solid map can now mesh


Suppress the edges
drag direction the part
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Solid Map Volume: Tips and Requirements

• Splitting solid geometry


• Try to divide the part into the fewest regions possible
• Less divisions = less work = less time
• Less divisions = larger regions
• More control over mesh size
• Not forced to use smaller mesh size due to small regions
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Solid Map Volume: Tips and Requirements

• Fillet control
• If needed, split the fillet surface along its length
• Suppress the original fillet edges

Create the
Split the fillet solid mesh
lengthwise Suppress the
original edges
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Solid Map Volume: Tips and Requirements

• Controlling mesh pattern with shell mesh


• Solid map : volume will use mesh pattern of shell mesh on the source face
• Use automesh panel (recommended but not required)
• Automatically associated with the surface
• Ensures connectivity with adjacent elements
• Can use other shell meshing panels (drag, spin, spline, etc.)
• Need to associate the elements to the surface before solid meshing
• Use node edit : associate panel to do this

Default Create shell Solid map uses the


mesh shell mesh pattern
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Solid Map Volume: Tips and Requirements

• Meshing adjacent volumes


• Mesh volumes that are immediately adjacent to volumes that have already been
meshed
• Ensures proper mesh connectivity if possible
• 2 start points will probably not result in matching mesh patterns
• Start with smaller volumes
• Mesh pattern of small volumes will be used on an larger, adjacent volume
• Must be connected to the source face of the larger, adjacent volume

Start with the Mesh pattern from the smaller


smaller region region is carried through the larger
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Solid Map Volume: Tips and Requirements

• Meshing adjacent volumes, continued


• Drag perpendicular to adjacent volumes
• Along faces are always rows/columns of quads
• Allows adjacent volumes connected by their along faces to be easily
connected & equivalenced
• Avoids discontinuities
• Manually specify the source & destination faces in solid map : volumes

All quad faces

Drag direction 1
Drag direction 2
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Demo + Do-it-yourself

Exercise: Creating, Editing and Hex-


Meshing Solid Geometry
• Page 143
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Chapter 5: Tetra Meshing

Volume Tetra

Standard Tetra

Checking Tetra element Quality

Re-meshing Tetra elements


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Tetrameshing: Standard Tetrameshing

• Standard tetrameshing uses 3D > tetramesh panel > tetra mesh sub-panel

• Process:
• Generate a surface mesh of shell elements
• Check quality and connectivity of the plate elements
• Generate the tetrahedral mesh
• Delete the original surface mesh
• Edit if necessary to obtain good quality
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Tetrameshing: Standard Tetrameshing

• Requirements for the shell mesh:


• Enclose one, and only one, continuous volume
• There can be no free edges. (Otherwise not a solid geometry)
• There can be no T-connected edges.
• There can be no duplicates in the mesh.
• Elements should not fold over and overlap each other
• Avoid very low minimum tria angles
• Avoid a large difference in size between adjacent elements
• Avoid a large difference is size between two sides of a wall thickness

• For quad elements in the shell mesh:


• Can split quads into 2 trias and create tetra elements under them
– OR –
• Can keep the quad element and create pyramids under them
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Tetrameshing: Standard Tetrameshing

• Floatable Trias:
• Adjacent tria faces on the tetrahedral mesh may have their diagonal reversed from
the shell mesh if tetras are better quality

- OR -

Shell Mesh Tetra Mesh


Faces

• Fixed Trias:
• Adjacent tria faces on the tetrahedral mesh always match the shell mesh

Shell Mesh Tetra Mesh


Faces
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Tetrameshing: Volume Tetrameshing

• Volume tetrameshing uses the tetramesh panel > volume tetra sub-panel

• Provides a quick method of generating a tetramesh

• Has some specialized options:


• Use Proximity – Creates smaller elements next to small features to make a
smooth transition from small to large
• Use Curvature – Will place more elements along curved surfaces based on user
specified settings
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Tetrameshing: Volume Tetrameshing

• Use proximity and use surface curvature options

No options Use surface


curvature

Use surface
Use proximity curvature and
proximity
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Tetrameshing: Quick Tetramesh

• Geom/Mesh page of the utility menu

• Provides a quick method of generating a


tetramesh

• Maintains specified minimum element quality


criteria

• Resulting tetramesh may deviate from the


geometry to maintain good element quality

• User can select “sacred elements” or “sacred


surfaces” to force the tetramesh to closely follow
the original elements/surfaces

• Click Help on the Quick Tetramesh panel for a


description of the inputs
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Do-it-yourself

Exercise: Tetra meshing a Housing


• Page 166
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Chapter 6: Analysis Setup

Setting up Loading Conditions

Formatting models for Analysis


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Analysis Setup: What is it?

• Definition of all information for an analysis besides the mesh


• Specification of solver to be used
• Creation materials, properties, etc.
• Assignment of a solver specific format to HyperMesh entities
• Creation boundary conditions (constraints, loads, contacts, etc.)
• Definition of other required information (solution requests, general run
parameters, etc.)
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Analysis Setup: HyperMesh Capabilities

• HM is a“solver neutral” pre-processor


• Works with many different solvers
• Can convert between supported solvers
• Capable of assembly from input files of different solvers
• Can be customized to support other solver codes

• Can set up many types of analysis


• Structural (Stress, NVH, Durability, Non-Linear Structural)
• Radioss (Linear), Abaqus, Nastran, Ansys, Marc, nSOFT
• Manufacturing (Flow / Mold-Filling, Extrusion)
• Moldflow, CMold, HyperExtrude
• Safety (Impact / Crash, Occupant Safety)
• Dyna, Pamcrash, Radioss, Madymo
• Optimization (Topology, Topography, Shape, Size / Gauge)
• OptiStruct, Nastran
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Boundary Conditions: Supported Entity Types

• FE Loading
• Loads (constraint, force, pressure,
Constraints
moment, temperature, flux, velocity, Forces
acceleration)
• Equations (mathematical link
between nodes)

• Contacts
Pressures
• Group (defines contact between
entities)
• Contact Surfs (defines a list of
entities that can be used as master or
slave in a group)
Contact
• Reference Entities
Surface
• Sets (a simple list of a particular type
of entity)
• Blocks (a list of entities contained
within a box shape)
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Boundary Conditions: Supported Entity Types

• Coordinate Entities
• Systems (coordinate axes)
• Vectors

• Plotting
Vectors
• Curves (X-Y data)
• Plots (a display of curves with axes) Systems

• Output Requests
• Loadsteps (combinations of load
collectors)
• Output Blocks (request output from an
analysis for certain entities)

• Control cards (job-level, global parameters


for the analysis)

Plot with a Curve


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Boundary Conditions: Tools

• Analysis page
• Analysis page is devoted to setting up analyses

• User profile macro menus


• User profiles add macro menu pages with tools specific to that solver
• Abaqus – Step Manager, Contact Manager, Component Browser
• Ansys – Contact Wizard, Component Manager, etc.
• LS-Dyna – Name Mapping, Constrained Rigid Body, Content Table, etc.
• Nastran – Subcase Manager, Part Info, 1D Property Table, etc.
• Radioss Bulk / OptiStruct – Subcase Manager, Component Table, etc.
• Radioss Block – D01 Tool, Sections, Component List, Material table, etc.
• etc.
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Boundary Conditions: Loads on Geometry

• Loads can be created on geometry as well as FE entities


• Set the entity selector to a geometry entity
• Create the load
• Create the mesh
• Use the load on geom panel to map
the loads from the geometry to the
elements

Create load on Create the Map the load to


geometry mesh the mesh
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Do-It-Yourself

Exercise: Setting up Loading Conditions


• Page 178
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Solver Formats: Interacting with Solvers

• HyperMesh interacts with many solvers


• Each solver has its own unique formats, terminology, etc.
• Example: compare nodes and elements in Abaqus and OptiStruct / Nastran
• 3 nodes
• 2 quad elements
• Format / structure is obviously different

Radios (Linear) Abaqus

*NODE
GRID 1 0.0 1.0 0.0 1, 0.0 , 1.0 , 0.0
GRID 2 0.0 0.0 0.0 2, 0.0 , 0.0 , 0.0
GRID 3 1.0 0.0 0.0 3, 1.0 , 0.0 , 0.0

*ELEMENT,TYPE=S4,ELSET=part_1
CQUAD4 1 1 1 2 3 4 1, 1, 2, 3, 4
2, 3, 4, 5, 6
CQUAD4 2 1 3 4 5 6
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Solver Formats: HyperMesh “Templates”

• HyperMesh can interact with different solvers by using “templates”

• The selected template tells HyperMesh what solver the model is for

• The template also tells HyperMesh how entities are formatted for that solver
• Each entity may have several available formats for that solver
• Each format has fields that make up its definition
• These fields may need to have values entered by the user

• Example: a component for Radioss (Linear) can be a PSHELL or PSOLID


format
• PSHELL: holds shell elements, ID = 1, material = 1, thickness 5.0
PSHELL 1 15.0 1 1 0.0

• PSOLID: holds solid elements, ID = 2, material = 1


PSOLID 2 1 0
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Solver Formats: Solver Formats for Collectors

• Collectors format is specified by loading a “card image”

Example solver keywords available as element types:


HyperMesh
Collector
Type: Radioss (Linear) LS-Dyna Abaqus

PSHELL, PSHEAR, *PART *SHELL SECTION,


Component PSOLID, PCOMP *SOLID SECTION,
*RIGID BODY, etc.
PBAR, PBEAM, *SECTION_SHELL, *SURFACE
Property PGAP, PELAS, etc. *SECTION_SOLID, INTERACTION,
*SECTION_BEAM, etc. *FRICTION, etc.
MAT1, MAT2, MAT4, *MATL1, *MATL2, *MATERIAL, *GASKET
Material MAT8, MAT9, MAT10 *MATL3, etc. BEHAVIOR, etc.
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Solver Formats: Solver Formats for Elements

• Elements format is specified by setting an “element type”

Example solver keywords available as element types:


HyperMesh
Element
Configuration: Radioss (Linear) LS-Dyna Abaqus

CBEAM, CBAR, *ELEMENT_BEAM *ELEMENT, TYPE=


Bar CBEND B31, B31H, B33,
B33H, etc.
CQUAD, CQUADR, *ELEMENT_SHELL *ELEMENT, TYPE= S4,
Quad4 CSHEAR S4R5, M3D4, M3D4R,
R3D4, DS4, etc.
CTETRA *ELEMENT_SOLID *ELEMENT, TYPE=
Tetra4 C3D4, C3D4H, DC3D4,
C3D4E, DC3D4E
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Solver Formats: Solver Formats for Loads

• Loads format is specified by setting a “load type”

Example solver keywords available as element types:


HyperMesh
Load
Configuration: Radioss (Linear) LS-Dyna Abaqus

SPC, SPCD, ASET, *BOUNDARY_SPC_NODE, *BOUNDARY,


ASET1, SUPPORT, *BOUNDARY_ *BOUNDARY, TYPE=
Constraint QSET1, etc. ACCELERATION,
PRESCRIBED_MOTION_
VELOCITY, etc.
NODE
Force FORCE *LOAD_NODE_POINT *CLOAD
PLOAD, PLOAD2, *LOAD_SHELL_ELEMENT, *DLOAD, *DFLUX,
Pressure PLOAD4, QBDY1 *LOAD_SEGMENT *FILM, *DECHARGE
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Solver Formats: Tools

• Preferences > User Profiles…


• Loads the appropriate template for that solver
• Template can also be set manually
– Files pull down > Load > template file
– “g” on the keyboard (Global Panel)

• Sets the files > import > fe sub-panel to the


appropriate file type

• Loads a macro menu with tools specific to


working with that solver

• Customizes the HyperMesh menu


• Removes panels that are not used with that solver
• Removes controls inside a panel that are not used with that solver
• Renames some panels & controls in panels to match solver terminology
Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Solver Formats: Tools

• Collectors pull-down and collectors panels


• Create
• Assign a card image to the collector being created
• Edit the card image fields if desired
• Assign a material to the collector being created
• Update
– Assign a material to an existing collector
– Assign and/or edit a card image of an existing collector

• Elem types > load types panels


• Set a “current element / load type” for an element / load configuration
• Any new elements / loads of that configuration created will have that element
/ load type
• Change the element / load type of existing elements / loads
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Solver Formats: Tools

• Collectors > Card Edit or toolbar >


• View / edit the card image of any entity in the model
• Includes entities that are not collectors (nodes, elements, loads, etc.)

• Model Browser
• Right click a collector and select edit card
• View / edit the card image of the selected collector

• Preferences > graphics


• template labels type
• Activate the graphic displayed names of entities in solver (template)
terminology rather than HyperMesh (solver neutral) terminology
• Helps keep track of what is in the model
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Solver Formats: Tools

• Solver Browser
• Displays solver-based cards in a tree format
• Uses organization & structure of the represented
solver
• Performs basic actions involving cards
• Create new cards
• Delete existing cards
• Edit attributes of existing cards
• Solver Browser can be found in the View pull-down
menu
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Solver Formats: Tools

• Summary panel
• Displays a text window with various types of information about the model
• Helps to review the model and make sure all information has been entered
properly

Summary Type Included Information


Components Component Name, ID, Material Name, Thickness, Mass,
#Elements
Center of Gravity Component Name, ID, Mass, X, Y, Z
Elements Type of Elements, Element Configurations
Error Checks Load Collector, Load Steps, Components
Loads Load Collector, ID, FX, FY, FZ, Magnitude
Moment of Inertia Moment of Inertia
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Solver Formats: Process

1. Create the entities needed for your model


• Keep in mind what is needed for the solver and analysis being used
• Entities need to be properly organized in collectors
• All entities in a collector share the same attributes

2. Load the proper card image or type where needed


• Generally use the Setup/collectors, elem type, or load type panel
• Elements and loads will always have a type
• Sometimes collectors may not need a card image
Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Solver Formats: Process

3. Enter values in the card images as required


• Use or Collectors > Card Editor panels to check card images
of all collectors
• Some card images require other entities to be selected as a reference
• Example: Dyna requires a component’s card image to point to a property
collector for thickness information, etc.

• The goal in formatting for analysis is:


• All entities have the proper formats (card image / type)
• Card images of all entities have necessary information entered

• Understand the details of how HyperMesh interacts with your solver


• Refer to the External Interfacing portion of online help for details
• Altair has training classes for interfacing with some solvers
• Contact Altair support for additional questions
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Do-It-Yourself

Exercise: RADIOSS Linear Statics Setup


• Page 187
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Chapter 7: Connectors Weld

Adhesive

Bolt

Area contact

Replace parts
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Connectors: What are they & why use them?

• Geometric entities that define connections between other entities


• Used for welding, bolts, adhesives, etc.
• Link geometry or FE entities
• Can be “realized” into FE representations of welds, etc. for any supported solver
• rigids, CWELDs, MAT100s, ACMs, etc.

• Connectors allow for easy and rapid:


• Creation of FE welds, bolts, adhesives, etc.
• interactively or from:
• XML file
• MCF (master connectors file)
• Spot welds only
• Switching between different FE configurations of
welds, bolts, adhesives, etc.
• Part swapping and reconnection
• Replacement by names or IDs
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Connectors: Types of Connectors

• Spot • Bolt
• Connections at a point • Connections at hole locations
• Spot welds, rivets, etc. • Bolts

• Trim Mass
• Non-physical mass
• Simplification through replacement of parts
with mass only or add mass to existing part.
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Connectors: Types of Connectors

• Seam • Area
• Connections along a length • Connection of areas
• Seam welds • Adhesives
• Connects geometry only
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Connectors: Terminology

• Link Entities - The entities that are being connected


• User can explicitly define link entities or specify a search tolerance
• Can be components, elements, surfaces, nodes, or tags
• Typically components are linked

• Connector Location - Where the entities are linked


• Nodes – created at the node location
• Points – created at the point location
• Lines – created for the line
• line may be split into multiple projection locations as specified by the offset,
spacing, and density values
• Elements – created at the element location (adhesives only)
• Surface – created at the surface location (adhesives only)

• Connector Realization – The creation of the finite element representation of that


connector
• Rigids, springs, etc., or custom configurations such as ACMs, CWELDS, etc.
Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Connectors: Terminology

• Connector State – Whether an FE representation of a connector has been created


• Unrealized - The initial status of the connector entity upon creation
• Realized - The status only if creation of the FE weld representation at the
connector was successful
• Failed – The status if the creating the FE weld representation at the connector
was not successful

• # of Layers – number of FE weld layers to attempt to generate for the connector


• 2T, 3T, etc.

2T Weld 3T Weld
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Connectors: Terminology

• Connect When: – Specifies when the link entity information is added to the
connector
• Now - Allows you to add link entity information now.  For this option, you must
select the connect what entities and num layers to successfully create a
connector.
• At FE Realize - The link entities to the connector are determined while realizing
the connector.  The link entities are determined by the projections and proximity
from the connector location.  

• Re-Connect Rule – Defines method for connector re-attachment during part


swapping/replacement
• None - If a link entity is deleted, the link entity is removed from the connector
• By ID - If a link entity is deleted, the connector retains the ID of the link entity, and
will to a new entity with that ID upon realization
• By Name – Same as the by id rule except that the entity name is retained
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Connectors: Tools

• File >> Import >> Connectors… – Import Master Weld Files to automatically
create connectors

• Auto Connectors…
• Mesh / Geom page of utility menu
• Same as File > Import > Connectors
• Gives additional options

• Connectors module
• 1D page >> connectors
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Connectors: Tools

• Connectors Module
• Spot
• Bolt create, edit, and realize
• Seam that style of connectors
• Area
• Apply Mass – adds a mass value to entities
• Used to represent mass of parts that are not present in the model
• FE Absorb – Create new connectors from existing elements of recognizable FE
representations of welds, bolts, adhesives, etc.
• Add Links – Add link entities to existing connectors
• Unrealize – Delete FE representations of welds / bolts / adhesives associated
with existing connectors
• Compare – Checks the MCF against displayed model file
• Quality – Check for duplicate connectors, combine connectors, check quality of
realized elements
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Connectors: Tools

• Connector Browser – Hierarchal browser that


provides information and the ability to edit
connectors.

• Shows;
Type of Connector
Link Information
State of connector

• Editable
• Edit link entities, export mwf files, etc

• Found in Tab Browser Area


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Connectors: Tools

• Visualization – Controls how connectors are displayed


• Color connectors by state, layers, or component
• Visibility by state or layers (can turn the display on or off)
• Control size of connector display
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Demo + Do-it-yourself

Exercises 1,2 and 3: Connectors


• Page 199-225

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