BASIC

HYPERMESH
TUTORIAL
NIRDESH CHAUHAN
M.S.MECHANICAL ENGINEERING
MICHIGAN TECHNOLOGICAL UNIVERSITY
ADVISOR: DR.ODEGAURD

This tutorial is the beginner’s guide to understand basics of meshing techniques and implement
meshing methods on models with the help of powerful tools like Hypermesh from Altair.

12/19/2012
INTRODUCTION
Altair HyperMesh is a high-performance finite element pre-processor that provides a highly
interactive and visual environment to analyze product design performance.

With the broadest set of direct interfaces to commercial CAD and CAE systems, HyperMesh
provides a proven, consistent analysis platform for the entire enterprise.

With a focus on engineering productivity, HyperMesh is the user-preferred environment for:

Solid Geometry Modeling

3D Visualization of all element types (1D, 2D and 3D elements) within a FEA model eases model
checking and visual verification. Using sophisticated batch meshing technology, HyperMesh
eliminates the need to perform manual geometry clean-up and meshing, thus accelerating the
model development process.
Model Morphing
Delivering the most powerful model morphing tool in the industry HyperMesh allows users to
modify existing meshes to meet new designs and reduce model development costs.

Detailed Model Setup

Generating surfaces from finite element models enables analysis engineers to easily
communicate and share product modifications with design teams. Modern, configurable, and
easy-to-use graphical user interface provides seamless data exchange for pre and post
processing.

Surface Geometry Meshing

The surface meshing module in HyperMesh contains a robust engine for mesh generation that
provides users with unparalleled flexibility and functionality.

This includes the ability to interactively adjust a variety of mesh parameters, optimize a mesh
based on a set of user defined quality criteria, and create a mesh using a wide range of
advanced techniques.
 Solid Mesh Generation
Using solid geometry, HyperMesh can utilize both standard and advanced procedures to
connect, separate or split solid models for tetra-meshing or hexa-meshing.

Partitioning these models is fast and easy when combined with Hyper Mesh’s powerful
visualization features for solids. This allows users to spend less time preparing geometries for
solid meshing. The solid-meshing module allows users to quickly generate high quality meshes for
multiple volumes.

Batch Meshing
The BatchMesher™ module in HyperMesh is the fastest way to automatically generate high-
quality finite element meshes for large assemblies. By minimizing manual meshing tasks, this
auto meshing technology provides more time for value-added engineering simulation activities.
Batch Mesher provides user-specified control over meshing criteria and geometry clean-up
parameters as well as the ability to output to customize model file formats.
Mesh Morphing
HyperMorph is a powerful HyperMesh module for interactively and parametrically changing the
shape and of a finite element model. Its unique approach enables rapid shape variations on the
finite element mesh without sacrificing mesh quality, or changing node id’s and element id’s.
HyperMorph can be used to dynamically create shape variables which can be used for
subsequent design optimization studies.

Starting Hypermesh
• Go to the start menu – all programs- click on
Altair HyperWorks 2011- open HyperMesh
• The following window will pop up with
default interface.

• From user profiles select HyperMesh and the program will ask you for customized user
interface for different kinds of solver applications.
• Select default (HyperMesh) as your profile and hit enter.

INTRODUCTION TO THE INTERFACE

• After customized profile interface selection the HyperMesh will open with following
window. We will introduce each main region of the interface.
• The interface is the same as most of the Microsoft environment applications.
Model Browser
The model browser is a kind of „list of contents― providing information about the loaded FEM
model. In this depicted example the mesh of the model is stored in a component named „mesh―,
the component owns a number (ID) and a color. The lD is being used by the FEM solver, the color is
used for displaying elements. At the same time the model browser controls which FEM entities are
being displayed.

Panels: General Layout

Panels often have sub-panels Accessed by radio buttons on the left side of the panel.

Panels generally work from left to right Example: Project / to plane sub-pan

How to read panels

GREEN: press this button for the application of the action like- create – reject – delete

BLUE: Is usually means the review of the action without making any changes in model

RED: Close panel. No further action. Closing current action to go to previous menu.

Yellow: Hypermesh is expecting input from you.

Normal function flow of the panels

IMPORTING WING

• Typically any CAE projects starts with the import of given CAD data e.g. CATIA, STEP, UG,
IGES, SolidWorks etc. (of course, you may create your CAD model in HyperMesh as well).
• Many times the troubles start now as the imported geo-metry is not reasonably
meshable (btw, this one of the many reasons why HyperMesh is used in so many places
i.e. HyperMesh is a commercial expert system with supe-rior tools to overcome meshing
troubles).
Some problems related to geometry:
• Surfaces are not stitched together (i.e. there is a gap between surfaces)
• Very small surfaces are squeezed between regular surfaces
 • Surface edges do not line up properly forming jumps
• see figure above
1) Left: CAD with jumps
2) Middle: mesh with irregular shaped elements;
3) Right: improved CAD with regular mesh)
• The geometry is a thin-walled volume structure - simplification needed: mid-surface
model
• Surfaces intersect (t-connection) but don‘t „feel― each other
• Geometry is much too detailed (e.g. tiny fillets which are not needed for the analysis)

To import solid part follow below mention steps:

1) Make sure your CAD model is saved in STEP format.
2) Go to file menu and select import geometry option. Or from the toolbar select the import
geometry logo as shown below.

3) Next the import geometry box will pop up. Now select the appropriate file format from the
drop down box and browse the wing.step file from the location you have saved on your
computer as follows.

4) After selecting correct file path select import file as shown in below image step . The
imported part should look like as below.
The color of the imported geometry indicates some features as follows.
The color of the geometry should not be red. It indicates the error of connections between edges.
For example in image below the color is red. If it happens you have to check your step file in
SolidWorks. Try to arrange coordinates. Make sure the curve is closed.And try again by saving file as
different name.

5) Close the import dialog box.

MESHING THE PART

• Once geometry cleanup (e.g. surfaces ares stitched to-gether — no unwanted red edges
inside the geometry) is completed meshing is next.

Some rules of thumb:

• The mesh should look rather smooth and regular (keep in mind that the analysis is
based on your mesh & mesh quality.
 • Use the simplest element type suited for the problem. For the airfoil geometry tri
elements are best suited. Usually triangle elements are best for complex shaped
surfaces by providing fine meshing.
• Start with a coarse mesh and then by decreasing the element size go for the fine mesh.
• Understand the modeling results; then use a finer mesh if needed
• Try to limit mesh related uncertainties to a mini-mum if possible—make it simple it will
get more complicated automatically.

BASICS OF MESHING

• Element size = the element size in the model may deviate from the specified size
considerably (it depends on the size of the surface)
• Mesh type = mixed; default (is a combination of many quad-shaped elements and some
tri elements). Leads to rather smooth meshes.
• Elements to surface comp vs. Elements to current comp - specifies the storage place of
the elements
• Start meshing; explore the meaning of the other set-tings latter!
• Some surfaces apparently have cause troubles. Not really. It is a matter of your visual
settings. In this example the geometry is still shaded, overprinting the mesh in some
spots. Putting the geometry in wireframe and shading the elements improves the mesh
visibility.
• element quality parameters
Some typical values
Warpage = 20
Aspect = 5
Skew
Min angle Quads = 40
Max angle Quads = 140
Min angle Tria = 30
Max angle Tria = 15
Jacobian = 0.5
Taper = 0.5
Now for our model follow these steps to create tetra 3D mesh
1) From the tool panel choose 3D mesh and select tetramesh as follows.
 2) In next step select volume tetra and select following values in the box. First of all
select the enclosed volume box. Than select the wing volume. It must turn in to
white color before proceeding further.

In 2D element type box there are four options:

1 Trias: pure triangle elements

2 Quad: pure quadratic elements
3 Mixed: combination of triangle and quadratic elements
4 Rtrias : Right angle triangle elements

The element type is totally depends upon the shape of the geometry. There is no single rule
which element to choose for particular geometry. It totally based upon user’s experience. At
beginning one can try different elements and from trial and error method you can get the skill
to choose correct element set for particular geometry.

In case of very complex assembly or geometry we can divide the assembly or part in various
sections of the relatively simple geometries and then mesh the each section with differently by
selecting different parameters for individual sections.

For most complex geometries well fined tetra elements are the best suited. So for this
particular shape we will choose tetra elements. We can start element size with 1 and then
reduce up to 0.2. For this problem 0.02 size is more than enough.

There are various techniques applicable to any single meshing application for the part. The
meshing is sometimes called art as well as science.

To apply trial and error method you need to delete the mesh quite often. Here is the step
which will help you to delete elements.
After applying various trials we can finalize the mesh as following figure. To visualize the mesh
we need to rotate and zoom the graphic area. Here is the basic understanding of the features.

The box above will help to move part in different direction and zoom in and out can be done by
selecting zoom options.

We can also visualize the different kind of views like isometric, wireframe, hidden edge , solid
etc by this feature tool bar situated above the panel options.
The final meshed part should look like this.

Now here we have finished our HyperMesh meshing application. Now we have to save this part
in appropriate format so that we can perform finite element analysis on this model.

Hypermesh saves the entire file in .hm as default format .That is the HyperMesh parent format.
But we can also save files in form to be appropriate for the other solver tools.

For information Hypermesh is compatible with following file formats.

HyperMesh provides direct import and export support to the industry's most popular solvers.
Additionally, HyperMesh provides a completely tailored environment for each supported
solver.

Modern and Efficient CAE Modeling Environment Easily Handles Large Models and Assemblies
Batch Meshing for Automated Rapid Model Generation
• OptiStruct®
• RADIOSS™
• MotionSolve®
• ABAQUS
• NASTRAN
• ANSYS
• MOLDFLOW
• LS-DYNA
• PAMCRASH
• PERMAS
• MADYMO
• MARC
• FLUENT
• Star-CD
• CFD++
• Acusolve
• SC/Tetra
• CGNS

We are planning to use Abaqus solver so follow below steps to save file in Abaqus compatible
format.

Open the export solver deck as mentioned above then in file selection box slect the abaqus
solver.

In the template we have three options: Standard3d , Standard2D, Explicit .We can use the
standard 3D format. After selecting abaqus solver input file format, in Abaqus we would not be
able to make any changes in the model for example geometry , dimensions , mesh .But we
would be able to change material properties , boundary and load conditions.
Select the file name wing and select the proper path, HyperMesh will save it in wing.inp format.