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

Altair HyperWorks 10.0

Introduction to HyperMesh

Day 1

Adriano A. Koga
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Chapter 1: HyperMesh Introduction

Getting Started

Opening and Saving Files

Working with Panels

Organizing a Model

Controlling the Display

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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-panel

1) What to do: 2) What to do it to: 3) How to do it: 4) Do the action:

Pick a sub-panel Select entities that Give parameters Execute the
for the function will be affected that define how function
to be used the function will
be executed
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Panels: General Layout

Some sub-panels are organized in columns

Each column is a different method
Work from top to bottom in the relevant column
Example: surface edit : trim with surfs/plane sub-panel

2) Method to 3) What to do 4) How to do it:

1) What to do: use: it to: 5) Do the
Give parameters
action:
Pick a sub-panel Work in the Select entities that define how
for the function appropriate that will be the function will Execute the
to be used column affected be executed function
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Model Organization: HyperMesh Entity Types

Geometry Points
Points
Surfaces
Lines Lines
Surfaces
Solids
Connectors (used for welding)

Solids

Nodes Elements
FE Model
Nodes
Temp Nodes (marks a node with a small circle)
Elements

Temp Nodes
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Model Organization: HyperMesh Entity Types

FE Loading
Loads (constraints, forces, pressures, etc.)
Equations (mathematical link between nodes)
Forces

Pressures
Constraints

Contacts
Group (defines contact between entities)
Contact Surfs (defines a list of entities that can be
used as master or slave in a group)
Contact
Surface
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Model Organization: HyperMesh Entity Types

Multibodies
Ellipsoids (defines a shape for rigid bodies)
Mbplanes (defines a shape for rigid bodies)
Mbjoints (defines the connection of 2 rigid bodies)

Safety
Sensors (defines a trigger to start an event)
Control Volumes (defines airbags)
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Model Organization: HyperMesh Entity Types

Coordinate Entities
Systems (coordinate axes)
Vectors
Vectors Systems

Reference Entities
Sets (a simple list of a particular type of
entity)
Blocks (a list of entities contained within a Beam Section
box shape)

1D Element Cross Sections

Beam Sections (cross sectional
properties for a property collector)
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Model Organization: HyperMesh Entity Types

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

Output Requests
Loadsteps (combinations of load collectors)
Output Blocks (request output from an Plot with a Curve
analysis for certain entities)

Labels Title
s
Titles (label for a displayed item)
Tags (assigns a name to an entity) Tags
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Model Organization: HyperMesh Entity Types

Morphing
Handles controls model shape during morphing
Domains divides a model into regions (for domain based morphing)
Morph volume A cube shaped volume that morphs all entities that are located
inside the shape (for volume based morphing)
Morph constraints Control the motion of nodes during morphing
Symmetries forces regions to be morphed symmetrically
Shapes model state during morphing saved for retrieval at a later point

Handles

Morph Volume Symmetries Domains

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Model Organization: HyperMesh Entity Types

Optimization
Designvars Variables that are changed during optimization (ex: thickness)
Optiresponses Values being measured (ex: von Mises stress)
Objectives Responses to maximize/minimize (ex: minimize weight)
Dobjrefs Objective reference response for minmax/maxmin optimization (ex:
minimize maximum von Mises stress)
Opticonstraints Limitations (ex: von Mises stress < Yield stress)
Optidscreens Filters constraints to reduce computation time
Dvprels Relationships between design variables and properties
Desvarlinks Relationships between design variables
Dequations A calculated value to be measured
Optitableentrs Table of constants
Opticontrols Parameters to control the optimization algorithms
DDVals Sets a discreet range of values to be used in a Designvar
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Model Organization: Collectors

The HyperMesh model is organized using collectors

There are many types of collectors
Most entities in HyperMesh must be placed in a collector
Each collector type holds a specific type of entity

Collector Types Can contain entity types:

Component Elements, Points, Lines, Surfaces, Connectors
Multibody Ellipsoids, Mbjoints, Mbplanes, Sensors
Assembly Components, Multibodies, Assemblies
Load Collector Loads, Equations
Material none (materials and properties dont contain other entities but are
Property still treated as collectors)

System Collector Systems

Vector Collector Vectors
Beam Section Collector Beam Sections
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Model Organization: Collectors

An entity can usually only belong to 1 collector of a given type

Ex: an element can only be in 1 component collector
Can create many collectors of the same type
All entities in a collector are the same color
Organization can be however the user desires
Component 4

Component 3

Component 1 Component 3
Component 2 Component 2
Component 1

1 component per part Multiple components per part

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Model Organization: Collectors

Model browser
View collectors and assemblies in a hierarchical
tree format
Create, delete, and rename collectors
Edit collector attributes Right-Click on
Organize collectors into assemblies Collector for
advanced
Drag and drop
options
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Model Organization: Collectors

New entities are created in the current collector

Creating a new collector automatically sets the current collector to that new
collector
Model Browser or can be used to change the current collector.
Include Browser can be used to change the current include.
Organize panel can be used to move entities into a different collector

Bold Current Collector

Bold Current Include

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Model Organization: Tools

Panels
Collectors Create new collectors

Model Browser Set the current collector for various entity types

Organize Move entities into a different collector than the one they are currently
contained in

Rename Change the name of an existing collector

Reorder

Collectors appear in a certain order when presented in a list to pick from

Reorder allows the order the collectors appear in to be changed

Delete Delete entities or collectors

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Do-it-yourself

Exercise: Reorganizing a Bumper Model

Page 29
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Display Control: Viewing: Toolbar

Dynamic Rotate (A) Manually rotate by grabbing a point and dragging

Rotate relative to the mouse cursor and screen center
Dynamic Spin (R)
Pan the model
Pan
Select and click on the screen to re-center model in
Center (C) graphics window
Rotate Left

Rotate Right

Rotate Up
Incremental rotations in respective directions
Rotate Down

Rotate Clockwise

Rotate Counter Clockwise

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Chapter 2: Geometry Cleanup

Importing and Repairing CAD

Generating Midsurface

Simplifying Geometry

Refining Topology to Achieve a Quality

Mesh
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Topology Repair: Importing Geometry

Import geometry data via:

Files > Import > Geometry drop-down menu

Toolbar > > Geometry

Common types of geometry files supported:

Unigraphics (NX2, NX3, NX4, NX5)
UG Part Browser
Import of *.prt files
Requires an installation of
Unigraphics to be available
CATIA (V4 & V5)
import of *.model files
CATIA V5 license required to import
V5 files
Pro/ENGINEER (Wildfire 2.0 & 3.0)
import of *.prt and *.asm files
IGES
Import of *.igs / *.iges files
STEP
import of *.stp files
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Topology Repair: Surface Definitions

Fixed point (Surface vertex)

Point associated with a surface
Surface Cannot be moved off the surface
Can lie on a surface edge or the
interior of a surface
Separates surface edges from each
other
Forces a node to be placed at that
location during meshing

Surface edge
Line associated with a surface
Defines a surfaces boundary
Cannot be moved off the surface
Has a fixed point on both ends
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Automeshing: What is topology?

Topology is how surfaces connect to adjacent surfaces of a part

Surface connectivity is controlled by the associated surface edges
If a surface edge is associated with more than 1 surface, those surfaces are
considered to be connected (equivalenced)
Surface edges are categorized, named, and colored according to the number of
associated surfaces:

Free edge (red) T-junction edge (yellow)

Associated with only 1 Associated with 3 or more
surface surfaces
Surfaces with a free edge Example: surfaces forming a
between them are NOT T-connection
equivalenced at that edge Surfaces are equivalenced

Shared edge (green) Suppressed edge (blue)

Associated with 2 surfaces Surfaces are treated as though
Surfaces are equivalenced
combined into 1 surface
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Topology Repair: Viewing Topology

Topology display mode is default for some panels (w/ Auto ON)
surface edit, quick edit, point edit, edge edit, autocleanup, and automesh

Can also be accessed via geometry visualization type

Auto Default (topology display in only default panels mentioned above)

By Comp Always in component color mode
By Topo Always in topology display mode
By 2D Topo Displays only 2D geometry in topology display mode
By 3D Topo Displays only 3D geometry in topology display mode
Mixed Displays 2D and 3D geometry in topology display mode
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Topology Repair: Viewing Topology

Toolbar > > Topology tab controls display of:

Visibility of free, shared, t-junctions, and suppressed edges

Visibility of fixed points
Level of surface transparency
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Topology Repair: What is it?

HyperMesh will attempt to properly clean up surfaces during import

Some types of geometry files have surface connectivity information which helps
HyperMesh. Typically native geometry files like Catia, UG, ProE, etc.
Geometry usually imports cleanly

Topology Repair consists of correcting connectivity errors between

adjacent surfaces
Possible errors include:
Unconnected adjacent surfaces
Duplicate surfaces
Missing surfaces

The Goal of Topology Repair: Restore the surface data to a perfectly

clean representation of the part
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Topology Repair: Process

General process is to:

Figure out what the ideal surface connectivity of the part should be
Observe the current display of topology colors (free, shared, t-junction)
Figure out what is causing the topology to be displayed this way
Use the tools in HyperMesh that get the connectivity from what it is to what it
should be as quickly and efficiently as possible

Example: Duplicate surface

deleted

Missing surface
created

Free edge pair

equivalenced
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Topology Repair: Tools

Edge Edit Panel

Equivalence (multiple edges at a time)
Search surfaces for pairs of free edges and combine into shared edges
Toggle (1 edge / edge pair at a time)
Select an edge; equivalences with other free edges found within a user specified
tolerance
Replace (1 edge pair at a time)
Select 2 edges to equivalence together
Control which edge to retain and which to move

Point Edit Panel

Replace (1 edge at a time)
Release Combine pairs of free edges with gaps between them into a shared
edges
Defeature Panel
Duplicates Identify and delete duplicate surfaces within a user specified
tolerance
Surfaces Panel
Spline / filler Select lines / surface edges to recreate any missing surfaces
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Topology Repair: Tools

Quick Edit Panel

Has a number of tools found in other panels
Focused on tools with minimal user input for rapid editing

Unsplit Removes / deletes an edge created by splitting a surface in HyperMesh

Toggle Same as edge edit panel; change edge type within tolerance
Filler surf Select a line on a free surface edge to recreate any missing surfaces
Delete surf Same as delete panel (surfaces only)
Replace point Same as point edit panel; move/retain point
Release point Same as point edit panel; must be associated with line
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Topology Repair: Strategy

Understand model size & scale to determine an appropriate global element size

Set a cleanup tolerance based on the determined global element size

Set appropriate value in options, geom cleanup, and automesh : cleanup
Cleanup tolerance specifies the largest gap size to be closed by topology functions
Tolerances > 15-20% of global element size can cause mesh distortions
Can change value multiple times for work on various areas of the model

Use topology display tools to decide what needs to be cleaned

Use equivalence to combine as many free edge pairs as possible

Make sure surfaces are not collapsed in undesirable manner

Use toggle to combine any remaining free edge pairs, 1 by 1

use replace function if more control is needed

Use find duplicates to check for any duplicate surfaces and delete them

Use filler surface to recreate any missing surfaces

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Demo + Do-it-yourself

Exercise: Importing and Repairing CAD

Geometry
Page 59
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Midsurfacing: Introduction

For many FE analyses, parts are represented by shell elements

Thickness is assigned mathematically, rather than geometrically
Mesh is usually placed on the midplane of the part

CAD geometry usually comes as a solid part, or a series of surfaces defining

a volume.

Midsurfacing creates a layer of surfaces on the midplane which can be

directly meshed
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Midsurfacing: Tools

Midsurfaces can be created using midsurface panel on the geom page

Auto Midsurface Automatically extracts midsurfaces from surfaces that enclose

a volume or a solid geometry
Can sometimes work if there are missing surfaces
The greater number of missing surfaces, the less reliable the result

Surface Pair creates a midsurface between 2 selected surfaces

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Midsurfacing: Tools

Once a midsurface has been created, it can be modified using tools on the
midsurface panel
Quick Edit Repair a midsurface by correcting where the verticies of the surface
were placed
Assign Target An extension to quick edit, and functions in a similar fashion
Replace Edge Fill in gaps and slivers by combining one surface edge with
another
same as in the edge edit panel
Extend Surface Extends two surfaces (e.g., ribs) until they intersect
View Thickness Review of the thickness of a midsurface using white lines
(probes) extending from each vertex of the surface
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Midsurfacing: Process & Strategy

1. Obtain a closed volume of surfaces or solids

Midsurface : auto midsurface requires an enclosed volume
Use topology repair techniques if needed

2. For complex parts, try defeaturing the surface defining the volume
This simplifies the part and may give better results with create : solid

3. Generate the midsurface using midsurface : auto midsurface

Use surface pair for areas that need more control
Use midsurface : editing tools for midsurfaces that need fine tuning

4. View the midsurface and correct errors using the midsurface editing
functionalities
Can generally use quick edit
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Do-it-yourself

Exercise: Generating a Midsurface

Page 70
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Defeaturing: What is it?

Depending on the analysis, certain details in the geometry may be ignored.

This may depend on:
Importance of the part in the overall assembly
Location of the feature relative to the area of interest in the analysis
Size of the feature vs. the average size of the mesh being used

Defeaturing is the removal of details in the geometry in order to make the

shape of the part simpler

Surface fillet

Pinholes
Edge fillets
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Defeaturing: Tools

Defeature panel on Geom page

Pinholes: Searches for closed loops of free edges (holes) within a
surface
Fills in the holes
Leaves fixed point at the center

Surf Fillets: Searches for surfaces that act as fillet between other surfaces
Tangentially extends them to form a sharp corner

Edge fillets: Searches for rounded corners on a surface

Squares off the corner

Duplicates: Finds and deletes duplicate surfaces

Symmetry: Finds symmetric surfaces within a single component
Deletes or organizes the surfaces into different components
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Do-it-yourself

Exercise: Removing details from a

Midsurface Model
Page 75
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Topology Refinement: What is it?

Topology refinement is modifying topology in order to obtain a quality mesh

Unlike defeaturing, this generally does not change the shape of the part

CAD geometry has topology details that interfere with mesh quality
Edges are created where ever there is a change in surface curvature
Even smooth areas can be split into several faces
The automesher will be forced to place nodes along the edges and fixed points
This may cause small element lengths, angles, aspect ratios, etc. depending
on the shape of the model

CAD geometry can also have surfaces with a complex outline

Highly complex shapes can make it hard to get a quality mesh
Adding in edges splits the surfaces into smaller and simpler regions which can be
meshed easier
Fixed points can be added in to force a node to be placed at that location, giving
more control
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Topology Refinement: Examples

Suppressing Adding Removing Adding Replacing

edges edges fixed points fixed points fixed points
Before
After
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Topology Refinement: Tools

Edge edit
Toggle Select a shared edge to suppress it
(Un)Suppress Select multiple edges to suppress all of them at once

Point edit
Add Add fixed points to help control mesh pattern
Especially helpful along edges to control node seeding
Suppress Removes unwanted fixed points
Replace Combines 2 fixed points together at a single location
Project Projects fixed points onto a nearby edge
Useful for aligning mesh between 2 edges

Surface edit All functions add edges by cutting surfaces

Adding edges can be useful for controlling mesh patterns in large areas
Trim with nodes Uses node locations to cut surfaces
Trim with lines Uses lines to cut surfaces
Trim with surfs/plane uses other surfaces or a defined plane to cut surfaces
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Topology Refinement: Tools

Quick edit
Has a number of tools found in other panels
Focused on tools with minimal user input for rapid editing

Split surf-node: Adds an edge to or divides a surface by cutting in a straight line between 2
selected nodes
Split surf-line: Adds an edge to or divides a surface by cutting a straight line between a
node and perpendicular to the selected line.
Washer split Adds a circular edge around a hole in a surface
Mostly used for creating all quad mesh around a hole
Toggle Same as edge edit panel
Remove Point Deletes a selected fixed point
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Topology Refinement: Tools

Quick edit, continued

Replace point Same as point edit panel

Add/remove point : point Creates a new fixed point at the selected locations
Add point: line Creates a user specified number of fixed points along the
selected edge
Project point Same as edge edit panel
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Topology Refinement: Tips

Mesh the part

Visually scan the part to look for poor mesh patterns
Use element checks in order to find areas of poor element quality
Check elems panel, QI Panel, etc.

Suppress edges with edge edit :(un)suppress

Use various settings for break angle to suppress many edges at once

Sometimes suppressing all edges and then unsuppressing desired edges can
be a good method.

Suppress all the fixed points before add more in

Gets rid of as many fixed points as possible, leaving ones that are required

Experiment!
There is no set process, so experience is a key factor in refining topology
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Do-it-yourself

Exercise: Refining Topology to Achieve a

Quality Mesh
Page 84
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Chapter 3: Shell Meshing

Automeshing

Checking and Editing Mesh

Batch Meshing
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Automeshing: What is it?

The automesh panel creates shell mesh on existing surfaces

Allows rapid generation of mesh
Most parts from CAD software come in as surfaces
Automeshing allows all surfaces of a part to be meshed at the same time
Mesh on properly connected geometry assures proper connectivity of mesh
Copyright 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Automeshing: What is topology?

Topology is how surfaces connect to adjacent surfaces of a part

Surface connectivity is controlled by the associated surface edges
If a surface edge is associated with more than 1 surface, those surfaces are
considered to be connected (equivalenced)
Surface edges are categorized, named, and colored according to the number of
associated surfaces:

Free edge (red) T-junction edge (yellow)

Associated with only 1 Associated with 3 or more
surface surfaces
Surfaces with a free edge Example: surfaces forming a
between them are NOT T-connection
equivalenced at that edge Surfaces are equivalenced

Shared edge (green) Suppressed edge (blue)

Associated with 2 surfaces Surfaces are treated as though
Surfaces are equivalenced
combined into 1 surface
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Automeshing: How topology affects the mesh

Surface edges control how mesh created on adjacent surfaces interact:

Free edges (red) Shared edges (green)

Free edge between Shared edge between

2 surfaces 2 surfaces

5 5
Nodes are placed along 2 Nodes are placed along 3 2
3
edge for meshing 5 5 edge for meshing 5
3 2 3
2 5
5

Mesh is discontinuous; Mesh has proper

nodes along the free edge connectivity; nodes along
are not equivalenced the edge are equivalenced
(Nodes only separated for
illustration)
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Automeshing: How topology affects the mesh

Surface edges control how mesh created on adjacent surfaces interact:

Suppressed edges (blue) T-junction edges (yellow)

Suppressed edge Non-manifold edge
between 2 surfaces between 3 surfaces

5 5
Edge is ignored; nodes Nodes are placed along 4
5
are not placed along 5 edge for meshing 5 3
4 5 3
the edge 3
5 3 5

Area is treated just like 1 Mesh has proper

surface; there is no line connectivity; nodes along
of nodes along the edge the edge are equivalenced
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Automeshing: Process and Strategy

Use geometry cleanup tools to address surface connectivity

Automesh the surfaces
Set the approximate element size you want
Use type and algorithm to set the overall mesh style
Alter individual densities to find better mesh patterns
Change some biasing on problem surfaces (this can change mesh pattern as
well)
Goal: get the mesh to be approximately 80-90% good quality
Use HyperMeshs mesh editing tools to fix the 10-20% elements that have
poor quality or bad mesh pattern
Dont delete a mesh that is 90% good. Keep it and fix the 10% that is bad

Experience is key: EXPERIMENT!

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

Demo + Do-it-yourself

Exercise: Meshing a Channel Bracket

Page 101
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Demo + Do-it-yourself

Exercise: Mesh cleanup of a Plastic

Cover
Page 113
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Batch Meshing: Introduction

Performs geometry cleanup and automeshing in a batch mode

Can dramatically improve productivity since there is minimal user interaction
(especially for large assemblies)
Uses criteria and parameter files to determine how the parts should be
meshed
Can mesh multiple files in the same run
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Batch Meshing: Process & Required Input

1. Create / specify Configurations

Combination of element criteria and

geometric parameters

Element criteria are element

quality requirements

Geometric parameters are

other requirements (element
type, removal of pinholes,
removal of fillets, etc.)

Criteria and parameters can be

edited with the Criteria and
Parameters Files Editor
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Batch Meshing: Process & Required Input

2. Register and specify User Procedures (optional)

Custom TCL scripts (macros) created by the user
Performs additional operations on models during the batch run
Pre Run and Post Run options can specify procedures performed before or after
the run
Can specify when the procedure should be performed during the run
Pre-geometry load as soon as batch mesher is invoked
Pre-batch mesh just before loaded geometry is meshed
Post-batch mesh after meshing is finished

3. Set up the Batch Mesh job

Specify a directory where geometry files are located
Select geometry files from the directory
Select a configuration to use for the mesh type for each file
Specify any user procedures to be performed on each part
Specify a directory where the meshed files will be located
Run the batch mesh job
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Batch Meshing: Process & Required Input

4. Monitor the Run Status of the job

Use the Run Status tab to keep track of all your submitted jobs
Use Load Mesh to open a selected file in a new HyperMesh session to view the
resulting mesh
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Demo + Do-it-yourself

Exercise: Batch Meshing a Shell Bracket

Page 130