One Software, Many Solutions

Structural Analysis and Design Software for Aerospace

WEIGHT

Panels and Beams

Unstiffened Panels

The most basic panels are sheet metal and laminates. These concepts do not have stiffeners or cores to provide buckling stability.

Sandwich Panels

Useful for structures that have biaxial compression and/or shear loading causing buckling. A commonly used aerospace composite panel concept, but not for primary loaded commercial airframes.

Stiffened Panels

Useful for structures that are mostly under uniaxial loading. Open sections such as ‘I” are often used for airframe wing skin and closed sections such as ‘Hat’ for fuselage skin.

Grid Stiffened Panels

Used for metal biaxial and shear loaded structure such as an aircraft rib. These concepts have many dimensions to optimize.

Beams

Beams can be analyzed and sized. Specific beam stiffness formulation and failure analyses are performed. Modeled with 1D elements.

Fastened and Bonded Joints

FEM Joint

A FEM joint is a HyperX derived entity. They are generated automatically from the intersection of structural zones.  One- and two-member line joints are used for load processing.

Edge Allowable Joint

Design of a joint begins with edge allowable joints. FEA loads are extracted in the joint coordinate system and compared to pull off and shear allowables.

fastened joint

Fastener types, diameters, spacing, and number of rows are sized. Analysis include fastener bearing and bearing-by-pass on the laminate.  NASA 5020 analyses include pull off and torque.

rivet joint

Rivet types, diameters, spacing, and number of rows are sized. Analysis is based on allowables from testing rivet and sheet metal combinations. 

Bonded joint

Adhesive material, thickness, overlap length, and taper angle are sized. Analyses include linear/nonlinear peel and interlaminar shear stresses; and VCCT energy solution for disbonds.

Composite Laminates

Effective Laminates

A smeared representation of a laminate. Three variables: ply material, laminate thickness, and laminate angle % in the 0/45/90 directions.

Discrete Laminates

Layup stacking. Four variables: ply material, thickness, angle, and stacking order. Primarily used to represent imported laminates from the FEM defined with data such as Nastran PCOMP.

Laminate Families

Layup stackings defined as columns in a spreadsheet or table with shared plies. Sizing produces manufacturable laminates that have continuous sequence of layers laid up over a part. 

Producibility

Laminate Trends

Generate Laminate Families

Generated families have stacking sequences and ply counts that are tuned to provide low weight and manufacturable solutions for specific zones or structures.

Import Laminate Families

Existing families can be imported to HyperX and used for composite optimization.

Study Angle Percentage

Ply angle (0⁰,45⁰,90⁰) percentage limits in laminate optimization influence both weight and producibility. HyperX’s design study tool is used to examine the trends.

Study Laminate Families

HyperX’s laminate family design study tool is used to analyze weight and manufacturability trends resulting from different drop patterns, ply shapes and Main Stacking Sequences (MSS).

Plies

Ply Sequencing

The minimum-weight laminate for a zone is not always the most producible. Ply sequencing assembles zone laminates into producible plies on a structure.

Ply Scoring

Producibility of plies is assessed by considering two primary features: ratio of perimeter length to ply area, and orientation of fibers relative to ply boundaries.

Ply Visualization

Review ply shapes, drops, and stacking sequence as well as cores and core taper in HyperX before exporting for manufacturing.

Ply Modification

Users can manually modify plies after generation. HyperX provides several tools for easy editing. Updated margins can be generated after ply modification.

Composite Stiffened Panels

Stiffened Panel Ratios

Cross section ratio bounds can be used to ensure that the optimized geometry is producible. Designs with short, squat or tall, slender geometry can be filtered out.

Composite Panel Section View

HyperX goes beyond finding an optimum layup for each stiffened panel object (web, cap, etc) and determines ply connectivity between objects.

Stiffened Panel Dimension Studies

Height and stiffener spacing can be constrained by producibility as well as subsystem requirements. HyperX can study weight impact due to these constraints.

CAD/CAM Interface

AFP Data Import

As-manufactured fiber directions and thickness for AFP structures on double curvature can vary from the original design. HyperX can import this data for re-analysis.

CAD Boundary Export

HyperX can optimize “organic” boundaries of plies and zones to suit structural loads. The boundaries of these zones or plies can be exported in a CAD format.

CAD Ply Export

Plies optimized on the FEM in HyperX must be mapped to CAD software to be finalized for manufacturing.

Metal Structures

Machining

HyperX generates producible designs for machined grid stiffened panels (such as orthogrid) by considering factors such as machining tolerance and geometry rules.

Dimension Overrides

Although machined structures can support variable thicknesses, considerations such as fastener grip length require specific dimensions to be specified in HyperX

Stock Sizes

Non-machined metal parts must respect available material stock sizes to be producible. HyperX can enforce that stock sizes are used when performing optimization.

Certification

Analysis Consistency

Consistency from PDR to Part Release

Use HyperX in all phases of vehicle design to maintain consistency in workflow and implemented analysis.

FEM Modeling Progression of Stiffened-Panels

Design cycle consistency is further illustrated by the HyperX stiffened-panel sizing process – outlined in the table below.

Database Templates

Save all project level data and method preferences in a HyperX Database Template. Use these templates as a starting place for all team members to ensure one source of truth for analysis and sizing.

Enterprise Workflow

Automatically separate-out individual part databases from a single internal loads GFEM. Size all parts independently, maintaining consistent assumptions, then recombine into one full-structure database.

Material Database

Store all material data in HyperX to use in analysis and sizing. Establish sophisticated data allowables to deploy to team members

Fastener Database

Store all fastener data in HyperX for joint analysis and sizing. Define this data in one place and efficiently share among a team of collaborating engineers.

Analysis Traceability

Legend

Plot all relevant input and computed data directly on the model for enhanced understanding of all sizing and analysis results occurring throughout the analysis.

Watch Window

Tabulate data for a selection of zones. Use this real time, interactive data to trace through analysis calculations and supplement reports.

Analysis Watch Window

The Analysis Watch Window automatically lists every single margin of safety for the zones selected. 

Stress Reports

Excel-based Stress Reports

Spreadsheet Stress Reports extract all relevant data to summarize: FEM files, database settings, margin summary tables, critical load cases, and sizing results.

Word-based Stress Reports

Word-based Stress Reports are generated in an organized format with headers, table of contents, and sample calculations of each failure criterion with identified critical data.  

Analysis Details

Excel spreadsheets containing all intermediate data used to calculate the margins of safety for each zone and for each failure criteria.

Joint Loads Report

Loads corresponding to discretely modeled fasteners are exposed by these reports.

Analysis Methods and Customization

Aerospace Industry Methods

Instantaneously analyze and size structure for positive margin with respect to hundreds of non-FEA based failure methods commonly used in industry.

Custom Plugins

Directly incorporate in-house analysis methods into HyperX via plugin. Obtain analysis method and legacy code implementation while maintaining HyperX workflow.

Structural Analysis and Design Software for Aerospace