When do you use HyperX Software?
HyperX provides project phase, specific workflows for individual analysts and teams to mature their structure from a conceptual design all the way to part release. It provides a seamless process for performing sizing optimization using the same detailed analyses for conceptual design review (CDR), as it does for the preliminary design review (PDR), all the way to final design and part release certification.
Use HyperSizer to standardize your company’s analysis with its native verified and validated analysis methods, or with your plugged in methods. Since the same analysis methods are used from preliminary to final design, there are no surprise negative margins of safety that would detrimentally affect your schedule or cause weight growth.
In the early phase of aircraft design, engineers are typically focused on speed and exploring the design space. Design to loads are entered either directly with table entry, or by using smeared coarsely meshed GFEMs. In either case, quick trade studies are performed to make decisions on material systems [thermoset/thermoplastic/resign infusion] and architectural layouts [such as wing rib and fuselage frames spacings]. Other design decisions to be made include panel concepts such as Sandwich vs Tee or Hat Stiffened.
During concept definition loads cycling occurs frequently with FEM updates and resulting FEA computed forces. As the structural members are being changed, the internal static load path is redistributed and converged.
In the conceptual phase there are billions of practical and relevant structural design alternatives to process. Even high performance computing (HPC) with multithreading and multiprocessing cannot evaluate all of these candidates. Needed is a way to funnel down options that enable the engineer to interactively steer the sizing optimization, fully benefiting from his experience and intuition with power of computation.
The HyperX capabilities listed to the right provide solutions to these needs.
PANELS AND BEAMS
Conceptual design starts with trading between different panel concepts to attain the lightest weight design. This is done by optimizing each concept’s unique dimensions to the loads in the corresponding FEM property zone, [with automated FEA force extraction].
The most basic panels are sheet metal and laminates. These concepts do not have stiffeners nor cores to provide buckling stability. Sandwich panels are useful for structures that have biaxial compression and/or shear loading causing buckling.
Useful for structures that are mostly under uniaxial loading. Open sections such as ‘I” or “Tee” 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, or space launch vehicles. These concepts have many dimensions to optimize.
SMEARED FEM MESHES
HyperX supports several different strategies for modeling panels. The simplest of which allows all objects to be ‘smeared’ into a single surface of 2D shell elements. By doing so, any panel concept shape can very accurately be analyzed and sized without remeshing the FEM.
FEM ZONE GENERATION
Automatically split large FEM property areas into many analysis/sizing zones at geometric boundaries such as intersecting structure. Optimize zone shapes and sizes to load gradients.
Start with rapid sizing which is a non-parametric approach to sizing that does not require user to input variable bounds.
Switch to parametric sizing using effective laminates that represent the layup as homogenous anisotropic material where the thickness is sized with min & max variable bounds and step increments.
During conceptual phase of design explore alternative configurations. Rapidly evaluate different architectural layouts, material, panel, and joint designs. Establish weight and structural performance trade studies for your project.
Upload your HyperX results from your local database to a shared database hosted in either the cloud or on company servers. Interactive 2D curve trendlines give immediate insight into design studies. Others can view the results using typical web browsers.
HyperX’s interactive optimization approach facilitates the user to start with an open design space with millions of candidates and funnel down to a preferred design.
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.
In preliminary design, leading up to Preliminary Design Review (PDR), the vehicle is well-defined. The FEA has 1000’s of load cases to represent the complete flight envelope and off nominal events. Loads groups and structural analysts are working together to converge internal load paths and to meet required airframe stiffnesses. In the case of a wing, these are EI and GJ cut section values per station.
Part cross-sections and layups are being selected. Laminate ply drop ramp rates such as 20 to 1 are being met.
Line loads are used to begin evaluating joint concepts.
FEA eigenvalues are computed to predict buckling.
Critical design marks the shift to a mature structure design with most decisions made on manufacturing tooling, panel cross sectional dimensions and acreage layups are locked down. Since most of the design has been chosen, higher-fidelity models contain more elements to discretely model features such as stiffeners, fasteners, sandwich core ramps, and metal fittings. Final material allowables are established for strength checks, including damage and fatigue criteria.
This phase typically has aerospace engineers working to resolve negative margins of safety to final FEA load iterations in order to submit passing designs for Critical Design Review (CDR).
The aircraft design cycle ends with part release. In order for parts to be released to the shop floor, they must be fully defined in part drawings, with all manufacturing considerations considered. These drawings are typically accompanied by detailed stress reports, which contain summaries of all design and analysis requirements, margin reports and screenshots of important part data.
At this phase iterations are done between stress sizing and results produced by AFP software such as CGTech’s Vericut. Margins are defined that account for simulating fiber paths of complex curved parts that quantify steering radius limits and laps and gaps in slit tape placement and corresponding updates to the FEM ply rosette angles.