First, import a finite element model (FEM) directly into HyperSizer along with the corresponding FEA-computed loads. HyperSizer then analyzes using non-FEA failure methods to quantify safety factors and eliminate negative margins of safety for thousands of mechanical and thermal load sets. It then optimizes to quickly determine the lightest weight combination of material systems, cross-sectional dimensions, and ply layups for all panels and beams in the structure and automatically iterate with FEA for load convergence.
Import a Finite Element Model that is either a single plane of shell elements or that discretely models panel stiffeners (stringers). Four fundamental meshing techniques (shown below) are supported. Regardless of the modeling technique, HyperSizer performs the exact same analyses. However, the more discretely meshed a model is, the less opportunity for sizing optimization since variables become locked down by the mesh.
A primary benefit of HyperSizer is the ability to perform trade studies of different panel/beam concepts using HyperSizer’s equivalent stiffness approach. This is a key feature of HyperSizer that allows stiffened panels to be modeled with a single plane of shell elements (Technique 1). For any panel cross section, HyperSizer formulates the temperature dependent stiffness matrix which is then used to calculate the stresses and strains through the depth of the panel. With this technique the mesh is not required to align with the stiffeners so HyperSizer can evaluate any panel cross-sectional shape without remeshing the model.
HyperSizer extracts FEA-computed loads for all mechanical and thermal load sets and perform hundreds of industry standard failure analyses. On the HyperSizer Failure Tab, toggle a particular failure analysis on or off. If toggled on, HyperSizer will report a margin of safety.
Optimize the panels and beams to resolve all negative margins of safety for your selected toggled on set of analysis methods. In HyperSizer, enter a range of cross sectional dimensions and available materials to define the pool of candidates in the design space. Based on your defined range of variables, HyperSizer generates permutations of all possible candidates and analyzes them to find the lightest panel and beam dimensions that return positive margins for active failure modes to all load cases.
Design composite structures for strength, stability and manufacturability by following HyperSizer’s six-step composite optimization process. Use this process to find the optimum ply coverage and end-of-ply transition zones on the part surface, solve for ply count compatibility across the zones, and sequence the global ply ordering to reduce weight and minimize ply drops.
Iterate with FEA using HyperFEA™ to execute the solver and to control the iterative convergence. After HyperSizer has optimized the design of the vehicle, generalized thermoelastic stiffness terms are imported to the FEM for another iteration of computed internal load paths. HyperFEA provides this automatic iteration.
Integrate with company established analysis methods using plug-ins to integrate legacy codes into HyperSizer with programming languages such as Fortran and C++. Use COM to execute HyperSizer externally from applications such as Excel, Matlab, and integrated environments such as ModelCenter and Isight.
Generate stress reports that include the calculations for all HyperSizer-computed margins of safety, material properties, design-to loads, optimum design dimensions, etc. These comprehensive engineering reports are invaluable for FAA certification and assisting the stress engineers with detailed stress calculation data to support the hardware throughout its life cycle.