Quantum Consultants, Inc.

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FE MODELING USING HYPERMESH

1. Welcome
 Orientation & Introduction
 Passwords & Log sheet
 Tutorial – 1 [Time – 1 Day]
 Elements Checks

2. 2-D Meshing
 Introduction & 2-D Mesh Generation
Methods
 Tutorial – 2 [Time – 4 Days]
 Element Quality
 Templates, Dictionaries & Mid-planning
 Tutorial – 3 [Time – 6 Days]
 Tutorial – 4 [Time – 6 Days]
 Tutorial – 5 [Time – 2 Days]

3. 3-D Meshing
 Introduction to Solids & 3-D Mesh Generation Techniques
 Solid Checks
 Tutorial – 6 [Time – 6 Days]
 Tutorial – 7 [Time – 10 Days]

4. 1-D Elements & Connections

 Introduction to 1-D Elements
 Tutorial – 8 [Time – 3 Days]

5. Pilot Project
 BIW – Sub systems
 JCI - Seat assembly

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1. INTRODUCTION
1.1. FEA / FEM
 FEA stands for Finite Element Analysis
 An Element is a simple square, triangle, wedge or cube shaped that is used by computer to fill the
shape of the parts.
 The elements used to construct the model are defined by the grid of points that give their location, and
connection info to other elements. These coordinates are called grid points or nodes.
 Our job involves taking line and surface data of the parts supplied by our customers and build a finite
element model. We then set up a ‘run’ for the correct type of analysis to be performed on the part. This
will give us results as an estimation of how the part will perform in its intended use.
 A deck is written using FE model with all loads and boundary conditions. This consists of the
information about element, loads, constraints and what type of output information is required.

1.2. Solvers
 Solver is a software that numerically calculates the results specified by the deck
 Major solvers used

NASTRAN LS-DYNA 3D ABACUS

 Implicit Solver  Explicit Solver  Implicit Solver & Explicit
 Best / Fastest solver for  Best / Fastest solver for Solver
 Linear Static Analysis  Crash Analysis  Best / Fastest solver for
 Normal Mode Analysis  Requires small step for  Material Non-linearities
 Frequency Response accuracy  Contact
 Problem times typically less  Large displacements /
than 100 ms. strains.

1.3. Elements

0-D Elements 1-D Elements 2-D Elements 3-D Elements

 Scalar  Consists of 2 or  Commonly called as  Commonly called
Element more nodes SHELLS. SOLIDS
 Consists of  HM always draws the  Used for thin walled  Cube or brick shaped
one node connection between parts where length and/ elements
 Example : the nodes as lines if or width of the part is  Used to represents thick

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Mass the two nodes are not at least 10 times greater objects and / or objects
coincident. than thickness with changing thickness
 Example: Rigids,  Example: Quads and  Example: hexas, pentas
Springs, Gaps, bars trias. and tetras.
etc.

Some commonly used elements in NASTRAN are tabulated below,

Name Configuration Types Nomenclature in Nastran

Mass Mass CONM
Rigid Rigid RBE2
Rigidlink, Spider Rigidlink RBE2
Bar Bar2 CBAR
K, Spring Spring CELAS1, CELAS2
Gap Gap CGAP
Trias Tria3 CTRIA3, CTRIAR
Quad Quad4 CQUAD4, CQUADR, CSHEAR
Penta, Wedge Penta6 CPENTA
Hex Hex8 CHEXA
Tetra Tetra4 CTETRA

1.4. Hypermesh Layout

Graphics Area
Header Bar

Permanent Menu
Main Menu Area

 Main Menu:
 Triangle before any word signals
indicates that there are one or more
choices than whatever is shown. Usually
the choice might be elements, lines, surfaces, components etc.

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 Lists of picking functions are: Window, On plane, Duplicate, By adjacent, Displayed, Retrieve, By
group, By adjacent, By attached, All, Save, By config, Reverse, By id, By sets, By Comp, By
assemblies, By surface.

 Permanent Menu details:

Z: Allows to draw a circle or line in the graphics area to zoom
P: Replot, or refresh the screen
W: will set certain options for windows
F: fit button
R: Rotating the view
S: Zooming in and out by sliding the mouse in a vertical
motion
C: View center
T: Allow to pick a plane and view it true size
A: Second method of rotating the view in real time
View: Allows to select standard vie
Options: Allows to define several viewing options
Global: To set proper collector, global size of element etc.
Template: Allows for correct settings and element types
Display: Controls the collectors to be view.

 Main menu pages:

Page Name Functions

Geom. Line creation and geometry editing functions.
1D 1-D element creation.
2D 2-D surface and element creation and editing functions.
3D 3-D surface and element creation and editing functions.
BC’s Boundary conditions, system and load creation functions.
Tool Model editing, utility functions, model checking functions,
and informational functions.
Post Post-processing and xy plotting functions.

1.5. Collectors

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The basic unit of Hypermesh is the collector. It is a database entity that collects other entities, essentially
grouping together all the data pertaining to that entity and allowing us to handle the data as a group. The
collector panel is used to create and edit collectors and their card images.

Component Material Load

Collectors (comps) Collectors (mats) Collectors (loadcols)

GEOMS ELEMS Property System

Collectors (props) Collectors (systcols)

1.5.1. Component
 Holds the elements and geometry
 Each component can have both the element or ‘elem’ part and geometry or ‘geom’ part.
 Every thing in a component can only be one color, one material, and thickness.
 If a component contains some 2-D elements, then there cannot be any 3-D elements and vice versa.

1.5.2. Material
 Holds all the materials that are used within the model and their associated properties
 For most automotive components, the parts are metal, and metals have same properties in every
direction.
 Isotropic material is used and Young’s modulus, Poisons ratio and density are given

1.5.3. Loads
 Holds all load values and directions
 Consists of Forces with magnitude and direction, Pressures and where the part is held [Constraints] in
the case of Static analysis.

1.5.4. Systems

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 Used to define output for forces or properties of something, which is not aligned with global axis.
Instead, it is given a local coordinate system.

1.5.5. Properties
 Defines physical properties for 1-D element and scalar elements, beams, springs, and dampers such as
cross section shapes, areas, K values, and moment of inertia.
 For Solvers such as LS-Dyna, the materials and thickness are assigned through properties.

1.5.6. Titles
 These are typed words or numbers that we want to he read to clarify something when printing screen
dumps or visually labeling, for reports, viewing onscreen or other printout purposes.
1.6. TUTORIAL - 1
This is tutorial will familiarize you with some of the meshing techniques in Hypermesh

2. 2-D MESHING
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2.1. Introduction
 2-D or ‘Shell mesh’ is used for constant thickness parts, or relatively thin parts such as ribs and sheet
metal parts.
 The quad and Tria elements are the element configurations used.
 The client and / or analyst on a project will specify meshing guidelines.

Main guidelines are one or all of following:

1. Total number of elements in model
2. Minimum size of elements – required for Ls-Dyna
models
3. Average size of elements
4. ‘X’ number of elements across certain thickness
5. Circle around circles. Usually a minimum of 8
elements is desired
6. 100 % nodes
7. 900 welds
8. Specific values for element checks
9. Nodes associated to surfaces
10. Elements nodes aligned with specific line data
11. Tria to Quad ratio not exceeding x%
12. Meshed at mid-plane
13. Ignoring or not ignoring geometry features such as holes and fillets smaller than a specified size
14. A refined mesh (smaller elements) in the area of interest

2.2. Before Beginning to mesh

Before starting any mesh job, it is a good idea to look over the part and develop a strategy for how you are
going to go about meshing the part.
 One of the first things to look for in any part is symmetry. A common mistake for beginning modelers
is to mesh a symmetrical part with unsymmetrical mesh.

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 Don’t forget to look for symmetry in other forms such as repeated shapes that can be meshed and / or
translated / duplicated such as multiple ribs, darts, and even the same part used in an assembly more
than once.
 Once symmetry and / or repeating
patterns have been determined, look
for areas that have complicated
curved surfaces, holes, sharp
angles, or high detail areas.
Generally whatever area looks hard
to mesh should be done first, then
go to the easier sections.
 The best rule is to mesh from
interior of the part to the outside
edges of the part. Doing the circles
and hard areas first and meshing
outward.
 Since quad elements yields more accurate results than tria elements, it is good meshing policy to use
quads as much as possible and minimize the use of trias to areas that they necessary.
 Defining a Vector or Plane:
HM panels that allows to move or split entities also requires to specify a direction or define a plane.
Generally N1, N2, N3 options allows to create a user-defined direction.
 Selecting two nodes, N1 and N2, allows to define a vector direction with base point at N1 toward
N2.
 Selecting three nodes, N1, N2 and N3, allows to define a plane with base point at N1 (unless
otherwise specified). The vector is normal to the plane and its direction is determined by the right-
hand-rule.
 N2
 N1
N1 – N2 [Vector defined
between 2 points]  N2
N1 – N2 –N3 [Vector defined  N3
 N1 normal to plane]
2.3. Meshing Functions

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Functions to produce 2-D Functions to produce 2-D & 3-D Special Functions
Elements Elements
Ruled Drag Edit Element
Spline Line Drag Automesh
Skin Spin -

2.3.1. Ruled
 Ruled will create a surface and / or mesh between two sets. The two sets can be either lines or nodes,
but it can only be one or the other within each set

 Ruled is used when the shape of the part between the two sets is linear. The sets of nodes or lines do
not have to
be linear.

2.3.2. Spline
 Spline can be used for irregular shaped surfaces, the boundaries for the spline mesh must be picked
from either 3 or 4 nodes or lines picked consecutively around one direction.

 Very accurate for planner surface meshes and may not give accurate 3-D surface.

2.3.3. Skin
 Skin
function
allows creating a skin surface and / or mesh from set of lines.
 Line used to create skin surface and / or mesh automatically smoothened before it is created.

2.3.4. Drag
 This function is the quickest to use and when used properly will create the best elements also.
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 Any linear and / or planer surface that does not change direction along its length is ideal for drag.

2.3.5. Line Drag

 This function is useful for creating quad elements around the perimeter of a part that is not all straight
or circular.

 It can also be used for a cross section that is constant along an irregular curve.

2.3.6. Spin
 This function is the quickest and simplest way to create circles around circles, and create elements (or
create surface) around geometry that has a constant radius and cross section.

2.3.7. Element Edit

 Edit element can produce elements by picking the configuration of element desired, and then picking
the correct number of nodes needed to create the element.

 Since this only creates one element at a time, it is best used for small areas or if none of the other
methods will create the desired mesh
 It should never be used entirely for large areas because of the time involved.

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2.3.8. Automesh

 It is used when surface data already exists for the area that is to be meshed.
 It is the quickest method of meshing.
 Many times if no surface data exists, it is best to go into one of the previous functions and create the
surface from existing lines and nodes with surface only. And then go into automesh to take advantage
of editing the vertices.

 The automesh subpanels include:

1. Interactive: Allows to mesh surfaces in an interactive mode. Before creating the mesh, single or
multiple parameters can be set.
 Reset mesh params to: Resets the meshing parameters.
 Elem size: Allows to specify the element length to pre_calculate default element density.
 Use mesh params: Allows to specify additional meshing parameters such as tria transition
meshing or chordal deviation meshing.
 Elements to current component: Saves the elements that are created within the current
component, regardless of their original components.
 Elements to surface’s component: Saves the
elements that are created within the current
component to which surface belongs.
 Remesh: Allows to remesh surfaces with poor
element quality. Here the existing mesh is deleted
before the surface is remeshed.
 Highlight Surf: HM scans the displayed surfaces for
defined mesh and highlights those surfaces which failed to create a mesh in the last attempt.

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2. Automatic : Allows to mesh surfaces automatically. It has same features as the iterative subpanel,
except that it creates elements on a surface without invoking the automeshing module.
3. Mesh params: Allows to set up specific mesh parameters before meshing the selected surfaces.
This will help us to get good transition in the curved areas.
 Tria transition feature:

 Using the Quads Mapped Mesh Element type and Smoothing Controls
 Using mesh params [Use size and Biasing]
1. Quads – Size only

2. Quads – Skew only

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3. Quads – Size and Skew

 Using the Mixed Mapped Mesh Element type and Smoothing Controls
 Using mesh params [Use size and Biasing]
1. Mixed – Size only

2. Mixed – Skew only

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3. Mixed – Size and Skew

 Chordal Deviation Meshing :

 It is a meshing algorithm that allows HM to automatically vary node dencities and biasing
along curved surface edges to gain a more accurate representation of the surface being
meshed.
4. Cleanup: Allows to modify surface topology by splitting a surface from node to node, replacing
points, and toggle edges.
 Split surf: HM splits surfaces from location of first node to second node along the normal
projection of the straight line between the selected points. This mirrors the “Trim with two
node function on the surface edit panel”

 Unsplit surf: Removes surface split line from associated surfaces, and deletes them from the
model. This command is also used to remove pinholes. This mirrors the “Remove interior trim
lines function on the surface edit panel”
 Replace points: Delete the points to be moved and relocates the associated geometry to the
retained point. This mirrors the “Replace points function on the geom clean up”
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 Toggle: Converts individual surface edges from one edge type to another with single mouse
clicks. We can click once on a free edge that has neighboring free edge within the given
geometric tolerance to combine the two free edges into a single shared edge. This function also
used to suppress and unsuppresses edges. This mirrors the “Toggle function of geom cleanup”
5. Add points: Allows to add fixed points to a surface from existing free points or nodes. It mirrors
the “Add points sub-panel in geom clean up”
6. Remove points: Allows to suppress fixed points by deleting the selected points or convering them
to free points. It mirrors the “suppress points sub-panel on the geom cleanup”

 The automeshing module subpanels [Interactive] include:

 Density: Allows you to control the element density along the edges of the domain. Edge densities
can be specified by either average element length or by chordal deviation along the edge
parameters.
 Biasing: Allows you to control the element biasing along edges of the domain. Element biasing
is the placing of elements along an edge so that element size is smaller at one end than at the other,
and is one way to improve element quality when doing transitioning.
 Type: Allows you to choose whether the mesh should be made using quads, trias, or mixed quads
and trias.
 Algorithm: Allows you to specify the meshing and smoothing algorithm to use for each face of
each surface when you are following a surface-based approach to the automeshing module.
Meshing Algorithms:
 Autodecide
 Map as Rectangle

 Map as Triangle

 Map as Pentagon

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 Advancing Front making Qund Element

 Advancing Front making Tria Element [Used for making Tetra models]

Smoothening Algorithms:
 Autodecide
 Size Corrected
 Shape Corrected
 No smoothening
 Details: Allows you to work on one face of a surface at a time. Changes to the menu items allow
you to make changes to that face's meshing parameters. The currently active face is highlighted in
white in the graphics region.
 Checks: Allows you to check the quality of generated elements before they are saved to the
database.
 All the subpanels contain the mesh, reject, smooth, undo, and return functions:
 Mesh: Directs HyperMesh to scan through all of the faces in the current frame of reference for
ones that have not yet been meshed or have a mesh that is out of date with respect to the user-
specified parameters, and then attempts to bring them up to date. If the current subpanel is
density, algorithm, type, or biasing, the current frame of reference is the entire surface. If the
current subpanel is details or checks, the current frame of reference is the highlighted face.
 Reject: Discards a generated mesh of one selected face or of all of the faces of the current surface.

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 Smooth: Applies to each face in the current frame of reference its specified smoothing algorithm
for as many iterations as are indicated in the algorithm subpanel.
 Undo:Allows you to return the nodes of its mesh to the positions they were in before the last time
you applied a smooth to that mesh for each face in the current frame of reference.
 Abort: Immediately exits the automeshing module without saving any elements or nodes to the
HyperMesh database. If the module was entered via a surface creation panel, any surface that may
have been created is discarded.
 Return: Exits the automeshing module, saving elements or nodes to the HyperMesh database.

2.4. Function Keys:

Key Function key only Function key plus SHIFT Function key plus CTRL
F1 Hidden Line Color Print Slide
F2 Delete Temp Nodes Create Slide File
F3 Replace Edges Print EPS
F4 Distance Translate Create EPS file
F5 Mask Find Print B/W EPS
F6 Edit Element Split
F7 Align Node Project
F8 Create Node Node Edit
F9 Line Edit Surf Edit
F10 Check Element Normals
F11 Collectors Organize
F12 Automesh Smooth

2.5. Tutorial - 2
This tutorial deals with meshing
two brackets within one file. These

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two parts do not have step by step directions. It is up to you to determine how you will go about meshing
them.
 Crate separate collector for geometry and mesh
 Meshing Guidelines
1. Circles around circles
2. Two element across thickness or change in geometry
3. Put quads around perimeter of part
4. An average size around 5 mm
5. Minimum size of 2.5 mm
6. No more than 5% trias.
 Record no. of hours spent on each day.

3. Quality Checks
3.1. Mesh Quality
 Good mesh quality is something that must be learned through training, practice and experience.

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 During the meshing process and when the part is fully meshed, you need to continually perform
quality checks on your mesh. Use F10 function, this is the short cut to ‘element checks’.
 Once a part or component is fully meshed, the order in which the checks are performed is important.
Edge checks and Equivalencing should be done

5.1. Edges & Equivalencing

 An edge is a 1-D element that is produced from 2-D or 3-D elements. They consist of two nodes.
Hypermesh considers these elements of type PLOT.
 An edge element is produced when any two adjacent nodes on an element belong only to that element.
 Equivalencing searches a specified distance from each node to any node(s) within the tolerance (a
specified value you input). Any node that does not belong to the nodes parent element, that is within
the tolerance will be equivalenced, (combined, made to share the same node ID)
Procedure for Equivalencing:
1. Save the file, equivalencing is irreversible!
2. (a). Go to F10 and find the minimum size, remember this.
(b). Know your model. Are there areas that will be closer to the minimum size that should not be
equivalenced. The following steps assume that there are no areas closer than the minimum element
size.
3. First step in the edges function is selecting the elements by appropriate method for which you want to
equivalence.
4. Second is entering a tolerance that is half the minimum distance.
5. Pick the "preview equivalence" button. view nodes if any, confirm.
6. All temporary nodes will be erased and the only nodes showing will be the nodes that are going to be
equivalenced. Confirm by visually inspecting the visible nodes.
7. If all is ok pick "equivalence", this part is irreversible.
8. Now enter the minimum length as the tolerance, and repeat steps
1(save the file only if it is still ok) and 5 - 7.
9. Now enter the minimum length as the tolerance, and repeat steps 1(save the file only if it is still ok)
and 5 - 7.

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10. Repeat with higher tolerance values, usually the highest tolerance you can go up to is about twice the
minimum length.
11. Once the preview starts showing nodes that you do not want to equivalence. DO NOT equivalence
and pick the "find edges" key.
12. This final check can only be done visually and should be done by first going to display and turning all
components both the geometry and elements off. In display elements, find edges automatically creates
a edge component, the edge ‘elem’ component should be the ONLY ONE ON.
13. VISUALLY INSPECT ALL EDGES.
14. Correct any errors, (edge elements that should not be there) and repeat the necessary steps from above
or remeshing untill the situation is correct.

Note: It is a good idea to periodically equivalence and check edges as you go along, it will reduce the time
that you spend improving element quality. It is necessary to do equivalencing before the check elements
checks are performed, the main reason is that no duplicates or connectivity problems can be found untill
the elements are equivalenced. Secondly, equivalencing moves nodes so element quality can be effected
by equivalencing.

3.2. Check Elements [F10]

The element checks are an important part of the model. Below is the list of typical mesh quality
requirements. This list includes values for quality attributes, which meets typical minimum requirements.
However, just because the mesh meets the minimum requirements does not mean that is a good mesh. You
should always be trying to create the best mesh possible under any given element density and time
requirements.
 Warpage: It is a measure of how close a quad element is to be being planer. A perfect planer element
will have the warpage of zero. Warpage should be eliminated in a mesh as much as possible. Warpage
requirements are typically to have a maximum value of 10, with less than 5% of elements having a
warpage greater than 5.
Warpage=(h/l)
h
l

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 Skew: It measures the angle that is created as a square is turned into a parallelogram or rhombus.
Perfect skew value is zero. The skew angle should be reduced as much as possible. Typical required
values are to have skew less than 450 or 600.

Skew Angle = 90 - a

 Aspect Ratio: It is the ratio of the maximum length side of an element to minimum length side of an
element. This should be reduced as much as possible. An aspect ratio of 5 is a typical required value.

L
Aspect Ratio = (L/l)

 Quad Angles: The angle between two sides of a quad element should be 900 as much as possible.
Typical required values are to have all angles between 450 and 1350. There should be no need to have
quad elements that dot meet these requirements.

a Max. Quad. Angle = A

Min. Quad. Angle = a
A

 Tria Angle: The angle between sides of a tria element should be 600 as much as possible. Typical
required values are to have all tria angles between 200 and 1200. Some times smaller angles are
required to model geometry with small angles.

Max. Tria Angle = A

Min. Tria Angle = a

A a

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 Jacobian: It is measure of how close the shape of an element is to the ideal shape. Opposite sides of
elements should have same length as much as possible. Typically less than 5% of elements in a mesh
should have jacobians less than 0.7 within the minimum value of 0.5

Ideal Actual
Element Element

 Length: Length will highlight all elements that have at least one side of the element that falls below
the specified value. This check is important for determining tolerance values for equivalencing,
minimum lengths and overall mesh size.
 Connectivity: It checks for element that shares 3 or more nodes (with identical ids) with another
element. Generally this is an error and should be corrected. This check will also warn about
duplicates.
 Duplicates: This check will find any element that shares all the nodes with another element. This
check will not find connectivity problems.
 Normals: This check applies only to 2-D elements. The normal is defined by the ordering of element
node id’s. An element normal of a continuous mesh should face in the same direction as the element
normals of the adjacent elements.

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4. Templates, Card Images & Mid-Plane

4.1 Reading in IGES files and setting the translator

 Most commonly used format for importing the lines and surfaces data from CAD packages.
 A file that is an IGES file is usually designated by the extension iges or igs.

To read in such a file hypermesh must be opened up first. Once Hypermesh is up, the iges file can be
imported through "import data". "Import data" is found under the "file" command. The first entry must be
made at the "translater" path. There are many different types of files Hypermesh can import. Each file
type has its own translator.

Depending on which machine you are on, one of the three paths will need to be selected to import an iges
file. The complete path for each follows, with the directories and/or file that you need to select in " ".

For pc's |translator=| C:\ALTAIR\HM\3.1\BIN\feinput\iges.exe

For SG's |translator|= /soft/hm3/altair/hm/3.0/IRIX/template/feinput/iges

On the unix system it is pretty easy to get lost if you go off the path.
If you find yourself lost, first say "none" then clear the display path, and type in "/" (no quotes) and click
on |translator=|. This will start you at the root directory and then you can select "soft" and finish the path.

Next, the |filename =| button is used to select the filename you want to import. The procedure is different
for the pc's. To get the file on the pc's, you will need to be mapped on to the network. After the |filename
=| button:

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1. For the pc's, the complete path will depend upon how you are mapped onto the network. First type
after |filename =| the drive letter. In this example, we will use H: as the drive. Yours will probably be
different, this is ok. You should have it come on within your directory on the system. If it doesn't you
just have to change directories more often. Once the network is mapped, unix and pc's are the same.

2. By clicking on "filename" you will bring up the files and directories at that location. By picking the
path names you want you can move up and down through the whole system. Picking a file will
automatically bring you back to the import page. If it is the correct file, pick import and the file will
start importing.

Trouble shooting, if it doesn't come in, most commonly the type of file or translator is wrong,
hopefully the extension on the file is correct so you can look at the filename and correctly pick the
correct translator.

4.2 Reading in Nastran decks (elements) and setting the translator

The Nastran template is used when

1. Elements need to imported into an existing file.
2. Elements need to be exported out of a file so they can be combined (imported) into a new file.

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3. The Nastran deck needs to be written for the computer run.

4. When setting up a Nastran deck, required for element types and assigning dictionaries, properties etc.
So the nastran deck can be used for combining files so multiple people can work separately to mesh an
assembly and later combine the meshes into one file.

You cannot combine Hypermesh files!

To set the Nastran template go to the global panel, within the global panel, select "template" and the
following path.
for pc's |translator|= C:\ALTAIR\HM\3.1\BIN\feinput\nastran.exe
for SG's |translator|= soft/hm3/altair/hm/3.0/bin/IRIX/template/feoutput/nastran/general

4.3. Card Images:

 Card images store the information on what type of elements are in a component, the type of material
and its associated properties, the thickness of the shells, and the properties of 1D elements. Any
Hypermesh file must be set up specifically for the solver being used. However, the same file can be
set up for several solvers.
 The most common solver that the file is set up for is a Nastran run. The Nastran free-free modal run is
frequently used as a check for files with many connections. This run is used to check models to see if
they are connected correctly as far as the code is concerned.
 This check can be compared to a spell and grammar checker on a word document. The free-free modal
run can check for the equivalent of spelling and grammar errors - unconnected components, missing
card images, etc. And just like a spell and grammar checker, it cannot check the content of the
sentence, for example, "All cars have five square wheels." There are no spelling or grammar errors in
this sentence, however it will not be able to tell you that it is a false statement. A free-free run is
similar, it cannot check the validity of how the model was set up, but it can tell you if all the rules
were followed.
 Since a Nastran free-free modal run is very common, and relatively simple, we will look at how to set
up a model for nastran.

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Before any of the following steps can be done, we first must load the Nastran template.
Loading the Nastran template on the PC's.
1. Click on the "global" panel in the permanent menu.
2. Locate the "template file" and the path which should be
C:\ ALTAIR\templates\3.1\feoutput\. Double click on "template file"
3. Pick "nastran\".
4. Then pick "general"
6. The path will jump back to the global menu and the template
will load automatically.

Loading the Nastran template on the SG's on unix.

1. Click on the "global" panel in the permanent menu.
2. Locate the "template file" and the path which should be
/soft/hm3/altair/hm/3.0/bin/IRIX/template/feoutput/. Double click on "template file".
3. Pick "nastran\".
4. Then pick "general"
7. The path will jump back to the global menu and the template
will load automatically.

Collectors:
 For most models, material, property, and component card images need to be assigned.
 Go to collectors, there are three switches in collectors: create, update, and card image. You have
already been using the create for components. This is done when the create switch is selected and the
triangle selector is on "comps". Usually the components and mesh is created first, then the card
images are assigned later.

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 Create - use this switch when first creating a collector, also toggle the triangle to the type of collector
desired.

 Update - use this switch when the collector is already made and you want to change the material
assigned to the collector. The most common use for this might be assigning a previously made
component a material.
 Card image- this can be assigned before or after the collector is created. The card image tells the
solver what type of elements the collector holds and what are the specific values
assigned to it. A common example would be specifying a component to be a shell component and
within the card image the value of the shell thickness is entered.

Materials:
If the material card images are created first, then the properties and components can be created using the
correct material, saving an extra step later, in which you don't need to update the collectors.

Creating a material collector "steel"

1. Select the switch "create".
2. Select "mats" from the triangle selector.
3. Type in steel where it asks for name.
4. Click on the triangle under the words "creation method" and select "card image".

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5. Click on the word "card image" or on the blank area after it and the choice of MAT1 through MAT6
appear.
6. Click on MAT1. Material 1 indicates the type of material. Mat1 is the card image chosen for isotropic
materials -- an isotropic material is a material which the properties are the same in every direction.
Metals such as steel, aluminum, and magnesium fall into this category.
7. You have two choices on the right, "create" and "create/edit". Create will create the collector but with
no values assigned. We want to put in the material values so click on "create/edit".
8. The values shown do not have much explanation. To fully understand what each input field is asking
one must obtain a "CSA/NASTRAN Quick Look Users Guide" The values entered here go into the
Nastran deck as "cards" that are written out specifically for the Nastran solver.
9. The fields you will need to enter values are:
"E" = 210000 Young's modulus or elasticity
"Nu" = 0.3 Poisson's ratio.
"RHO" = 7.83 x 10e-9 Mass density in tons per millimeter ^3 (cubed)
These values are not the same for different types of steel, these values will do unless you are given
other specific values.

10. Now click on return and the steel collector is created with the values that you just entered.
11. To modify or check this collector, set the far left switch to card image, make sure the name of the
collector you want to check is in the name field and click on the "edit" button. The card values appear
and you can enter, check, or modify values. To save the values just click on "return".

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12. Some values such as ID are not allowed to be changed in the card, The ID value is the unique material
identification number assigned to the steel collector, it can be changed through renumber.

Components:
There are two possibilities with components, the component is already made with no card image (a
default material will automatically be assigned to every component) and two, you can choose the material
and card image when you first create the component.
Assigning a material, card image, and thickness to an existing shell component.
1. Pick the "card image" switch on the far left.
2. Choose "comps" from the triangle selector.
3. Select the appropriate component by clicking on the "name" field twice.
4. To check if a card image has been loaded for a component, click on "edit" from the bar choices on
the right.
5. If there is a card image loaded, the available fields will appear. If nothing appears, it means no card
image has been loaded. If something appears, go to step, otherwise go to step 6.
6. Click on the "card image" field and select PSHELL.
7. Click on the "load/edit" bar on the right.
8. The card image card fields appear. For shell components, the only value you will need to enter is
the "T" field. This is the thickness or gage of the material. This value can be determined from the line
data for the part.
9. The other field to take notice of is the "MID1" field, this is the material identification number. If a
zero or wrong MID value is indicated, it must be changed through update. The MID cannot be
changed through the card image.
10. To assign the MID of the steel component you created earlier, click on "update" on the left side of
the screen.
11. Select the component or components you want to assign the material to.
12. Click on the "material" bar and select the "steel" collector.
13. Click on the "update" bar on the right hand side of the screen.
14. Select the "material id" toggle so it is on (red).

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15. Click again on the "update" bar on the right of the screen. A message should appear on the
message bar that the collector was updated.
Simultaneously creating a component while assigning the card image and material.
1. Left button should have "create" selected.
2. Type in the name of the collector.
3. Toggle the triangle to card image, click on card image, and then pick "PSHELL".
4. Click on material and select the desired material.
5. Choose the desired color for the component.
6. On the right hand side click on "create/edit" and enter the thickness in the "T" field.
7. Hit return.
As you can see, there are far fewer steps when the material is already created and you assign the card
image, material, and thickness in one step.
In assigning a card image to a solid component, one with any combination of hexas, pentas and tetras. The
procedure from above would be followed except that "Psolid" would be chosen instead of "Pshell".
Thickness is not necessary.

Properties:
Bars:
Instead of assigning a card image to the components containing bar elements, the elements themselves
are assigned a property. This property is assigned through the "bar" function that creates the bar
elements. However, the property that is assigned through the bar function is created through the
"collector" function, and requires nastran template card images.

When using bar elements and bar property card images, we use the "Pbar" card image. There is a "Pbeam"
card image, but we use "Pbar" as this allows more simplicity as explained in the 1D tutorial.
Properties for bars should be created with the same name as the component
that they are assigned to.

When creating the bar property, go to the "collector" function.

1. Select create from the left-hand side switches.

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2. Select "props" from the triangle selector.

3. Give the property the same name as the component the property will be used in after "name=".
4. Toggle the other triangle selector to card image and select "pbar".
5. Double-click on material and select the appropriate material. (If it is not yet created, you can assign it

later through the update toggle.)

6. Enter the appropriate values needed. Usually "Aa", "I1a", "I2a", and "Ja".
7. Hit "return".

Spring Properties:
Spring properties are not correctly assigned to the elements in the deck when written out by Hypermesh.
So although a Pelas property card card image exists, and write out, they are not utilized correctly. In
house, the template has been modified so that instead of creating a property, Pelas property k values are
assigned through the "card" function located in the permenant menu area.
1. Go to "elem types" function and switch configuration "spring" from
"celas1" to "celas2".
2. Before assigning the k value through "card". Select the desired elements
and update.

Masses:
To create a mass element, go to the function "masses" not "mass".
1. Select the appropriate node(s).

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2. Enter the mass in tons.

3. No property or system is required.
4. Hit Create.
5. Inertia values if required can be entered. Go to the permenant menu "card"
6. By selecting the appropriate mass only one at a time, then hit "edit". The inertia values can be entered
in x1, x2, and x3.

In summary:
1. Pshell card images are assigned to components that contain quad and/or tria elements.
2. Psolid card images are assigned to components that contain hexa, penta and/or tetra elements.
3. No card images are assigned to components that hold 1d elements, bars, rigids, masses etc. If a card
image is assigned it is ok.
4. For Pshell and Psolid card image, to modify or assign materials; toggle the "update" switch.
5. To change anything else in property, components, or materials; toggle the "card image" switch.

4.4. Dyna file setup

1. To load the template, go to the permanent menu "global".
2. Double click on "template file" and select "ls-dyna/"and then select "dyna936.key".
3. The complete path on unix is:
/soft/hm3/altair/hm3.0/bin/IRIX/template/feoutput/ls-dyna/dyna936.key

Material Card Images:

A. Elastic materials: linear deformation. For most LS-Dyna models, this material card is used to model
some small individual internal mechanisms that are not under concern in an assembly but important
enough to include. In assemblies bolts are also commonly given an elastic card image.
1. Select the "collectors" function.
2. Select the "create" switch.
3. Click on the top triangle and select "mats"
4. Type in the name of the material after "name=".
5. Click on the triangle and select "dictionary".

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6. Click on "card image=" and select "MATL1" (MATL1 is chosen for all materials that are elastic).
7. Click on "Create/edit"
8. Enter the RHO, E, and Nu values. The units are commonly tons and
millimeters. The following values can be used for steel if none
are supplied.
RHO = 7.8 e-9, E = 210000, Nu = .3
The following values can be used for aluminum if none are supplied.
RHO = 2.8 e-9, E = 67000, Nu = .29
9. Once you have entered and checked the values, click on return..

Rigid Bodies: In a crash test model of a car, some parts such as an engine block are modeled. However,
since for most crash analysis the deformation and stresses of the engine block are not important and
usually negligible. The part can be considered "rigid". This way the parts mass and connections are taken
into account but the solving time is greatly reduced. Therefore the number of elements and element size is
irrelevant for component assigned a rigid material dictionary.

To create a rigid material:

1. Select the "collectors" function.
2. Select the "create" switch.
3. Click on the top triangle and select "mats".
4. Type in the name of the material after "name=".
5. Click on the triangle and select "card image".
6. Click on "card image=" and select "MATL20" (MATL20 is chosen for all
materials that are rigid).
7. Click on "Create/edit"
8. Enter the RHO, E, and Nu values. The units are commonly tons and millimeters. The following values
can be used for steel if none are supplied.
RHO = 7.8 e-9, E = 210000, Nu = .3
The following values can be used for aluminum if none are supplied.
RHO = 2.8 e-9, E = 67000, Nu = .29

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9. Once you have entered and checked the values, click on return.

Plastic Deformation:
For most sheet metal parts in a car crash model, large deformation is expected, and this deformation is
what we are interested in. For these components we need various stress and strain values along the plastic
deformation curve of the material. To create material card images for these parts:
1. Select the "collectors" function.
2. Select the "create" switch.
3. Click on the top triangle and select "mats".
4. Type in the name of the material after "name=".
5. Click on the triangle and select "card image".
6. Click on "card image=" and select "MATL24" (MATL24 is chosen for all materials that large
deformations are possible).
7. Click on "Create/edit"
8. Enter the RHO, E, and Nu values. The units are commonly tons and millimeters. The following values
can be used for steel if none are supplied.
RHO = 7.8 e-9, E = 210000, Nu = .3
The following values can be used for aluminum if none are supplied.
RHO = 2.8 e-9, E = 67000, Nu = .29
9. Click on "array count" and enter the number of stress/strain values that you have to enter and then
enter the values.
10. Once you have entered and checked the values, click on return.

Properties:
For all shell, solid, and bar/beam components, a property must be created for each. For rigid and non-rigid
shell components, a property must be created for each component individually, to keep things simple (as
possible), the property is created with the same name as the component. Shells must be separated into
their own component if they have a different material, different thickness, or they are a different physical
part. To create a property for a shell component:

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1. Select the "collectors" function.

2. Select the "create" switch.
3. Click on the top triangle and select "props".
4. Type in the name of the material after "name=".
5. Click on the triangle and select "card image".
6. Click on "card image=" and select "SectShll" (SectShll is chosen for all shell components).
7. Click on "material=" and choose the material you desire.
11. Click on "Create/edit"
9. The field for "ELFORM" has 2 as a default value. This is usually fine. Commonly we also sometimes
use 7.
10. The field for "SHRF" has 1 as a default value. This should be changed to 0.833.
11. The field "NIP" has 2 as a default value. This should be changed to 3. If a large deformation is
expected than the value 5 should be used.
12. The field "T1" is the thickness of the material. Enter the correct material thickness value.
13. Click on "return".

For rigid and non-rigid solid components, a property must be created for each component individually, to
keep things simple (as possible), the property is created with the same name as the component. Solids
must be separated into their own component if they have a different material, or if they are a different
physical part.
To create a property for a solid component:
1. Select the "collectors" function.
2. Select the "create" switch.
3. Click on the top triangle and select "props".
4. Type in the name of the material after "name=".
5. Click on the triangle and select "card image".
6. Click on "card image=" and select "SectSld" (SectSld is chosen for all solid components).
7. Click on "material=" and choose the material you desire.
8. Click on "Create/edit"

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9. Verify that the "ELFORM" field has the default value "1". (the AET can be left to whatever it is unless
the "ELFORM" is changed to 7, 11, or 12.
10. Click on "return".

Bar elements require properties. A property must be made for each cross section shape, cross section size,
and degrees of freedom. The most common property is for when a beam element is representing bolts and
similar fasteners.

Bolt properties represent a constant cylindrical cross section. Basically, properties for bolts can be divided
into two groups.
I. A bar element that allows rotation around its axis, such as a bolt and nut.
1. Select the "collectors" function.
2. Select the "create" switch.
3. Click on the top triangle and select "props".
4. Type in the name of the component after "name=". We have developed a naming convention for this
type of property. The property should be named "BOLT_J0". If there are two or more different diameters
(or shapes) it should be named "BOLT_J0_XX" where XX equals the bolts diameter.
5. Click on the triangle and select "card image".
6. Click on "card image=" and select "SectBeam" (SectBeam is chosen for all bar components).
7. Click on "material=" and choose the material you desire.
8. Click on "Create/edit"
9. Change the value in the "ELFORM" field to "2". This will change the entry fields.
10. The values for the following fields must be calculated and entered.
a. "AREA" is the cross section area
b. "ISS" is the cross section moment of inertia in x.
c. "ITT" is the cross section moment of inertia in y.
d. "IRR" is the cross section moment of inertia in z.
e. "SA" is the shear area (usually equal to "AREA")
11. The other fields can be left at the default values. "CST" field not referenced with "ELFORM" at 2. A
bar that does not allow rotation around its axis, such as a bar attached

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with a weld.
1. Select the "collectors" function.
2. Select the "create" switch.
3. Click on the top triangle and select "props".
4. Type in the name of the component after "name=". We have developed a naming convention for this
type of property. The property should be named "BOLT_XXmm", where XX equals the bolt diameter.
5. Click on the triangle and select "card image".
6. Click on "card image=" and select "SectBeam" (SectBeam is chosen for all bar components).
7. Click on "material=" and choose the material you desire.
8. Click on "Create/edit"
9. Change the value in the "ELFORM" field to "1". This will change the entry fields.
10. Click on "CST" and enter the value "1". This sets up the card image for a circular cross section and the
areas and inertias are automatically created.
11. Enter the bolt diameter in the "THIC1s" field.
12. Unless the bolt is tapered, the same value is entered in the "THIC2s" field.
13. The "THIC1t" and "THIC2t" fields are used only if the bolt or tube is hollow and then the inner
diameter is entered. They would both be the same unless the tube is tapered.

Component Card Images: All the shell, bar, and solid components require a card image.
1. Select the "collectors" function.
2. Select the "create" switch.
3. Click on the top triangle and select "comps".
4. Type in the name of the component after "name=".
5. Click on the triangle and select "card image", select "part".
6. Select the desired color of the component.
7. Click on "create/edit".
8. Click on "SID" and select the property you have already created that has the same name as the
component you are editing.
9. It is also possible to check for the correct material ID "MID"(you cannot change it here, only check
what is assigned).

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The preceding examples have all been creating the card images from scratch in a logical order. However,
in real files you are often editing, changing, or checking existing files. Editing the card images follows a
similar pattern.
1. Select the "collectors" function.
2. Select the appropriate type of collector (mats, props, comps, etc.) at the triangle selector at the top of
the menu
3. Select the "card image" switch.
4. Select the component you wish to check or edit in "name=".
5. Do not do anything where it says card image and just click on the right side where it says "edit". If
nothing appears on the screen there is no card image loaded. Go through the appropriate previous
steps to load the correct one.
6. If it is an assigned (or unassigned) material you need to change or
add to a component. Click the left-hand side switch that says "update".
7. Select the appropriate component(s) - here you can pick more than one, pick "select" after you have
toggled the appropriate components.
8. Click on "update" on the right side of the menu.
9. Toggle the "material ID" switch on (red) and then click on "update" one more time. "the materials
have been updated" will display on the action bar.

Rather than clicking on every material, property, and component through the collector function. Go to
page 4 and use the "summary" function. Load the "template file=" ../ls-dyna/property and click on
summary. Check for the appropriate card image loading here.

4.5. Meshing a component to mid-plane

 In Hypermesh there is no way to mesh directly on the mid-plane of a sheet metal part (or any other
part for that matter). First you must choose an inner or outer surface that you will create the 2D mesh
on.

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 It is very important when meshing a part that is to be mid-planed to anticipate to what extent the
elements will get smaller or larger in curved areas, especially in areas of fillets and rounds. This is
particularly important in LS-Dyna files where minimum element size is very important.
 Another type of geometry to be concerned with is any type of T-connections, such as encountered in
thin cast parts. These areas usually need to be offset separately, BEFORE offsetting, the placement of
connecting nodes must be planed ahead to where they will be needed AFTER the part is at mid-plane.
 Once the mesh is created and all the checks are performed, quality, edges, normals etc. Do not spend
too much time fixing warpage in curved areas before offsetting, it usually introduces warpage or
changes it. Pay attention to which direction your normals are facing, as this is the positive direction
when doing solid offset.
 Before you create the offset elements, first create a new component to keep the offset elements
separate from the original element component. If you have created this mid-plane component
earlier, don't forget to set your global to this component.
 From the supplied geometry of the component you are mid-planing, you need to determine the

thickness of this part. Using either the F4 or length functions, find thickness lines that you can
measure directly. Be careful, sometimes these lines are at an angle across the geometry and will give
an inaccurate thickness across, usually thicker than the part really is. Try a few areas until you get a
consistent reading.
 Now you are ready to go to the "Element offset" function. This function is found on the 2D page.
Besides the element selection pick, there are five choices you need to make. The first is density,
second is offset, third thickness, fourth a toggle of squared or round corners, and fifth is whether to
build shell or solid elements upon offsetting. The sixth option is bias, I can not think of a mid-planing
operation that would need this so ignore this for mid-planing.
1. First, density, should be set to 1(one).

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2. The offset value should be set to exactly half of the thickness

of the part.(the value that you needed to measure).
3. The third value, thickness, should be set to 0(zero).
4. The toggle between rounded and square corners is dictated by the geometry and you must
decide which is better.
5. The toggle between "build solid elems" and "build shell layers" should be set to "build shell
layers".
6. Pick the offset button.
 All the elements are now shell elements at the mid-plane of the geometry; visually check this to make
sure.

4.6. Tutorial -3
In this tutorial a bracket has to be meshed with fillets and chamfers. Guidelines are following,
1. Three elements across large fillet
2. Two elements small fillet
3. Circle around circles
4. Mesh size approximately 8 mm
5. Min. element size 2.5 mm
6. Mid-planned
7. Create a material ‘steel’
8. Assign ‘PSHELL’

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9. Also assign the material ‘steel’ and the correct thickness to the same components.

Note:
File Preparation: Copy all components [consists of line geometry] in a single component collector named
‘rhrhs_g’.

4.7. Tutorial -4
In this tutorial a bracket has to be meshed with fillets and chamfers. Guidelines are following,
This tutorial covers some new areas in meshing shells (100% nodes) and later, tutorial 5 introduces 1D
elements as well as other concepts into this model.

1. Create your tut_4 directory, and then open up Hypermesh and import the iges file from the following
directory similar to what you did for tut_3.
D:/Training/Hypermesh/Dhana/tutorials/tut_4_pbrake/pbrake_pc.igs

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2. Once again keep all the original geometry

in one component that does not get
modified.

3. Create two components one "left" and the

other "right". The iges data comprises of two
main parts that must be meshed. This iges
data has some problems with it.

a. First the two parts must be separated and

copied into the left and right components.

b. Some line data is missing.

c. Some line data is extra and not needed.

d. Some line data must be interpreted

correctly to determine how it is to be
meshed.

4. Once the two parts are copied into left and right, the inner or outer surface must be moved into their
new respective components such as left_inner and right_outer.

The meshing guidelines for this exercise are

1. Total number of shells for the two components should be approximately 2000 elements. You need to
estimate your global size, shoot for within 1800 to 2200 elements.

2. Observe a minimum size of 2.5. This is not an absolute minimum; keep elements that have a length of
less than 2.5 to under 5% of the total elements.

3. Circle around circles except for the three smallest holes. Those you can delete an element.

4. 100 % nodes and elements between the contacting surfaces between the two brackets. Should have 100
% elements also.

5. Two elements across thicknesses.

6. The components are to be midplaned.

7. Trias not to exceed 5%.

8. Absolute maximum warpage 15.

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9. Fillets are to be meshed with at least two elements across change in geometry.

4.8. Tutorial –5 [Use Automesh]

 Use ‘geom. clean up’ and clean the geometry

 Average size: 15to 20 mm.
 Record the time saving by comparing with manual
meshing.

Table of Element Quality

Attribute Requirements Model
Target % Failed Max / Min Target % Failed Max / Min
Min. 2.5 0% 2.5
Length
Warpage 10 5 15
Aspect 5 5 5
Skew 60 5 60
Jacobian 0.7 5 0.65
Quad Min 45 5 45
Angles Max 135 5 135
Tria Min 20 5 20
Angles Max 120 5 120

5. Solids

5.1.Solid elements should be used whenever:

1. The thickness of the part becomes greater than about 10% of the width and/or length of the part.
2. The part exhibits changes in thickness or geometry that cannot be adequately modeled with shells.

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3. Cast parts are commonly meshed in solids.

When meshing a solid, some basic rules become very

critical.
1. For complicated solids, always find the area you
believe to be the hardest area to mesh and start there and
mesh your way outward. The hardest area is rarely at an
edge of the part, but rather it is where ribs, holes, and fillets come together.

2. Always go for the best mesh possible for the geometry. In solids this may take a back step to rule #6,
using hexas rather than pentas if the possibility of splitting may be required.

3. When using one of the meshing functions, if possible combine as much of an area as you can to use in
one meshing step. This is assisted greatly by projecting adjacent features on to the surface the shells are
being produced on.

4. Always look for symmetry and repetitive features you can mesh once and then translate, reflect or
rotate.

5. Spend time to plan a strategy on how to mesh as much of the part as you can, planning what area, what
meshing function, how the resulting elements would be, and how does the geometry match up to the
elements that would be created. What meshing function would you use next, would the elements you just
created align up with the geometry? Repeat the cycle and steps for as much of the part as you can. Also be
sure to examine the part from all possible angles. A mesh in solid may look like it will work form two
angles, but may completely fail from a third direction or once the mesh rounds a corner.

6. Unlike shells, you may need to generate hexas even when quality problems would dictate using pentas.
The reason is that further down the mesh you may need to split across these elements and if there is a
penta, it will not be able to split without either a tetra or crack in the model. This is an area where
planning is critical, because on the other hand, you do not want to create poor quality hexas if it can be
avoided.

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5.2 When to use the different functions?

When deciding which function to mesh, first look to use the easiest and quickest functions first, if they
will not work go to the next easiest function. This is the order to decide what function to use.

1. Drag or Spin
2. Elem Offset
3. Linear Solid
4. Solid Mesh
5. Solid Map
6. If there are only a few elements to be made, consider Edit Element first.
7. Use Split, hexa element, after creating a mesh to modify it. There is no way yet to combine solid
elements in Hypermesh.
8. Line Drag is best used for tubes and bars, but may have some other applications.
For example do not use linear solid for an area that you could have used drag to create.

Very frequently, one of the above functions will not be able to mesh areas within a part. You then have to
start considering different possible combinations of the above functions to get the desired mesh.

5.2.1 Drag:

Whenever an area is planer. It does not even have to be a constant thickness. If the opposite side is slightly
angled or curved, you may still use project or node edit-associate to get the opposite nodes to the plane or
surface quickly.
5.2.2 Elem Offset:

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Use elem offset whenever a part is a constant or near constant thickness but it is not planer. Again, like
drag, if the geometry varies in thickness slightly, elements of the opposite side can be projected to the
plane(s) or associated to the other surface(s) if applicable.

5.2.3 Linear Solid:

If opposite sides are not the same size but similar in shape. Another requirement is the paths between the
two opposite sides are linear. An example for a shape that could be meshed with linear solid would be a
boss with a draft angle. Linear solid has the ability to create the element layers at specific intervals that
can be controlled by nodes.

5.2.4 Solid Mesh:

If opposite sides are or are not similar in size, and are or are not similar in shape and the path between
them are or is not linear. You require only lines for this. This can used instead of linear solids. However,
you do not have complete control of the mesh like in linear solid, but the path need not be linear. The best
feature of solid mesh is that you only require lines to complete the mesh.

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5.2.5 Solid Map:

Solid Map can used for the same geometric parameters as solid mesh; solid map would be used instead of
solid mesh for two conditions. First, the modeler requires an existing mesh or a mesh that solid mesh will
not produce. Second, there are surfaces between the opposite sides that contain curvature or definition that
only the surfaces can provide to accurately mesh the shape. Solid map usually must be used to mesh
complex curves such as some types of helical gear teeth. Careful set up of surfaces, lines, and mesh is
required for this function to work correctly. Solid map will not work if opposite sides are rotated more
than 90 degrees from each other.

5.2.6 Line Drag :

It is best used for tubes and bars, but may have some other applications. Drags a group of two
dimensional elements along a line

5.2.7 Spin:

Use this command to spin 2D shell elements to create 3D solids

5.3. Solid Checks:

 Solid checks - element quality

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 Visual - correct to geometry

 Edges/equivalence - visual
 Faces
1. edge check
2. normals
3. connectivity
4. visual

5.4. Tut_6:

Guidelines:
 Two elements across all thickness
 An average size of 4 to 5 mm and small fillets can be ignored, the spotfaces can also be ignored.
 The main rib (or pad) should have a symetrical mesh wherever the geometry is symmetrical.
 Circle around circle.
 Assign properties of steel to the engine mount
 Check model for free faces
 Perform free-free analysis on the model. Verify 6 rigid body modes.
 Element Quality

Table of Element Quality

Attribute Requirements Model
Target % Failed Max / Min Target % Failed Max / Min
Warpage 15 5 25
Aspect 5 5 15
Skew 60 5 75
Jacobian 0.7 5 0.45
Quad Min 45 5 35
Angles Max 135 5 145
Tria Min 20 5 10
Angles Max 120 5 130

Tut_7:

Guidelines:

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 Two elements across all thickness

 Circle around circle.
 Assign properties of steel to the engine mount
 Check model for free faces
 Perform free-free analysis on the model. Verify 6 rigid body
modes.
 Element Quality
Table of Element Quality
Attribute Requirements Model
Target % Failed Max / Min Target % Failed Max / Min
Warpage 15 5 25
Aspect 5 5 15
Skew 60 5 75
Jacobian 0.7 5 0.45
Quad Min 45 5 35
Angles Max 135 5 145
Tria Min 20 5 10
Angles Max 120 5 130

6. 1-D ELEMENTS

6.1 Introduction:

 The most common 1D elements are rigids, rigidlinks, springs, bars, beams, masses and gaps
 DOF # transmits motion from one node to all the others when on in

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1 translation in x direction
2 translation in y direction
3 translation in z direction
4 rotation about the x axis
5 rotation about the y axis
6 rotation about the z axis

 We will go over the setup of these elements and their common uses. Realize that the following
guidelines are typically used for the types of analysis done in-house.

6.2 Rigids

 Rigids are used to connect parts together. It consist of two nodes [Dependent & Independent nodes]
 The DOF must be entered for each rigid. A rigid is used when the parts are held together by something
like a weld or fastener, however, for analysis the strength of the fastener is not in question. Therefore
we use a rigid which will keep the two nodes connected as though the fastener will not fail or yield.
 Rigids should be kept in their own separate component, no card image or properties should be
assigned. However, since the DOF can vary, it is important to keep rigids with the same DOF
organized together in the same component. There is also a "weld" element that can be used which is
similar to a rigid.
In a model, each node on the rigid should connect to another element(s).
DYNA models: If this model is to be used for a LS-Dyna run, two rigids or rigid bodies should never
share the same node.
Nastran models - two rigids can share the same node.
Rigids that have length to them must be constrained 1-6.
Rigids that have zero-length can have any combination of dof selected.
An independent node can have many dependent nodes but a dependent node
can have only one independent node.
6.2.1 Creating rigids:

1. Function "rigids"
2. Left toggle "create"
3. Select independant node
4. Toggle dependent "node" triangle "multiple node"to "single node"

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5. Select desired dof. checks means this motion is transmitted

6. Select the dependent node

6.2.2 Rigid 1D Checks:

 Free 1-D's - Rigids should never be free.

 Rigid loops - there should not be any rigid loops.
 Dependency - there should not be any dependant nodes.
 Connectivity - you do not want to have any connectivity elements in this check.
 Duplicates - you do not want to have any duplicate elements in this check.
 Length - Having zero length is required for coincident node rigids, typically when using rigids for gap
elements or springs. If there is space between the connecting nodes, a 90-degree weld is desired and
the length should not be greater than the sum of the two gages (thickness of the two parts being
welded together) divided by two.

6.3 Rigidlinks

 Rigidlinks, sometimes referred to as 3T's, 4T's, and spiders, have one independent node and have 2, 3,
or more dependant nodes. 3T's and 4T's are commonly used to refer to how many parts they are
holding together. Spiders refer slightly to their looks, and are commonly used to simulate (in
conjunction with bar elements) fasteners such as bolts and nuts.
 Rigidlinks should be kept in their own separate component, no dictionary or properties should be
assigned. However, since the DOF can vary, it is important to keep rigidlinks with the same DOF
organized together in the same component.
 When using rigidlinks in Body in White models, a separate component should be used for 3t's and 4t's.
Rigids that have length to them must be constrained 1-6.

6.5.1 Creating rigidlinks:

1. Function "rigids"
2. Toggle "create"
3. Choose the first node which will be the independent node, usually the center node in a spider.
4. Toggle the dependent triangle "single node" to "multiple nodes".
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5. Select desired dof

6. Select as many dependant nodes as desired, they can be picked in any order
7. Pick "create".

6.5.2 Rigidlink Checks:

 Free 1-d's - it only takes 1 free dependant node for the rigid link to be a free 1d. There should not be
any free rigidlinks.
 Rigid loops - This check will not find rigidlink loops.
 Dependency - There should not be any dependent rigidlinks. Use review elements in the "rigids"
function, make sure that it does show that the desired node has an "I" and the others have a "D". For a
nastran run it is ok to have a rigid attached to a rigidlink. If there is a dependency problem just
"switch" the dependent rigid(s) through "update".
 The rule is: An independent node can have many dependent nodes but a dependent node can have
only one independent node.
 Connectivity - This check will NOT find any connectivity problems with rigidlinks.
 Duplicates - you do not want to have any duplicate rigidlinks in this check.
 Length - The length check does NOT check length on rigid links.
 There is one more check that can help find some but not all rigid type elements attached to other rigid
type elements, and that is going to "find".
The find check:
Select the left toggle which says "between comps", select all the components that contain rigid type
elements, than click on find. If there are any elements found, they should be carefully checked to
make sure it is correct. Again, if this will become a dyna run, rigid types connected to other rigid types
will cause the run to fail.

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6.5 Springs

 Spring elements can be used not only to simulate real coil springs but more commonly they represent
the give and take properties of seals and gaskets.
 Spring elements consist of two nodes, each handle one degree of freedom, so multiple springs can be
duplicated on top of one another to account for each degree of freedoms k value.

6.5.3 Creating spring elements:

1. Go to function "springs"
2. Toggle "create"
3. Only one dof is allowed to be chosen for each spring, make sure it is in the right direction, either
with the global axis or an assigned system. (Actually it is sometimes easier to update this after
they are all made.)
4. Currently, property is not assigned to the element when the nastran deck is written. So no property
is required.
5. Select the two nodes where you want to create the spring (in any order). Once all the springs
elements for the component are made.
6. Go to "elem types" and pick "spring" and change "celas1" to "celas2".
7. You need to select the elements (by component) and hit the "update" key.
8. Continuing in card, select the config as "spring" and the type as "celas2" then hit edit, you can
then enter the "K" value spring constant. When you return, the elements you selected will have the
k value assigned in the deck when it is written out.

6.5.4 Spring Checks:

 No free springs
 Rigid loops and dependency does not apply.
 Length - all springs should be zero length.
 Connectivity and duplicates are ok if that is what is desired. Duplicate spring elements should
have a different dof value and/or K constant.
 Check that the correct k value has been assigned.

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 Check that the right degree of freedom direction has been assigned.
 Verify that the elements are type CELAS2.
 If local systems are required, both nodes of each spring element need to be assigned to analysis.
(Remember they are zero length, you will have to translate elements to see of both nodes
highlight.)

6.6 Bars and (Beams)

 Bar elements are used when a cross section of the material remains the same along its length. They
consist of two nodes and the element handle is a "B".
 Bars require a property to be assigned to each individual element; therefore, bars elements should be
grouped into components sharing the same property.
 The component should not have a dictionary. In Hypermesh, the "bar" function can create bars and
beams. What determines whether the element becomes a bar or a beam is whether the bar or beam
property is assigned to it.
 Beam elements can account for forces, displacements, bending moments, torsional moments, and
cross-sectional warping. Bar elements do not support cross-sectional warping, usually we assign bar
properties to the bar elements.

6.6.1 Create the bar property:

a. Go to "collectors".
b. Toggle the "create" switch.
c. Toggle the triangle to "props"
d. Enter the property name (which should be the same name as the component the bar elements are
placed in)
e. Hit "card image"and select "PBAR"
f. Select the desired material if available, you can change or add this later with "update".
g. Hit "create edit" (once the dictionary is made you must select "card image" on left of screen and hit
"load edit".)

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h. Enter values and hit return.

Minimum Values assigned to the pbar dictionary are:
1. Check that the material "MID" is correct.
2. Cross section area "A"
3. Moment of inertia about x "I1"
4. Moment of inertia about y "I2"
5. Moment of inertia about z "J"

6.6.2 Creating bar elements:

a. Go to "bars"
b. Toggle switch to "bar2".
c. Click on lower left triangle and select "components".
d. Enter a value of "1" in the component direction that is perpendicular to the beam axis, it does
not have to be exactly perpendicular but it cannot be parallel with the beam axis.
e. Hit "property =" and select the desired property
f. Select "node A" and "node B" to create the bar element
g. When you are through creating the elements go to "elem types" and select "bar2" and verify
that "CBAR" is not "CBEAM". If cbeam, select the desired elements by component or config
etc. and click on update with cbar selected.

6.6.3 Checking bar elements:

 Free 1-d's - there can be free 1d's on bar or bar elements but they must be individually checked to be
sure that is correct.
 Rigid loops - does not apply
 Dependency - does not apply
 Length - does apply, there cannot be zero length bars or beam elements. For 8-10 mm bolts, the
length should not be less than 2 mm.
 Connectivity - there should not be connectivity element
 Duplicates - there should not be any duplicates.

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 The "V" component cannot be along the element axis.

 The correct property should be assigned to all bar elements.

6.7 Masses

An example of when mass elements are used is when a transmission case is modeled, the case is modeled
with solid/shell elements, but the gears and axles are important in the mass and inertia components
but they do not need to modeled in detail with solids. Mass elements do just that, the mass and inertia
values are applied to a mass element (node) and they are attached to the case by bars and rigid
elements.

6.8 Gaps

Gap elements are needed to prevent unconnected components from going through one another. To run a
gap solution takes a lot of computing power, they are only used when the contact plays a critical role
in the analysis.

6.9 General Points

1-D elements can be broken down into two categories in the modeling stage. Those that do not require a
property and those that do. None of the 1-D type elements require a dictionary to be assigned when
creating the component. Rigids, rigidlinks (spiders), masses, springs and welds do not require properties.
Bars, beams, and gaps do require a property.

6.10 Tutorial_8 [Parking Brake assembly]

This tutorial will encompass

1. Importing new mesh (merging files)
2. Using assemblies
3. Creating properties
4. Systems
5. 1-D elements
6. Doing a full set of model checks necessary on a shell assembly
model before turning it over for a free-free modal run.

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Your pbrake.hm file should have the following mesh and checks finished before proceeding on. The
names of the components can be different, but should be similar; you should not have any fewer or any
more components than what is listed.
1. Checking the Existing Mesh.

A. Visually check model for fit to geometry, planer sections, mid-planing, all holes etc.
B. Components
1. lvl1 - a component with all the needed original geometry intact.
2. left_brkt - a component with only the left bracket geometry and the mid-planed elements
for this component.
3. right_brkt - a component with only the right bracket geometry and the mid-planed
elements for this component.
All the non midplaned elements and duplicate inner and/or outer separated geometry (except
for what is listed above) should be deleted.

Delete:
1. Duplicate geometry components
2. Non_midplaned mesh
3. Unneeded components
4. Unneeded materials
5. Unneeded properties
6. Clear "all nodes"

C. Element checks (on midplaned components)

1. Equivalancing
2. Edges
3. Element quality. To obtain a very good mesh your parts should meet the following
guidelines. However, if they do not, do not spend more than a 4 to 8 hours correcting element
quality.
a. Duplicates
b. Connectivity
c. Jacobian <0.55 none, J <0.7 less than 5%

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d. Warpage > 12 none, W > 5 less than 5%

e. Aspect ratio > 5 none
f. Skew > 60, less than 1%.
g. length < 1 none, length < 2.5 less than 10%
h. Quad min angle < 35 none, 45 less than 5%
Quad max angle > 135, 150 less than 5%
i. Tria min angle < 15 none, 20 less than 5%
Tria max angle > 140 none, 120 less than 5%
j. 1-d checks - "elements have not been selected"
k. 3-d checks - "elements have not been selected"

4. Normals
5. Card images-
a. Material steel created with correct values assigned.
b. PSHELL card images assigned to the appropriate components with steel material
assigned and thickness entered.
6. Renumber - Make sure all unnecessary components, materials, nodes, surfaces, lines,
elements, properties, etc. are deleted first.
7. At this point save your file as tut_4.hm and also as tut_5.hm.

2. Finishing the Model.

A. Import existing mesh.

The file is located at D:/Training/Hypermesh/Dhana/Tutorilas/ /tut_5_pbrake_2/neon_handle_pc.dat.
The *.dat extension indicates that it is a nastran deck file, the pc part indicates that the file has been
modified to pc format so you can import it through mapping.
B. Imported Mesh Modifications.
1. "Rename" and change color (use whatever color you wish) of imported mesh.
a. comp "1" to sector_4
b. comp "2" to lever
c. comp "3" to sector
d. comp "4" to latch
e. comp "5" to spacer
2. Assign PSHELL card image to imported components.
3. Assign thickness to imported components.

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a. Sector_4 = 4.12
b. lever = 1.75
c. sector = 4.17
d. latch = 2.21
e. spacer = 4.76
4. Assign material steel to imported components.
5. Go through a complete set of checks over the imported components edges, quality, normals
etc. This is a very important step that should be done whenever you receive an imported mesh
from another source. There are many small elements less than 2.5 do not change size. For the
other elements of poor quality, correct the worst offenders do not spend more than 4 hours
doing this.
6. Can you find the error in how one component was meshed? There is a problem with how it fits
in with the other pieces. How would you correct this? Discuss this
with trainer before you continue. Clue, it does not have anything to
do with element quality.
7. Creating 1D connections & Property:
a. Create the following components (no card images or materials). A default
material will be automatically created, this is ok. The designation such as C1
refers to the location in a diagram of where the elements will approximately
be. Notice that C2 and C3 are the same
component, but the locations are different. More will be explained in the
notes below and lecture.
Location Nomenclat Description
ure
C1 Spid_z This component contains rigidlinks. The axis of the bolt is along
the Z-axis and the DOF is 123456. When this is used, free rotation
about the hole axis (if desired) is controlled by a J=0 bar. This is
used in the three hole locations at I in the diagram. The spiders
should also go out two circles of nodes.
C2 Spid_y This component contains rigidlinks. The axis of the bolt is along
the Y-axis and the DOF is 123456. At location B and G, the bar
elements will be connected directly to these rigidlinks. All rotation

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will be transmitted back and forth between the bracket mesh and
bar elements through these rigidlinks, (as long as the bars property
is pbeam and J= a non-zero positive real number).
C3 Spid_y Same component as C2. These rigidlinks dependent nodes will be
connected same as C2 - to the corresponding shell components
(sector, spacer, sector_4 etc.). What is different, is that the
independent node is attached to another rigid component, (C9) and
then the C9 rigids will be attached to the bar elements. This is
done to allow the parts (sector, spacer, sector_4 etc.) to rotate
freely about the bars (C6) controlled by the C9 rigids DOF.
C4 bz_m8_j0 This component contains bar elements. The z signifies the bar axis
is along the z-axis. The m8 signifies it is a metric bolt 8-mm in
diameter. J0 signifies that the bar does not transmit rotation about
the z-axis. Rigidlinks that attach to this bar will be DOF 123456.
C5 by_m10_j0 This component contains bar elements. The y signifies the bar axis
is along the y-axis. The m10 signifies it is a metric bolt 10-mm in
diameter. J0 signifies that the bar does not transmit rotation about
the y-axis. Rigidlinks that attach to this bar will transmit DOF
123456.
C6 by_m12 This component contains bar elements. The y signifies the bar axis
is along the y-axis. The m12 signifies it is a metric bolt 12-mm in
diameter. No j0 signifies that the bar DOES transmit rotation about
the y-axis. Zero length rigids (component C9 rigids will connect
the bar elements at locations A, C, D, and F to a rigidlink with
DOF 12346 that does not transmit rotation (component C3)).
C7 k_gasket_x This component contains the spring elements that connect the left
bracket to the right bracket through the rigids. These elements will
be produced through "linear 1-d" and eventually be zero_length.
These springs need the dof to be in 1, and K=.05.
C7 k_gasket_y Same as above but the dof will be in 2, and K=.05.
C7 k_gasket_z Same as above but the dof will be in 3, and K=.15.
C7 k_gasket_ri This component contains the rigids in DOF 123456. The
g independent node should connect to the shell elements and the

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dependant node should connect to the spring elements.

C8 k_o_ring_x This component contains the spring elements at attachment point
E. These Springs will require a rectangular system assigned to
each spring individually or one cylindrical system. The system(s)
will go in a systems collector not in this component. K=.25.
C8 k_o_ring_y Same as above but the dof will be in 2, and K=.1.
C8 k_o_ring_z Same as above but the dof will be in 3, and K=.1.
C8 k_o_ring_ri This component contains the rigids in DOF 123456. The
g independent node should connect to the shell elements and the
dependant node should connect to the spring elements.
C9 coin_rig This component will contain zero length rigids that connect the
component C3 rigidlinks to the C6 component bars. This allows
the bars to transmit rotation to the other bars while allowing the
spider connection to transfer everything but y rotation to the
connected mesh. DOF 12346.
C9 coin_rig This component will contain zero length rigids that connect the
component C3 rigidlinks to the C6 component bars. This allows
the bars to transmit rotation to the other bars while allowing the
spider connection to transfer everything but y rotation to the
connected mesh. DOF 12346.
C10 rig_connect This component will consist of rigids DOF 123456 that connects
the "lever" component to the component "sector". These are
required to connect the imported components so they rotate
together.
b. Create the following properties. Note that the properties have the same name as the component it
is assigned to. Whenever a property is made, it should have the same name
as the component it will be used in. So only one property per component. The formulas were
obtained from a machinery handbook. Realize that these are for a solid circular cross section
shape only.
Property Nomenclature Description
[Same as comp.]
P1 bz_m8_j0 The property values are calculated from a circular cross section
with a diameter of 8 mm. The following values need to be

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calculated.
a. Verify that the MID (material ID) is correct.
b. "A" = Cross section area PI(r)^2
c. "I1" = Moment of Inertia about x (PI(D)^4)/64
d. "I2" = Moment of Inertia about y (PI(D)^4)/64
e. "J" = Moment of Inertia about z use .1 as nastran will
not except zero.
P2 by_m10_j0 The property values are calculated from a circular cross section
with a diameter of 10 mm. The following values need to be
calculated.
a. Verify that the MID (material ID) is correct.
b. "A" = Cross section area PI(r)^2
c. "I1" = Moment of Inertia about x (PI(D)^4)/64
d. "I2" = Moment of Inertia about y (PI(D)^4)/64
e. "A" = Moment of Inertia about z, use .1 as Nastran
will accept zero, and LS-Dyna will not.
P3 by_m12 The property values are calculated from a circular cross section
with a diameter of 12 mm. The following values need to be
calculated.
a. Verify that the MID (material ID) is correct.
b. "A" = Cross section area PI(r)^2
c. "I1" = Moment of Inertia about x (PI(D)^4)/64
d. "I2" = Moment of Inertia about y (PI(D)^4)/64
e. "J" = Moment of Inertia about z (PI(D)^4)/32. This
value is calculated since this is not a j=0 component.
The bars need to be able to transmit twisting about the
axis. (torsional loading)

8. Create k_gasket spring elements between the nodes of the 100% node area. To do this use the "linear
1D" function, create two elements (density 2). The elements created are plot configuration, the same
as edges. After creating the elements:
1. Equivalence the nodes to the shell mesh as one side is free.

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2. Go to function "config edit" and switch the top row of plot elements to springs.
3. Organize the springs by duplicating them to the y and z components.
4. Equivalence the springs.
5. Refer to the 1d handout on how to assign k values, dof, and element types. DOF is
handled through the spring function with the "update" button.
6. Go to "config edit" and switch the bottom row of elements to rbe2. (two noded
rigids). The bottom row should be dof 123456.
7. Replace the nodes in common with the spring/rigid to the shell node connected to the
spring. The springs should become zero_length.

9. Create spring systems and k_o_ring springs. [Area E]

a. Detach component sector_4, toggle "offset nodes" on, enter a value of 1.0 for an
offset and offset.
b. Create a node midway between each of the offset nodes and the node where it was
originally positioned.
c. Create spring elements attached to the spacer component and the newly created
midpoint nodes.
d. Create rigids for component "k_o_ring_rig" with the independent node attached to
the component "sector_4" and the dependant node attached to the spring at the newly
created mid nodes position, dof 123456.
e. Create rectangular systems for each of the detached nodes pointing radially in (or
out) or create one cylindrical system. Assign both nodes of all the spring elements for
analysis. This must be done while the nodes are spread apart.
f. Duplicates through organize the springs into the y and z o ring components. Be sure
to update the dof, element type, and k value to correctly correspond to each component.
h. Replace the mid-node (without equivalencing) of the spring/rigid to the spacer
nodes so that the springs are zero-length.
10. DO A FULL MODEL CHECK. (full checklist explained in 6.11).
11. Write out a dat file and check the deck for any errors or missing data

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12. Submit a free free modal run, SOL 3 for the deck and extract the first 15 eiganvalues. View the
results on Hypermesh and verify the numerical results, account for all warnings, does the
animation
13. This model once it passes examination, is now ready for some static analysis in the
NASTRAN class.

6.10.1 Supplemental Instructions

 The topics covered in tutorial 5 will be assembling and checking a model with multiple components.
 Two files will be needed. The first is the HM tutorial 4 HyperMesh file. If you have completed tutorial
4 use your file. If you have not done tutorial 4 you may take the file tut4.hm3 from the PC qciproj1 in
directory c:/my_documents/Dhana/HM-Tutorial 5.
 The second file you will need is the file a NASTRAN deck which includes 5 other parts to be
assembled with the two from tutorial 4. This file is called NEON_HANDLE_PC.dat and can be found
in the same directory listed above.
 Thoroughly check all of the models in both files.

The Connections:

1. The left_bkt will be connected to the right_bkt by 3 bolts at the bottom of the two brackets. Create
rigid spiders at theses holes on both brackets and connect them with a bar with J set to 0. The rigids
will be in collector spid_z and the bars will be in collector bz_m8_j0 and assigned the property with
the same name. These bolts are illustrated in the file tut5.cnct1.hm3.

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2. Components latch and sector are welded to the spacer by equivalencing the nodes at the interface
between these components. This is already done.

3. Components sector_4 and latch are bolted at four large holes around the main pivot hole. Again,
spiders are used at all of the holes with bar elements connecting the spider centers between the two
components. The spiders will be in component spid_y and the bars will be in component by_m10_j0.
This is shown in file tut5.cnct3.hm3.

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4. Components lever and sector are welded together with rigid elements. These rigids should be put in
collector rig_connect. This is shown in file tut5.cnct4.hm3.

5. The main pivot. Here there is a bar connecting left_bkt and right_bkt. This bar will transmit torsion
between these two components so it will have torsional stiffness and will be connected directly to the
spider centers at the main pivot holes on these two collectors. The lever, latch and spacer rest on this
bar, but they are free to pivot around the bar. Thus, a rigid element that has the rotation about the y-
axis free (d.o.f. 4) is put between the spider centers of these components and the nodes on the bar

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elements. Use appropriate collectors for all elements as described in the tutorial material. The
connections are illustrated in file tut5.cnct5.hm3.

6. A rubber o-ring is used to connect sector_4 to the spacer. The o-ring has different properties in the
radial, tangential, and axial directions and will be represented with spring elements. At each of the
nodes around the spacer and sector_4 interface there should be 3 zero length springs in three different
collectors and a rigid element to fill the gap between the two components. Create a cylindrical
coordinate system at the center of the spacer. Assign this system as the analysis coordinate system for
the nodes of the springs. This is shown in file tut5.cnct6.hm3. This is described in section 9 of the
tutorial material.

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7. A gasket is used between the left and right brackets where they are in contact at the bottom. This is
described in section 8 of the tutorial material. The gasket is modeled with spring elements in the three
translational directions. There will be 3 zero length springs in different collectors with a rigid to fill
the gap between the nodes of the brackets. There is a section in the middle where the two components
are not in contact. Do not make a connection here.

6.11 Full Model Checks:

 Steps to perform before submitting a free-free modal run.

1. Visually checking the model.
This is a very important step. Rotate the model and visually check all features making sure that nothing is
forgotten and that the mesh is representing the geometry correctly. Are symmetric areas meshed
symmetric, or is the mesh symmetric but the geometry is not? Are all ribs meshed? Are the components at
mid-plane? Are all the components meshed? The number and type of questions depends on the model and
you will need to determine what are all the correct questions. Do keep in mind that it is amazing how
frequently this step is overlooked and that mistakes can be avoided just by visually checking the model.
a. Is all the geometry meshed?
b. Are all shells at mid-plane?
c. Symmetric mesh in symmetric areas?
d. View the geometry from different angles, is the mesh representative of
the geometry?

2. Organization.
The way that the components are named and ordered can be a great aid in easing the ability for you to
check the model, and most importantly so the customer or coworkers can easily make sense of the file and
find what they want. Unnecessary components, geometry, materials should be removed. Assemblies
created for common groupings. All names should be logical and convey the needed information, example
"bar_m10_x_j0" , "celas_x", "a_plr_in_lft". Geometry and mesh in the same component or named the
same with a "g" or "e" designation and ordered next to each other in the component list. The idea is to
have a near standardized format so that the final model is as easy to work with, edit, modify, and check as

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possible for anyone, not just for who created it.

3. Quality Checks
Briefly run through the element quality checks and correct the mesh to the desired meshing guidelines.

4. Edges & Normals

Do preview equivalence on each part (or component) separately, correct errors. Find edges one part (or
component) at a time and check edges with no other elements or geometry on the screen. Normals -
adjust normals on all shell parts.

5. Quality Checks - Run through all the quality checks 1d, 2d, and 3d, thoroughly. Don't forget
connectivity and duplicates. If you start editing the mesh, go back to the first step, visually checking
the model, and proceed to the next step(s).

6. Face checks - (solids only) Does the mesh meet the requirements such as two elements across all
thickness?
b. Do an edge check on faces.
c. Do a normal check on faces
d. Do a connectivity check on faces
e. Visually check faces for any cracks, remember this is the only way you can find certain crack
errors.

7. 1 D checks - Any obvious errors found in step 5 should have been corrected, however 1d elements
need to be checked by component and/or element type more thoroughly to verify that the model is
correct. In order for the 1d checks to go as quick and accurately as possible, hopefully they were
organized in components as taught in the 1d lecture in class. If orientation, property, dof, j, etc are
different, the like elements should be grouped in the same component, separate from the elements,
which differ in any one of the assigned values.

8. BIW check or welded body check

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If you have an assembly of different parts welded together such as a body in white, it is a good idea to
check each part to see if it has been welded correctly. A good procedure for doing this is the following.
a. Bring up one shell component (part) on display.
b. Use "find" attached elements.
c. Inspect where the rigids or welds appear on the part, do all the flanges have an appropriate number
of welds? Are there any other areas that look like they should be welded?
d. Now bring up "all" on display elements, mask around the same part. (do not use find)
e. Now, any other parts that come in contact can be seen along with the welds.
f. If there are welds in an area that in step c were blank, it is not connecting to this component
g. If there were no welds along a flange in step c, you can now see what component needs to be
welded.
h. If there were no welds along a flange and there still is no part visible, it is ok (or a part was not
meshed or given for this area)

9. Attached Test
If you have an assembly, body in white, transmission, etc, you will want to know that everything is
attached. With everything displayed, go to "mask", pick one element (any element), and then click on
"element" again to bring up "attached", click on "attached". Then click mask. Any elements you have left
behind on display, will need to be attached, deleted or some how corrected.

10. Rigids
a. Free 1-d's - there should never be free rigids.
b. rigid loops - there should not be any rigid loops.
c. dependency - there should not be any dependant nodes.
d. Connectivity - you do not want to have any connectivity elements in this check.
e. Duplicates - you do not want to have any duplicate elements in this check.
f. Length - Having zero length is required for coincident node rigids, typically when using rigids for gap
elements or springs. If there is space between the connecting nodes, a 90 degree weld is desired and
the length should not be much greater than the sum of the two gages (thickness of the two parts being
welded together) divided by two, the length should not be less than the thinnest part also. To check
this correctly you will have to display only rigids.

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g. DOF - check all rigids that require dof different than 1-6, these must be zero_length. Make sure all the
other rigids dof is 1-6.
h. If a rigid has a length greater than zero, it must have all dof locked. 123456.
For Nastran models that will be converted to Dyna decks it is important for nodes of any type of rigid
body to NOT share nodes with any other type of rigid body. In Nastran, nodes can be shared as long as
they don't violate the previous rules. (See the rigidlinks "find" and summary check below.)

11. Rigids
a. Free 1-d's - it only takes 1 free dependant node for the rigid link to be a free 1d. There should not
be any free rigidlinks.
b. Rigid loops - This check will not find rigidlink loops
c. Dependency - There should not be any dependent rigidlinks. Use review elements in the "rigids"
function, make sure that it does show that the desired node has an "I" and the others have a "D".
For a Nastran run it is ok to have a rigid attached to a rigidlink. If there is a dependency problem
just "switch" the dependent rigid(s) through "update". The rule is: An independent node can have
many dependent nodes but a dependent node can have only one independent node.
d. Connectivity - This check will NOT find any connectivity problems with rigidlinks.
e. Duplicates - you do not want to have any duplicate rigidlinks in this check
f. Length - The length check does NOT check length on rigid links
g. DOF - check all rigids that require dof different than 1-6, make sure all the other rigids dof is 1-6.
h. The "Find" check (for Nastran models)
 There is one more check that can help find some but not all rigid type elements attached to other
rigid type elements, and that is going to "find". (This is not a complete check: final verification
must be visual)
 Select the left toggle, which says "between comps", select all the components that contain rigid
type elements, than click on find. If there are any elements found, They should be carefully
checked to make sure it is correct. Again, if this will become a dyna run, rigid types connected to
other rigid types will cause the run to fail.

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i. For LS-Dyna models, the "find" check is not needed because there is a summary template that can
find rigids sharing nodes with rigids. It is the Ls-Dyna/error check.

12. Bar elements

a. Free 1-d's - there can be free 1d's on bar or beam elements but they must be individually checked
to be sure that is correct.
b. Rigid loops - does not apply
c. Dependency - does not apply
d. Length - does apply, there cannot be bars or beam elements with length less than approximately 1-
2 mm. To be checked correctly, only the bar and beam elements can be displayed.
e. Connectivity - there should not be a connectivity problem with the elements
f. Duplicates - there should not be any duplicates
g. The "V" component cannot be along the element axis. Checked within "bars" using the "review"
button.
h. Is the correct element type been updated? Example: are cbars supposed to be cbeams.
i. The correct property should be assigned to all bar elements. Checked within "bars" using the
"review" button.
j. If local systems are required, are the correct nodes assigned to analysis? Two nodes per bar or
beam element.
k. Does the property type match the element type? pbeam w/ cbeam, pbar w/ cbar.
l. Now check all the bar/beam properties themselves. Are the values correct for area, i1, i2, j, etc.
m. If several bars are representing a bolt, axle, or a part that the axis would be a straight line, the bars
should be linear also. In addition they should also run exactly along the proper axis (such as the x,
y, or z).

13. Spring elements

a. You should not have any free springs.
b. Rigid loops and dependency does not apply.
c. Length - all springs should be zero length. To check this correctly, only the spring elements should
be displayed.

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d. Connectivity and duplicates are ok if that is what is desired. Duplicate spring elements should
have a different dof value and/or K constant.
e. Check that the correct k value has been assigned, which is done through "card" in the permanent
menu.
f. Check that the right degree of freedom direction has been assigned. (If a local system is used make
sure the dof fits the correct system. This is done through the springs function.)
g. verify that the elements are type CELAS2
h. One node of the zero-length spring should be attached to a rigid.
i. If local systems are required, are the correct nodes assigned to analysis. Remember these are zero
length elements so both nodes of the spring need to be assigned to a system for analysis. Failure to
do this will result in false results but will not give fatal or warning message.

14. Systems
a. Are there any unused systems?
b. Check each system in review for the "A" at the desired nodes to be using the system.
c. Is the type of system correct and is it orientated correctly. Note- if you do not write out a system
for a run because it is not needed for a specific case, the nodes set for analysis will reference the
missing local system and the run will fail.

15. Mass elements

a. There can be duplicate masses if that is what is desired. The duplicates usually will represent a
different part with a different mass.
b. To check the elements assigned mass, go to "masses" and select the element and then click on
"review" (or) if there has been an assigned inertia value to the masses, check the values through
the permanent menu "card".
1. Toggle the triangle selection to elements.
2. Pick the desired config. and type in the appropriate fields and then select only one mass
element at a time and click on edit.
3. There will be a field for the mass, offsets - x1, x2, x3, and inertias i1, i2, j.

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16. Mass Calculation

Go to the tools page, "mass calc", is the result correct if you were given the weight? If you were not given
the weight, is it reasonable? This will also help verify that you are using correct and consistent units.

17. Delete all unnecessary components, lines, surfaces, material, systems, properties, sets, etc before
going to the next step – renumbering
18. Temp nodes - clear all temp nodes.
19. Renumber - *be careful* if you are modifying some models, the model should not be renumbered or
groups, interfaces, and miscellaneous information will be lost. Otherwise, renumber all entities, nodes,
elements, components, materials, properties etc. when first creating the model.
20. Summaries
On the tool page, there is the "summary" function. Run the following summaries:
1. Nastran/elements - This is good for counts, and making sure you have the proper type of elements.
For example you should not have any plot elements, check for errors such as if you have cbars
when you should have cbeams. Celas1 elements when you should have celas2 etc? For each type
of element listed you will want to check the Nastran deck file for correct output. For example if
you have cbeams, you will want to check the deck for CBEAM and also for the associated
PBEAM cards for correctness.
2. Nastran/properties - This is an excellent check for seeing which component was assigned a pshell
or psolid dictionary, if there is a thickness assigned, and what material values were assigned.
3. HM/comp - This is a good check to see that each component has only the correct type of elements
within the component. Such as a pshell component should not have any hexa or bar elements. It
will also show what material is assigned to the component. You should now be ready to write the
Nastran deck

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7. Sample Projects

a). BIW - Rap Door Coupe Sub –Assembly Modeling

1. Model Element Density and Modeling Guidelines

 Use an average size of 33.3mm. There are grid lines of most component geometries that are spaced
every 100mm in x, y, and z. Keep the nodes on the gridlines as much as possible with 3 elements
evenly spaced between gridlines. DO NOT put the nodes on the gridlines IF element quality will be
sacrificed or the geometry of the part will be compromised to do so.

 Model features greater than 15 mm and holes greater than 30mm. Capture features that add
stiffness to the part such as corners and stiffening beads. You may refine the mesh to capture stiffening
features, but try to keep the element size above 10mm.

 There should be one element across the width of any weld flanges.

 Parts that are welded together must have identical mesh patterns along adjoining surfaces. This
is to insure that the rigid elements used for the welds will be normal to the surfaces. Project the
elements from the smaller part to the larger part to achieve the matching mesh pattern.

 Parts that run from side to side must have nodes on the centerline of the car (y=0). No elements can
cross the centerline of the car.

2. Quality
No more than 5% of elements with warpage above 12. Absolute maximum of 20.

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No more than 5% of elements with Jacobian less than 0.6. Absolute minimum of 0.7.
All quad angles should be between 45 and 135. No exceptions.
Tria angles should be between 20 and 120. Exceptions made for tight geometry.
No more than 7% TRIA elements in any component.

3. Naming

Each part has been assigned a 3 digit number. The geometry for each part will be named ###_g. The
elements for each part will be named ###_e.
Any individual part that crosses the middle of the car is assigned two consecutive numbers such as
172,173_g. The elements for this part would be in one component 172,173_e.

When two parts are in the same geometry collector such 170,171_g they are most likely reflections of one
another. An element collector should be created for each part such as 170_e and 171_e.

4. Load NASTRAN PSHELL dictionaries for all element components.

5. Welding
According to the modeling guidelines, there should be one element across weld flanges, the element size
along the weld flanges should be about 33 mm, and the elements of mating parts will match where the
parts are in contact. Along the weld flanges a rigid element should be used to represent the welds every 66
mm or every other element. The rigids will be placed in a zig-zag pattern such that one will be on the
inside of the flange, the next on the outside, the next on the inside, etc, leaving at least one set of free
nodes between welds.

If the elements were matched while creating the shell components, the rigids will be normal to at least one
of the surfaces. If not, project one of the nodes so it is normal to the surface of the other. Flanges may be
extended or trimmed up to 5mm such that the nodes between two flanges will match. When making

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modifications such as extending the flanges to make the nodes line up, try to choose the flange or
modification that will give the least change in stiffness or mass to the model.

5. Modeling Strategy

The components of the car have been divide into several sub-assemblies. Each sub assembly will be
assigned to one person who will take care of the connectivity between each and make the rigid elements
that connect the components of the sub-assembly. The sub-assemblies were chose such that there will be
relatively few connections between the sub-assemblies, and the sub –assemblies will all take
approximately the same amount of time to model. The people modeling adjacent sub-assemblies will have
to coordinate such that the elements match.

Matching the elements to obtain 90o rigid elements is easiest if the smaller components are modeled first.
Those elements can be projected to the larger components. Furthermore, small components at the
boundaries of two adjacent sub-assemblies should take precedence so that they can be matched in both
sub-assemblies without any remodeling.

Once all sub-assemblies are completed, they will be assembled, and the largest panels of the car which
connect to many smaller components will be modeled. The remaining components will be the side outer
panel, dash panel, and floor panels.

6. Sub – Assemblies

 Rear Underbody (RRU)

This includes the components under the rear floor. These are the rear rails, rear bumper, rear
suspension mounts, 4 bar, and 5bar.

 Rear Wheel House and Shelf (RRW)

This includes the inner and outer rear wheelhouses, the shelf and the rear panel. This area surrounds
the trunk.

 Upper Engine Compartment (UPE)

This includes the upper tie bar, upper rails, shock tower, and fender closeout panels.

 Longitudinal Rails (RAILS)

This includes the front bumper, main rails, and front cradle mounts.

 Front Under Body (FRU)

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This includes the extension of the rails under the floor, the rear cradle mounts, and one bar.

 Roof and Quarter Panels (ROOF)

This includes the roof, headers, roof bow, roof rails, quarter panels,
and b-pillar.

Geometry is not available for some of the floor underbody

components. Also, the floor panel, dash panel, and outer doorframe
are not included, as they should be completed after all of the
smaller parts are finished.

b). Seat Assembly

In this project, the given assembly is divided into subgroups and distributed to individuals. Each
individual will be modeling the components under their respective subgroups. Finally, the concerned
group leader will collect all the components in his team and give all assembled parts to team members to
do the connections based on the given reference model.

1. Guidelines
a. Mesh size 5-12 mm depending on size and function (use the reference file as a guideline)
b. Min length 2.5 mm
c. Mid-plane
d. Circle around circle on all holes greater than 6 mm
e. Two elements across a thickness and across fillets unless the size goes below 2.5 mm.
f. Create connections, small spider, large spider, bars etc based on the reference model.

2. Individual Componenets:
1. BKFRM1

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2. BKFRM27
3. DUALRECL

4. DUALRECL_2

5. DUALRECL_3

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6. DUALRECL_4

7. DUALRECL_5

8. IBUPFRM2

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9. IBUPFRM2_2

10. IBUPFRM2_3

11. IBUPFRM2_4

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12. IBUPFRM2_5

13. LOWFR2

14 LOWFR2_2

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15. LOWFR2_3

16. LOWFR2_4

17. OBUPFRM2

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18. OBUPFRM2_2

19. OBUPFRM2_3

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20. OBUPFRM2_4

21. OBUPFRM2_5

22. PAN2

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 Quantum Consultants, Inc.
Global Solution Delivery Center
Cyber Towers, Hyderabad

23. TWLBAR2

24. TWLBAR2_2

25. TWLBAR2_3

HM Training Page 86 of 87
 Quantum Consultants, Inc.
Global Solution Delivery Center
Cyber Towers, Hyderabad

HM Training Page 87 of 87