The Complete Guide to FEA/CAE with HyperMesh & OptiStruct

Launch Hyper Mesh 2024, open a session, select the solver profile (Optistruct or abacus), and set a directory as you learn to prep models for solving.

Learn to interact with hyper mesh models by zooming, panning, rotating, and fixing the rotation center using middle scroller, plus/minus, circle zoom, and other shortcuts; switch to Optistruct for compatibility.

Navigate the Hyper Mesh graphical user interface, observe the title bar with file name and optistruct solver profile, and explore the interface, pages, and tools like the entity editor.

Master importing and exporting diverse file types in HyperMesh, including native .mm, geometry CAD, solver decks, connectors, and results, and merge CAD with mesh for cross-team collaboration.

Master the import and export workflow by merging HyperMesh geometry with a solver deck to produce a final output, while observing files and syncing views.

Import and merge geometry, solver deck, and connector data to build a complete hypermesh assembly, using step CAD files and dot xml files for the connection.

Explore the HyperMesh model browser and its content, including collectors, components, properties, materials, assemblies, and how geometry, elements, and loads organize in a typical FEA workflow.

Learn efficient selection in HyperMesh using the entity selector to pick elements, components, and geometry, with box, circle, freehand, and polyline tools for inside, outside, and visible selections.

Explore multiple selection methods in HyperMesh, including by assembly, by component, by configuration, by age, by phase, by ID, and by material, with display options and path selection.

Master hypermesh selection techniques, including selecting displayed elements, reverse, adjacent, attach, and similar options, plus by path and by face selections across elements, nodes, and components.

Learn to control visibility in HyperMesh using show, hide, and isolate for components, elements, geometry, and loads, leveraging the view control toolbar and keyboard shortcuts.

Master global and local geometry and mesh visualization in hyper mesh, toggling geometry, mesh, surface edges, and transparency with shortcuts like G and X to verify alignment.

Save and recall custom views with store view and v1, v2, and v3. Use true view and align to perpendicular faces, and explore section cut and lock view for visibility.

Master view control in HyperMesh to find entities, isolate regions, visualize element connectivity, loads and SPC, and inspect 2D/1D elements with handle visualization for large assemblies.

Measure distances, angles, and radii using interactive and dimensioning modes; lock direction with shift and chain measurements with control, then use calculate for mass, area, and center of gravity.

Create or modify geometry in CAD to save time when small design changes occur, adapt to CI needs, and proactively bridge design and CAE roles for analysis-ready solutions.

Explore building blocks of geometry, including hard points, lines, surfaces, and solids; learn to visualize, select, and convert between surfaces and solids, and manage geometry in hypermesh.

Demonstrate using the sketch tab to create lines, rectangles, circles, polygons, and splines, with constraints and dimensions, and realize sketches as lines or surfaces on a chosen plane.

Modify sketches by transforming, rotating with a specified angle, and snapping to grid for precise horizontal and vertical positions; trim, break, extend, offset, mirror, pattern, and construction lines.

Learn to create points and nodes, set coordinates, and place center points using control and F8, then interpolate nodes on lines and surfaces with linear, exponential, and bell curve biasing.

Learn to extract points and nodes on lines, surfaces, and solids. Use arc center, intersection, and parametric options to place and split nodes with precise control.

Learn to create and edit shapes and lines in the topology tab, including rectangles, circles, arcs, and polylines, using center, corner, diameter, and imprint options.

Learn to create standard solid shapes such as boxes, cylinders, and spheres in HyperMesh, using biplane and free drawing options, fit to geometry, and bounding to convert surfaces to solids.

Explore topology in geometry cleanup for fea/cae, identifying free, shade, non-manifold (t-junction), and suppress edges in hypermesh, and learn how topology guides meshing decisions.

Learn why geometry cleanup is essential in hypermesh, including identifying non-manifold edges and duplicate surfaces. Apply stitching and tolerance adjustments to ensure node connectivity and a clean, reliable mesh.

Explore geometry cleanup in hyper mesh, including topology view, geometry tolerance, patch and spline surface creation, extending and stitching edges, trimming non-manifold and free edges for a clean mesh.

Learn geometry cleanup with cross extend to extend and intersect surfaces, adjust distance and angles, use stitch and suppress tools, and create skins between lines for clean meshing.

Open the iges geometry file, verify topology, set cleanup tolerance to automatic, then use split, stitch, and patch to create surfaces and save the corrected HyperMesh model.

Perform geometric cleanup on a plastic tray in HyperMesh, remove duplicate surfaces, fix tolerances with stitch at 0.1, create new surfaces via patches, and verify topology before saving.

Explore HyperMesh's surface repair option to fix free edges, non-manifold and duplicate surfaces, using stitch, patch, and delete, then convert repaired geometry to a solid.

Explore the surface repair workflow in HyperMesh console panel, identify geometric problems, fix edges with stitch and intersect, patch holes, and convert corrected surfaces into solids.

Discover geometry D featuring to remove small holes, fillets, and logos, guided by part importance, area of interest, and mesh size, using batch D featuring and feature management.

Master manual defeaturing in hypermesh using the D feature to remove holes, fillets, logos, and small features by measuring radii and diameters and adjusting center points for clean meshing.

Master defeaturing in hypermesh by applying the D feature to remove holes, edge and surface fillets, and small edges, using manual and batch workflows, with tags to preserve critical geometry.

Apply batch D featuring to simplify geometry by removing holes, suppressing flat features, and deleting duplicate surfaces, using auto cleanup and parameter edits to finalize the defeatured model.

Master feature management and feature detection in HyperMesh to identify holes, fillets, and logos, set detection criteria, highlight results, and remove unwanted features for cleaner meshing and analysis.

Learn the basics of 2d meshing using the mid-surface and thickness assignment. Understand when to use 2d meshing, its benefits for thin-walled parts, and its limitations requiring 3d meshing.

Set the solver profile to optistruct and build a 2D mid-surface mesh with a 10 mm element size. Use parameter and criteria editors and density edits to improve element quality.

Explore automatic mid surface extraction options in HyperMesh, including mask input geometry, prefix naming, cross-component extraction, and thickness limits with arbitrary ratio tradeoffs.

Explore midsurface extraction methods in HyperMesh, including offset, plane plus offset, plane plus sweep plus offset, and skin offset, with practical steps, limits, and the edit plate workflow.

Extract the mid surface in HyperMesh by using the offset method on curved geometry, bypassing the plane function, and verify edges and curvature with updated mid-surface and topology checks.

Explore two-dimensional element shapes by contrasting quad and triangular elements, including first-order (linear) and second-order (parabolic) variants, node placement, and the impact on accuracy and stiffness.

Explore 2d free-form meshing in HyperMesh: import geometry, stitch surfaces, set target element sizes, adjust density and biasing, and switch between map, rectangle, and free mesh options.

Learn 2D meshing with HyperMesh by preparing geometry, removing fixed points, and setting target and minimum element sizes. Use remeshing and align to achieve structured quad mesh and verify quality.

Learn to map complex geometry with faceted and freeform methods in HyperMesh, using align, size variation, and skewness controls to generate structured meshes for rectangles, circles, triangles, pentagons, and hexagons.

Master the edit element tool to repair meshes via split, replace, merge, and smooth for quality, and use move to adjust triangles, holes, and nodes along edges.

Master the quick edit tool to split surfaces, update meshes, and manage topology revision, remesh settings, washer splits, and filler surface for precise FEA/CAE meshing.

Learn how to mesh holes in HyperMesh and OptiStruct using washer guidelines, including 1.5 to 2x hole diameter and an even, triangle-free mesh.

Master practical meshing guidelines for fillets in HyperMesh, including two layers of cored elements, minimum size criteria, and avoiding transitions on completely cored constant radius fillets.

Apply guidelines for tri elements in HyperMesh: avoid touching triangles, avoid on washers or constant radius fillets, prevent opposite triangles, and minimize tri count with edge transitions when needed.

Master batch meshing in HyperMesh with OptiStruct by using parameter and criteria editors, topology edits, two-millimeter mesh size, proximity-based edge suppression, and hole treatments like washer or seed.

Extract the mid-surface from a solid, set target element size for batch meshing, and refine the 2D durability mesh with rebuild, edge swap, and smoothing to ensure quality before proceeding.

Merge the holding bracket geometry with the free form and batch meshing, optimize mesh density and topology, and improve element quality through edits, splits, and smoothing.

Explore element quality in finite element analysis, linking mesh quality to accuracy and faster solution times, and learn key parameters like aspect ratio, skewness, jacobian, and warpage.

Learn how aspect ratio, defined as max edge length over min edge length, affects accuracy and convergence in finite element analysis, with 2d and 3d guidelines and modal analysis results.

Measure the warpage parameter as the out-of-plane deviation of a chord element in the 2D element family. The ideal value is zero, and any value under 15 degrees is acceptable.

Understand skewness as the measure of element quality, defined as 90 minus theta minimum, and learn to compute theta minimum for 2d and 3d elements.

Evaluate the jacobian parameter, the determinant measuring deviation from square or equilateral shapes. Apply min/max length and angle guidelines to ensure quad and triangular mesh quality.

Analyze quality checks for tetra elements, including tetra collapse and volumetric skew, by computing height over area with a 1.24 factor and volume distortion relative to the ideal.

Explore when to use 3d meshing for solids, standard shapes (tetra, penta, hexa, pyramid), and three translation dof per node with no rotational dof to capture deformation.

Examine 3d element shapes, including hexa, tetra, penta, and pyramid, and compare node counts, memory, and accuracy to guide unstructured meshing choices.

Learn to generate hexa meshes for thin solid components with 3d meshing in HyperMesh, using batch mesh, setting thickness layers, and managing mesh association with solids.

Explore solid topology, including bounding faces, partition faces, and fin faces, in 3D topology. Learn to assess and achieve one- or three-direction mappability through partitioning and guided 2D meshing.

Convert unmappable solids into mappable solids in HyperMesh using the split command, surfaces, and extend trimmer to enable 3D hexa meshing and guided mesh extrusion.

Learn to convert unmappable solids into mappable solids using targeted splits, planes, and lines, then generate 3D map meshes and prepare for hexa meshing.

Learn to generate hexahedral meshes for a four-component arm bracket in HyperMesh, focusing on manual extrusion, topology, splitting, patching, and guide-driven meshing to follow complex geometry.

Learn how to prepare and map a component for HyperMesh by converting surfaces to solids, stitching, repairing closed shells, and using the map command to generate a structured 3D mesh.

Import the crankshaft iges file, exploit symmetry by splitting the solid, and mesh with map to develop a professional level 3D mesh.

Explore tetra meshing in 3d, adjust average or maximum element size and element order, apply curvature-based refinement and proximity, and ensure a closed volume for a valid mesh.

Learn to prepare a knuckle joint model for tetra meshing in HyperMesh, adjusting dimensions, removing small fillets, and validating a robust 2D to 3D mesh with tetra collapse criteria.

Learn how to create and use connectors in HyperMesh to model welded, bolted, and bonded assemblies, defining where, what, and how to connect and realizing the equivalent representation.

Learn to create spot welds in HyperMesh by configuring control, defining the EFI representation, and realizing connectors with correct distance, diameter, and element type.

Learn to create seam welds in HyperMesh using lines and connectors, define FFI representations such as rigid and chord elements, include heat affected zones, and adjust the mesh for realization.

Represent bolted connections in hypermesh with rigid joints, RB2 or rigid link orbital elements, fasteners, and washer attachments; compare node-to-node and tie contact representations.

Explore automatic bolt connections in HyperMesh by using the auto fastener option, measuring hole diameters and tolerances, and adjusting body length to create and realize connectors across multiple components.

Use attachment and connect to model bolt connections as rigid elements for holes, with teams sharing attachments and using automatic link detection to realize beams.

Explore creating adhesive and hemming connections using area connectors, including arbitrary hexa and hexa contact, with link detection, tolerance settings, and material properties.

Import connectors from an XML file, inspect components, 2D elements, and thickness, convert parts to components, and realize spot welds across milestones using design phase XML.

Create a solid weld in HyperMesh by using 3d topology, split and stitch, and boolean intersect to ensure connectivity between vertical and horizontal plates.

Explore the theory of linear static analysis, including displacement, stress, and acceptance criteria, nonlinearity, and the governing equation f = k x under small deflection.

Explore linear static analysis of a cantilever beam under axial loading using a 1d beam mesh with circular 10 mm cross section and steel material to compute stress and deflection.

Post-process axial loading results for a cantilever beam, verify the analysis with the output file and reaction forces, and visualize displacement, axial stress, and element forces in HyperMesh & OptiStruct.

Explore the Optistruct file structure by identifying key files: .fem input, .fm ascii, 3D result, .env session, .out, and .state and message files.

Understand the Optistruct input structure—input output, case control, bulk data—and edit the FM file directly to streamline analyses.

Apply transverse loading to a cantilever beam to compute bending stress and displacement using HyperMesh and OptiStruct, with PBM properties and stress recovery points, validating Smax and 32 mm deflection.

Analyze a simply supported beam with a center 400 N load, computing reactions, bending stress, and deflection for a rectangular 10 by 4 mm steel cross-section.

Learn to pre-process a two-dimensional cantilever beam in hypermesh for optistruct, including geometry, meshing, material and property setup, boundary conditions, rigid element loading, and linear static analysis.

Post-process a 2D cantilever beam in HyperView, compare corner data and averaging methods for element stress, and export corner-stress results to validate against analytical values.

Analyze a beam bracket under a 30 kilonewton top-surface load. Model as a 3d problem with a rigid wall mounting and perform linear static analysis in OptiStruct.

Explore the theory of buckling analysis and eigenvalue buckling, focusing on structural instability, critical load, and the buckling load factor for axially compressed columns.

Explore four end conditions for column buckling and Euler’s critical load via effective length, with k values 2, 1, 0.7, and 0.5. Note boundary stiffness and modeling cautions in abacus.

Perform buckling analysis of a fixed-free column with HyperMesh and OptiStruct; compute the critical load from Euler’s equation using the minimum moment of inertia, then validate via static-buckling workflow.

Apply Euler buckling analysis to a pin-pinned column, freeing rotations about x and z axes and comparing analytical critical load of about 86 kN with first eigenmode near 85.9 kN.

Perform linear buckling analysis for fixed-fixed and fixed-pinned columns using Euler's equation to obtain critical loads, and validate results with HyperMesh and OptiStruct.

Perform buckling analysis of a steel mobile tower with rigid joints, steel sections of 3x2 and 1.5x1.5 mm, and a 1 N load to obtain the buckling load factor.

Explore a 3D buckling analysis of a steel spring in HyperMesh, scaling the model, creating a second-order tetra mesh, and extracting the first critical load and mode shapes.