Altair HyperXtrude 2023.1 Release Notes

Altair HyperXtrude, also known as the Inspire Extrude Solver, is a suite of finite element solvers for simulating the following manufacturing processes, and these solutions have interfaces in Inspire.
  • Binder Jet Sintering
  • Metal Extrusion
  • Polymer Extrusion
  • Quenching
  • Calibration
  • Metal Rolling
  • Friction Stir Welding
  • Resin Transfer Molding

Highlights

  • H3D writer speed-up
  • Initializing relative density data from EDEM simulations
  • Coupled HX - OptiStruct full cycle (transient) analysis

All Solutions

Enhancements

H3D writer speed-up
The H3D file writer has been improved to speed up the writing of the mesh used in the analysis. (HXT-443)

Binder Jet Sintering

New Features

Initialize relative density data from EDEM simulations
The sintering solver reads a CSV file with relative density distribution and initializes relative density using kd-tree. This CSV provides the relative density data at different (x,y,z) coordinates. This feature will be released with Inspire 2024. (HXT-513)

Metal Extrusion

New Features

Coupled HX - OptiStruct full cycle (transient) analysis
This upcoming feature, which is still being tested, enables the use of coupled analysis with OptiStruct with a full cycle analysis. This is now restricted to single-cycle analysis and makes some simplifying assumptions, such as ignoring the plastic deformation of the tool (even though it is computed). The frequency at which the OptiStruct solver is called can be controlled by the interface. This feature will be released with Inspire 2024. (HXT-620)

Enhancements

Parameters to control billet skin results
Two of the internal parameters used in billet skin analysis are now user-accessible. There is no GUI support for these parameters. These parameters are BilletSkinHighFilter (Default = 0.6) and BilletSkinLowFilter (Default = 0.3). (HXT-686, GIT-a91494e3)

Resolved Issues

Uniform bearing start location
A new BC parameter, uniform bearing start location, was introduced for variable bearing start location. The use of this variable is now restricted to only when a variable bearing start curve is used. (HXT-686)
Error when SFI BC is used for billet-dummy block BC
Issues created by new developments for variable time step specification are now resolved and the feature performs as expected. (HXT-701)
Crash while using quenching warpage analysis
A random crash, which was difficult to reproduce, no longer occurs while using elastic thermal residual analysis. (HXT-598)
Issues in identifying nodes corresponding to bearing coordinates
New updates, such as variable bearing start curve and others, no longer cause the identification of the nodes in the mesh that correspond to the bearing profile points (Inspire Extrude always uses nodes to get these points). This error was happening in decks that were created before. (HXT-214)
Weld surface result changes abruptly in the bearing and profile regions
The weld surface results were changing in the bearing and profile regions due to numerical approximations. To overcome this, the solver now uses the node chain data in the profile and bearing region to preserve the weld surface value. (HXT-713)
Temperature compensated strain rate value (Z) in h3d differs from the manually computed value
The solver considers the strain rate and temperature values at the centroid of an element to compute the Z-value. When the strain rate is more than the maximum strain rate, the maximum value of strain rate no longer needs to be considered for the computation in the solver. However, since the temperature average of the nodes of the face/element is different from the exact value at the centroid, the Z-values computed manually may still differ from the solver computed value. (HXT-714)

Polymer Extrusion

Resolved Issues

Visualization of results for simulations with puller speed
A puller speed simulation involves multiple user-specified mesh updates. During the course of the mesh updates, if the mesh becomes too distorted to solve, the solver stops the simulation after writing the results from the last successful mesh update step. However, the simulation labels were written based on the initial user-specified mesh updates. Therefore, for the mesh updates not simulated due to bad mesh, the result was not written. Now, simulation labels are written only for the successful mesh updates. (HXT-712)