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Gordon Murray Design

Overcoming the Challenges of Composite Design

Automotive manufacturers are utilizing lightweight materials as a method of minimizing mass and maximizing fuel economy. Automotive design company, Gordon Murray Design (GMD) believes that composite materials can play a much larger role in the manufacture of vehicles. To prove its case, the company has developed ‘iStream’, an efficient process for manufacturing low and high volume cars from lightweight material. To validate the iStream structure, GMD required an experienced simulation partner.

Formidable Challenges in Formula Student Racing

Industry: University
Challenge: Remove weight and improve performance from vehicles
Altair Solution: Optimization with HyperWorks tools
Benefits:
  • Reduce weight of vehicle while keeping or increasing the component stiffness
  • Speed up time of development process
  • Save material and real-world testing
  • Reach top rankings during competitions


Automotive Weight Management Article

The automotive development process is still focused on objectives such as durability and crash safety, while weight is often limited to the very end of the design process. Through the establishment of the “Optimization Center” (OC) concept, Altair ProductDesign has developed an innovative design model combining performance features with weight reduction goals. This article describes the OC concept dealing with everything from the optimization of single components to an entire optimization process known as “CAE Weight Management”.

Hatz Diesel Engines Benefits from Altair Partner Alliance by Covering Development Process with One License

The Motorenfabrik HATZ GmbH & Co. KG is a producer of industrial diesel engines and engine components for the heavy machinery and automotive industries. Hatz found a cost effective solution for acquiring high-end virtual prototyping software by utilizing the HyperWorks suite and tools from the Altair Partner Alliance.

World-Leading Crane Manufacturer TADANO FAUN Accelerates Its Design Processes with HyperWorks

Industry: Heavy Industry
Challenge: Generate accurate finite element method (FEM) calculations.
Altair Solution: FEM structural analysis utilizing the suite of HyperWorks tools
Benefits
•Faster time to results
•Flexible unit-based licensing model
•Cost reduction

Gordon Murray Design Discuss the Future of Automotive Manufacturing & iStream

Dr Ralph Clague, Powertrain Systems Manager at Gordon Murray Design (GMD) speaks to Altair ProductDesign about the current challenges in the automotive industry and how their iStream process can deliver lighter, low cost electric vehicles. Altair ProductDesign has worked with GMD to analyse and test the safety performance of its iStream, composite material based vehicles.

Altair BUSolutions

Developing the World’s First Series Hydraulic Hybrid Bus

The Federal Transit Administration (FTA) requires modern transit bus systems to provide more efficient services across America. Currently, U.S. public bus transit authorities are subsidized to meet operating budgets with State and local subsidies exceeding $19 billion per year and Federal subsidies exceed $7 billion per year. The goal of the BUSolutions project is to design and manufacturer a new bus with improved fuel economy, lower emissions and a lower life cycle cost than today’s buses.

PBS Professional at NASA Ames Research Center

It takes a super workload management tool to power grid, cluster and on-demand computing environments for computational modeling and simulation applications at NASA.

Global Appliance Manufacturer Mabe Analyzes Spin Cycle with HyperWorks to Improve Washing Machines and Bring Them to Market Faster

Typically when engineers consider the most complex problems involving multi-body dynamics, hydrodynamics, and noise-vibration-harshness, they are focusing on the complexities of automobiles or aircraft. Design issues that can be just as challenging, however, impact every household’s laundry room. For companies like consumer goods manufacturer Mabe, simulation has helped them better solve product issues such as balance ring distortion, move products to market faster and reduce cost.

Daimler - Calculation of Optimal Damping Placement in a Vehicle Interior

One of the most difficult jobs of a NVH Analyst is to sift through a seemingly endless set of results and find the key conclusions that will improve a design. Different assumptions and different subsets of data can give very different conclusions. This paper compares acoustic results calculated for a Class 8 heavy duty truck cab to choose an optimal configuration of damping material. The design was evaluated for structure and air-borne inputs, but only structure-borne inputs are considered in this paper.

Airbus

A380 Weight Reduction through Optimization

Through collaborative partnerships with Altair in the UK, the software was developed to produce an innovative rib design, which resulted in an optimized weight saving over 500kg per aircraft. Exceptional team working has been an essential component in ensuring the total integration of design, manufacturing and supply chain capabilities.

Tallent Automotive

Customized Solutions to Reduce Chassis Mass by 25%

To meet the growing demands for lightweight, fuel efficient vehicles, Tallent Automotive required a more automated method to produce minimum mass sheet metal chassis components which took performance targets and manufacturing constraints into account.

OPEL

Improving Design Productivity through Automation

OPEL identified the design process of engine mount systems as a candidate for a process automation solution. As an objective, NVH engineers had to be able to generate input decks even without detailed load case information. Knowledge had to be captured and re-used in a standardized workflow. Automatic optimization and robustness analysis of the mount parameters had to be integrated into the process to quickly improve final product quality.

Medtronic

Reducing Medical Stent Stress by 71%

Medtronic designs and manufacturers medical devices used the world over. Traditionally, computer aided engineering (CAE) and virtual simulation were not fully utilized within the industry as the verification process for often microscopic components was too slow. When designing a new medical stent (an expandable mesh inserted into a patient's artery to keep it open) Medtronic wanted to improve the design and speed up the validation process. Altair ProductDesign worked closely with Medtronic’s own engineers to optimize the performance of the new stent.

Unilever

Optimizing Packaging Designs & Reducing Prototype Costs

To remain at the forefront of innovation within the male grooming market, Unilever, constantly looks for ways to differentiate their products from competitor offerings. For the Lynx (Axe) brand, Unilever needed to adopt a simulation and analysis approach when designing a new deodorant packaging concept and required a development partner to assist with the design and testing of the new can.

NASA

A Safer Landing with Water Impact Analysis

Using Altair’s own HyperWorks virtual simulation suite, Altair ProductDesign built an accurate finite element model of the module from CAD data supplied by NASA, as well as a section of water and air which matched the conditions from the lake used during the physical tests. The effect on the module’s structure during impact was simulated to gauge how well the results correlated with the physical tests. The results showed excellent correlation between the simulation and physical tests, identifying areas where the model, input parameters and meshing methods could be improved to give a more accurate prediction of the event.

Scania

Reducing the Development Cycle with Assembly Automation

European based heavy vehicles manufacturer, Scania, is known for its ability to deliver highly customized products. This concept creates a significant challenge for computer aided engineering (CAE) departments, as engineers must rapidly verify a number of different variants with finite element simulations. Therefore, automating the entire virtual model assembly process was a major goal for Scania. The process, which included tasks such as positioning hundreds of components, creating contact definitions and building part connections with pre-strained bolts, was time consuming and prone to error.

Heart Valve Analysis

Predicting Aortic Stenosis through Simulation Aortic valve Stenosis is a heart value disorder that narrows the aortic valve opening due to calcium build up in the leaflets. This prevents the valve from opening properly and obstructs the flow of blood causing the heart to work harder. Finite Element Analysis (FEA) has the potential to allow researchers to study the condition without the need for traditional physical testing. An efficient process was required to make this possible since modeling tissue behavior, back pressure, and the interaction between tissue and blood are highly complex challenges. Altair ProductDesign led this self funded project to improve the simulation and analysis of heart condition research.

Unilever

Customized Solutions to Reduce Packaging Waste

With increasing pressures on all manufacturers to reduce the environmental impact of their products, consumer goods giant, Unilever, needed a way to minimize the material used in its packaging while ensuring that it remained strong enough to withstand transportation loads and a variety of use conditions.

Applications of Advanced Composite Simulation and Design Optimization

Usage of fiber reinforced composite material entered an new era when leading aircraft OEMs took an unprecedented step to design and manufacture essentially full composite airframe for commercial airliners. Composite structures offer unmatched design potential as the laminate material properties can be tailored almost continuously throughout the structure. However, this increased design freedom also brings new challenges for the design process and software. Moreover, as a relatively new material, composite behaviors are more complex and less fully understood by design engineers. Therefore, reliable simulation for highly complex events like bird strike and ditching can play an important role in shortening the product design cycle. This paper showcases two area of CAE tools for composite applications. On advanced simulation, bird strike simulation with Altair RADIOSS [1] is demonstrated on an aircraft underbelly fairing. On design optimization, an airplane wing structure is designed using an innovative composite optimization process implemented in Altair OptiStruct [1-3]. OptiStruct has seen increasing adoption among aerospace OEMs, as demonstrated in the Bombardier application process described in this paper.

Scheduling Jobs onto Intel® Xeon Phi™ using PBS Professional

Working closely with Intel, Altair has ensured that PBS Professional supports the Intel® Xeon Phi™ architecture targeting high performance computing applications. This paper describes the basic and advanced configurations of PBS Professional for scheduling jobs onto Intel Xeon Phi devices.
PBS users: Download the toolkit to automate configuration of PBS for a Xeon Phi environment

Using HyperWorks to Generate Electrically Large Surface Meshes for Radar Cross Section or Antenna Placement Simulation

Radar Cross Section (RCS) and installed antenna placement are important parameters for aircraft designs. RCS is a measure of how detectable an object, such as an aircraft, is with radar. A large RCS indicates that an object, such as a jet aircraft, is easily detected.

SELEX Galileo used HyperWorks to generate arbitrarily large surface meshes, with defined electrical properties at the element level, for use with electromagnetic (EM) solvers to calculate either RCS of an aircraft or to determine where to place an antenna for optimum performance.

For this case study a fast-jet aircraft with approximately 100 million mesh elements was assessed for radar tracking and avoidance capabilities.

Simulation Streamlines Aircraft Door Development

The Eurocopter Group leverages analysis to cut design time and automate the process of developing safe aircraft closures.

By Michele Macchioni
Concept To Reality Summer/Fall 2011

Bird Strike Simulation Takes Flight

The increasing number of bird-plane impacts gives rise to new CAE methods to address aircraft safety.

By Robert Yancey
Concept To Reality Summer/Fall 2011

Structural Optimization Helps Launch Space Payloads

Aerospace company employs simulation software to reduce weight in the Launch Abort Manifold for the Orion Multi-Purpose Crew Vehicle.

By Blaine E. Phipps, Michael H. Young and Nathan G. Christensen
Concept To Reality Summer/Fall 2011

PBS Professional Utilizes Intel Cluster Checker to Validate the Health of an HPC Cluster

On clusters that are Intel® Cluster Ready (ICR) certified, PBS Professional can utilize Intel® Cluster Checker for gathering real-time information about the cluster at the very moment a job has been scheduled. Using this immediate feedback, PBS Professional can ensure that a job is only being executed on a cluster that has passed a check by Intel Cluster Checker.

Multi-disciplinary Optimization of Aero-structures

Learn about how HyperWorks can be used to perform multi-disciplinary analysis and optimization involving structural, thermal, dynamic, and fluid analysis.

Topology Optimisation of an Aerospace Part to be Produced by Additive Layer Manufacturing (ALM)

OptiStruct helped EADS achieve significant weight savings in the design of ALM (additive Layer Manufacturing) components.

Assystem Used HyperWorks CAE Simulation to Design, Simulate and Test Nuclear Encapsulation Vessels

Assystem is an international engineering and innovation consultancy group with a presence in 14 countries and 8500 employees. HyperMesh, RADIOSS and HyperStudy were used to design the safest possible nuclear encapsulation vessel for securely containing nuclear material. The designs not only achieved pressure vessel code PD5500 standards, but also helped Assystem gain external accreditation for the pressure vessel’s compliance to code. Download the Assystem Case Study

An Aerodynamic Study of Bicycle Wheel Performance Using CFD

A methodology is presented to apply CFD to study air flow around a rotating bicycle wheel in contact with the ground. The bicycle wheel studied here is an accurate geometrical representation of a commercial racing wheel (Zipp 404). Reynolds-Averaged Navier Stokes (RANS) and Delayed Detached Eddy Simulation (DDES) results are computed at a range of speeds and yaw angles commonly encountered by cyclists. Drag and side (or lift) forces are resolved and compare favorably to experimental results obtained from wind tunnel tests. Vertical forces acting on a rotating bicycle wheel are presented for the first time. A unique transition from downward to upward acting force is observed as the yaw angle is increased. Flow structures are identified and compared for different yaw angles. It is expected that a more complete comprehension of these results will lead to improvements in the performance and handling characteristics of bicycle racing wheels used by professional cyclists and triathletes.

A Comparative Aerodynamic Study of Commercial Bicycle Wheels Using CFD

A CFD methodology is used to study the performance of several commercial bicycle wheels over a range of speeds and yaw angles. The wheels studied in this work include the Rolf Sestriere, HED H3 TriSpoke, the Zipp 404, 808 and 1080 deep rim wheels and the Zipp Sub9 disc wheel. Wheels are modeled at speeds of 20mph and 30mph, in contact with the ground, using Reynolds-Averaged Navier Stokes (RANS). Drag, vertical and side (or lift) forces are reported for each wheel. Turning moments are also calculated using the resolved side forces to examine aspects of stability and maneuverability. Drag and side forces over the range of yaw angles studied compare favorably to experimental wind tunnel results. The previously reported unique transition from downward to upward acting vertical force on the Zipp 404 wheel for increasing yaw angles is observed for all deep rim wheels and the disc wheel studied here. Wheels were also modeled at a critical yaw angle of 10 degrees using Delayed Detached Eddy Simulation (DDES) to examine the transient aspects of flows around moving bicycle wheels. It is hoped that a more complete comprehension of these results will lead to improvements in performance, safety and control of bicycle racing wheels used by amateur and professional cyclists and triathletes.

A Practical Analysis of Unsteady Flow Around a Bicycle Wheel, Fork and Partial Frame Using CFD

CFD is used to study air flow around a rotating bicycle wheel in contact with the ground, extending previous ‘wheel-only’ work on this problem by including the fork, head tube, top tube, down tube, caliper and brake pads. Unsteady simulations, using a Delayed Detached Eddy Simulation (DDES) turbulence model, were run for 9 different wheel and front fork configurations, over 10 different operating conditions (5 yaw angles, repeated for two different speeds, commonly encountered by cyclists), resulting in 90 transient design points.

MIMOS Berhad Delivers HPC Across Malaysia with Cloud

In partnering with PBS Works, MIMOS Berhad brought onboard a strategic collaborator committed to help its clients overcome these limitations by deploying Altair's PBS Professional®, the industry leading commercial workload management and job scheduling solution.

MCE-5 DEVELOPMENT uses HyperWorks Suite to optimize engine performance

MCE-5 DEVELOPMENT is developing the MCE-5 VCRi variable compression ratio engine which reduces fuel consumption and CO2 emissions from 20% to 35%. The MCE-5 VCRi engine provides a concrete technological and commercial response to the environmental, energy and economic challenges faced by the automotive industry. The MCE-5 VCRi engine combines advantages of both Diesel and gasoline.

For more information on the MCE-5 VCRi project, please visit: www.VCR-i.com.

Improving NASA Altair Lunar Lander Design: Optimization Reduces Weight and Meets Design Requirements

Altair® OptiStruct® was used to provide conceptual design ideas necessary to reduce the Altair Lunar Lander Descent Module weight and meet specified design requirements not achieved in the baseline design.

Superior Industries Accelerates its Design Process With HyperWorks

Superior Industries was looking to identify a solution to aid in shortening the overall product design cycle through simulation. Altair HyperWorks, proved instrumental in automating some of the most tedious of tasks and dramatically impacted the design process.

Operational Numerical Weather Prediction Job Scheduling at the Petascale

Several operational numerical weather prediction (NWP) centers will approach a petaflop of peak performance by early 2012 presenting several system operation challenges. An evolution in system utilization strategies along with advanced scheduling technologies are needed to exploit these breakthroughs in computational speed while improving the Quality of Service (QoS) and system utilization rates. The Cray XE6™ supercomputer in conjunction with Altair PBS Professional® provides a rich scheduling environment designed to support and maximize the specific features of the Cray architecture.

Cleveland Golf Drives Product Innovation Through Simulation and Optimization Using HyperWorks

Much more goes into a golf club than simply wood, iron and graphite. To shape the performance, the distinctive appearance, the personalized feel and even the sound of the club striking the ball, manufacturers must precisely engineer every aspect of the design. Today, simulation-driven design has dramatically reduced development time for new golf clubs while allowing them to meet strict regulations more efficiently.

Getting the Right Design, Getting the Design Right

Conceptual design technologies impact product development.

By Alessandro Mazzardo
Concept To Reality Spring/Summer 2010

Forklift Manufacturer Cuts Pre-Processing Time in Half and Solves Stubborn Design Problems with Altair’s HyperWorks Suite

The main goal of NMHG and Chief Engineer Dr. Pedro Bastias was to virtually design, test and evaluate each product before any physical prototypes are made. Using HyperWorks, NMHG is saving time, cutting costs and identifying new ways to resolve stubborn engineering problems.

An Integrated Approach to Workload and Cluster Management: The HP CMU PBS Professional Connector

This paper describes the integration between Altair’s PBS Professional and HP’s Insight Cluster Management Utility (CMU), explaining how the concept of a “connector “unites these two tools to simplify cluster setup and job execution, and providing instructions for performing key PBS Professional tasks within Insight CMU. Click here to access more CMU resources.

Scheduling Jobs onto NVIDIA Tesla GPU Computing Processors using PBS Professional

With the advent of the Graphical Processing Unit (GPU) as a general-purpose computing unit, more and more customers are moving towards GPU-based clusters to run their scientific and engineering applications. This model allows users to use a CPU and GPU together in a heterogeneous computing model, where the sequential part of the application runs on the CPU and the computationally-intensive part runs on the GPU.

HyperWorks Improves Development Processes in Automotive Industry

In 2008 PWO Germany (Progress-Werk Oberkirch AG) had to develop and produce a new steel made automotive cross car beam (CCB) for the dash board of a new car. PWO received the CAD model, the design space definition and other pre-defined standards of the component from the customer and developed and produced the fitting cross beam based on this information. PWO used the HyperWorks Suite to develop the component. HyperMesh was used to transfer the CAD model into a FEA model, which was then used to run dedicated analysis and simulation tasks. To fulfill the requirements for crash and modal analysis, the company used OptiStruct to optimize the component, RADIOSS and other external solver to run the calculations and HyperView for the post processing. HyperForm was used to check the production feasibility of the individual components and for metal forming simulation tasks. It was important for PWO to have a software suite available that could cover all simulation tasks within one graphical user interface and licensing system.

HyperWorks Improves Development Processes at Automotive Consultancy

csi entwicklungstechnik GmbH, a leading engineering service provider for the automotive industry has enhanced its simulation power with Altair‘s HyperWorks Suite. The company consolidated its CAE tools and now uses the large scale of HyperWorks, which offers a solution for almost every application needed in modern product development. csi will apply OptiStruct for optimization tasks, MotionView and MotionSolve for multi-body applications, and HyperMesh for pre-processing tasks. Additionally HyperShape/CATIA will be used for CAD integrated optimization and weight reduction.

Improving Efficiency and Accuracy at Eaton Aerospace with HyperWorks

The Hydraulic Systems Division of Eaton’s Aerospace Group designs hydraulic components and systems on many of the world’s military and commercial aircraft in the skies today. Eaton uses Altair HyperWorks within it's simulation processes to improve solution efficiency and accuracy.

Cutting physical testing costs by 95% with HyperWorks

WJH Engineering Consultants provides finite-element analysis and design for many of America’s largest developers of medical devices. Company President, Jim Harrison, works directly with engineers at companies producing medical devices and with doctors to understand the clinical application of these products, including any anatomical loads or displacements that should be incorporated into their design.

HyperWorks Accelerates Design Process and Development of Diesel Export Locomotive at RDSO

Altair HyperWorks helped RDSO reduce development time and optimize structural characteristics of the diesel export locomotive. Physical testing on these large, complex structures had to be limited. Using HyperMesh/HyperView pre/post processing capabilities, RDSO were able to simulate design and verify that engineering specifications are being met and help validate the final design.

Airline Seat Testing Soars to New Heights

French manufacturer Sicma Aero Seat SA relies on virtual dynamic testing in the evaluation of its custom aircraft seats.

Simulation and Analysis Investments Help Drive PLM Market Growth

The need to improve designs and reduce the cost of prototyping is fueling increased investments in simulation and analysis tools.

HyperWorks helps to improve development processes at F.S. Fehrer Automotive GmbH

F.S. Fehrer Automotive GmbH in Kitzingen is using the HyperWorks Suite to develop seat parts, form cushions and complete vehicle interior systems. The engineers use HyperWorks and especially RADIOSS for static and modal analysis. The seat of a vehicle is the direct and closest connection of the passenger with the automobile. Design and seating comfort play an important role in personalizing the vehicle model and convey the feeling of quality to the passenger. In addition, safety and variability are vital aspects for the development of interior parts of a vehicle.

HyperWorks Helps to Develop Race-Winning Yacht for Volvo Ocean Race 2009

The CAE suite HyperWorks has been used by ABstructures to structurally design and optimize the winning yacht in the Volvo Ocean Race, Ericsson 4. The yacht, skippered by Torben Grael, claimed victory in the Volvo Ocean Race on June 27, 2009 in St. Petersburg, Russia, after 8 months and more than 37,000 nautical miles sailed around the world under the harshest conditions.

A Comprehensive Process for Composite Design Optimisation

Composite structures offer unmatched design potential as laminate material properties can be tailored almost continuously throughout the structure. Moreover, composite laminate can be manufactured to fit the ideal shape of a structure for aerodynamic and other performances. However, this increased design freedom also brings new challenges for the design process and software. It is shown in this paper that optimization technology is well suited to exploit the potentials that composite materials offer.

Innovative Design Analysis Solutions to Handle the Complexity of Modern Structures

This is a press article published by CAD User Magazine in June 2009. "The signature buildings that architects love to put up these days might be designed to enhance the architect’s reputation along with the skyline of the client city, but their increasing complexities of shape pose significant challenges for the builders. In the first instance such large projects are never single sourced. They rely on close integration between a number of partners, each addressing significant issues. Secondly, they come with demands for shorter development times with increased pressure to reduce engineering costs (engineering, because of the complexity of the projects, being a major cost element)."

Rapid Airbag Folding Technique for Side Curtain Airbag

TECOSIM has developed techniques which can shorten the folding & packaging process time to a few hours and still achieve the essential airbag deployment performance. We will present methods which rapidly fold a free mesh and allow for rapid shape changes for a detailed folded model. These methods can significantly reduce the turnaround time to incorporate design changes into the working CAE model for side impact and OOP [Out Of Position] studies. This technology can integrate airbag development further into the virtual world to allow ‘CAE led’ design of airbag profiles, chambers and seam lines to be established early in the design phase and establish a fully folded deployable airbag for all virtual phases.

The Use of MBD Modelling Techniques in the Design and Development of a Suspension System

This paper describes the use of Multi-body Dynamics (MBD) modelling techniques in the design and development of a suspension system for a novel autonomous vehicle. The general approach and philosophy is described, whereby MBD techniques are used in conjunction with an independent (parametric) whole vehicle handling simulation. This is supplemented with examples, showing how MotionSolve was used (in tandem with CarSim) to develop the suspension elasto-kinematic geometric properties to meet specific cascaded targets, to optimise a weighing strategy, to predict forces under a variety of quasi-static and dynamic loads, and to estimate response to track inputs.

Hawk T Mk2 - Arrestor Barrier (BAN MK2) Engagement Analysis

As the UK Ministry of Defence (MoD) Design Authority for Aircraft Arrestor Barrier Nets, AmSafe products are used to stop aircraft from over-running the end of the runway. The British Arrestor Net (BAN) Mk2 is suspended across the runway over-run area by two electrically driven stanchions and raised or lowered by remote control from the Air Traffic Control tower. This paper describes the process and results of a FE analysis of the engagement of the Hawk T Mk2 aircraft into a Type A Barrier (BAN Mk2). The analysis was performed using RADIOSS, an advanced non-linear explicit Finite Element solver.

HUMOS - An FE Model for Advanced Safety and Comfort Assessments

Biomechanics modelling is becoming increasingly accepted as a tool for enhance assessment of vehicle safety, in particular in the field of injury assessment and virtual testing. Firstly, a generic RADIOSS model for safety applications (HUMOS2) is presented and applications are demonstrated. Important tools associated with the scaling, and positioning of the model is also described. Secondly, an innovative model for scaling of human organs (individualization) is presented. The method which employs optimization techniques, identifies critical (optimal) anatomical control points which allow for a best scaled model of the HUMOS2 representing an individual. Finally, some remaining challenges for future human models are discussed and solution paths are described.

Automotive Modal Testing Support and CAE Correlation Using Altair HyperWorks

To derive the natural frequencies and mode shapes of a given structure, the test Engineer has to decide on excitation positions that will efficiently excite all the modes of the structure in the frequency range of interest. Excitation positions are usually decided upon from experience or trial and error methods which can be time consuming and still not capture all of the modes in the selected frequency range. Using Altair HyperStudy and Radioss (bulk), Pre-test CAE analysis has been carried out to identify effective excitation positions before the commencement of modal testing, thereby significantly reducing pre-test lab time.

The Application of Process Automation and Optimisation in the Rapid Development of New Passenger Vehicles at SAIC Motor

As a relatively young automotive company, SAIC Motor has drawn on the expertise of its UK Technical Centre to help in its objective to bring a new range of vehicles to market in an aggressive time frame. CAE has formed an integral part in doing this and the UK technical centre has worked closely with Altair Product Design amongst others to utilise its Engineers’ skills as well as the Hyperworks suite of software. The paper aims to showcase what has been achieved to date, on the Roewe 550 medium car programme - currently on sale in China - and on another current vehicle programme, where processes have been developed further. Several interesting optimisation examples are highlighted in the development of the body structure as well as some key process improvement methodologies which have been jointly developed between SAIC and Altair to streamline the design process.

Delivering Innovation and Intelligence in Product Design

Packaging designers must constantly inject innovations to attract consumers in a constantly evolving and highly competitive market. Keeping ahead of the competition by bringing new and exciting products to market faster whilst maintaining quality, presents a major engineering challenge. A new packaging development process is described, which introduces advanced automated simulation and optimization technology right from the concept development phase. Detailed predictions of primary, secondary and tertiary packaging performance are made possible through use of advanced simulation technology. Design optimization is then employed using the modelling as a virtual testing ground for design variants. The approach provides clear design direction, an opportunity for wider experimentation, helps to improve performance and reduces uncertainty in the development process.

Evolutionary Design in Chassis Technology

This paper details the use of the Thyssenkrupp eDICT process for the design of sheet metal chassis components. eDICT (evolutionary design in chassis technology) is an innovative structured process flow for the design of optimal structures. eDICT uses the optimisation capability of Optistruct with a set of custom tools to guide and translate a design into a production feasible sheet metal solution. Fundamentally it reverses the usual design loop of CAD first then CAE assessment. The function is used to determine the design and the form follows. On recent projects eDICT has produced 25% mass reductions compared to the current series design. eDICT is also able to reduce development times and resource with an efficient solution production right from the outset.

Fast Tracking Rail Vehicle Design

Bombardier Transportation UK offers one of the most comprehensive and diverse rail vehicle portfolios in the world. The strategy is one of continuous development that provides the most effective and cost-efficient rail solutions for today and the future. A key ingredient is the use of Altair HyperWorks enterprise computer aided engineering (CAE) solution. Altair's technology is now present at every stage of the design process and has increased the efficiency of the product development process. The paper details how Altair tools have been used to generate Finite Element (FE) models of carbodies, bogies and secondary structures in reduced time scales. Significant weight and cost savings are achieved through structural optimisation of components such as large steel castings, aluminium extrusions and steel fabricated structures which are subjected to linear static, fatigue and abuse loading. Automated post processing facilitates the interpretation of results and the writing of detailed official reports.

Targeting Composite Wing Performance – Optimising the Composite Lay-Up Design

This paper shows how Altair OptiStruct, part of the HyperWorks suite, is used to provide a complete solution when designing with laminated composites, taking the design through concept stages to producing the final ply lay-up sequence. The technology is applied to the design of a laminated wing cover to produce a mass optimised design which meets the requested structural targets.

Composite Optimisation of a Formula One Front Wing

This paper will show the application of a 3-stage approach to designing the optimum composite structure for a front wing on a Formula One car using Altair OptiStruct 9.0 Continual development of aerodynamic components is normal practice in the world of Formula One and the time taken to respond is paramount if a team is to be competitive.

Application of Optimisation Tools to the Design of Advanced Carbon Fibre Bicycle: FACTOR 001

FACTOR 001 is the result of a creative project by BERU f1systems to explore the transfer of design approaches, technology and materials from Formula One to a groundbreaking training bicycle. The design brief did not require the bicycle to comply with existing technical regulations, which resulted in great freedom during the design process. This paper details how OptiStruct Optimisation tools were used to help generate efficient lightweight solutions for the design of complex carbon fibre components. Free-size optimisation was used to generate laminate boundaries, ply thicknesses and fibre directions, which met stress and displacement requirements. Physical testing carried out on manufactured parts highlighted the accuracy of the FE models and demonstrated the advantages of incorporating OptiStruct Optimisation tools in the design process.

The CAE Driven Safety Development Process of the New Ford Fiesta

The new Fiesta is about premium feel of a larger car, delivers a new level of safety, driving quality and efficiency. The new Fiesta will be a great contribution towards sustainability and cost effective motoring. The first thing to notice is the design, but the vehicle performance and body structure attribute behaviour are the specific highlights to point out in this presentation. The attribute performance is not based on coincidences; the performance is a result of state of the art engineering work. Especially the safety performance in EuroNCAP.

Fighting Knee Pain with Finite Element Modeling

The Musculoskeletal Biomechanics Research Laboratory at USC, is using HyperWorks to investigate why so many people are incapacitated by knee pain when others are not. This is a tough, intractable issue for people with arthritic knees since there is no cure for arthritis today. Early detection can help and is the focus of USC’s work. (HyperMesh is used to create finite element models to analyze stress on the cartilage of the joint.)

Altair® HyperWorks® and Product Design Consultation at Force Protection

At Force Protection Inc. Altair HyperWorks and Product Design work together to increase CAE throughput and improve survivability prediction in a new class of military vehicles built for unconventional warfare.

Application of HyperWorks in the Subsea Oil and Gas Industry

The volatile nature of deep sea installations presents a difficult challenge for engineers to create products which can withstand extremely high pressures in a variety of weather conditions. Duco selected HyperWorks to model subsea umbilicals, resulting in improvements to their analysis productivity allowing models to be constructed faster than before.

Simultaneous Robust and Design Optimization of a Knee Bolster at Jaguar & Land Rover

Jaguar Cars needed a practical process to simultaneously optimize the robustness of a design and its performance. Altair HyperStudy is applied to the design of an automotive knee bolster system whereby the design is optimized to account for different sized occupants, impact locations, material variation and manufacturing variation.

Injecting Innovation in Performance Engine Design with Altair HyperWorks

MAHLE Powertrain outsourced model generation of large complex parts such as heads and blocks to low cost countries to ensure sufficient mesh quality could be produced for their automotive engine designs. The third party’s improved capabilities proved valuable but ultimately MAHLE Powertrain wished to bring the process back in-house to maintain control and reduce external expenditure. To achieve this a new pre and post-processing solution was needed. HyperWorks was selected as the new platform as it afforded the required increase in productivity through its automatic mesh creation and batch processes.

HyperWorks at B/E Aerospace: Lighter, Safer Seats for Airline Passengers

When you settle in for a flight on a major airline, you are probably in a seat and surrounded by equipment designed and built by B/E Aerospace. With design and manufacturing facilities across the globe, B/E Aerospace is the leading manufacturer of cabin interior products for commercial and private passenger aircraft. One of B/E Aerospace’s leading products is its line of commercial and business airline seats. These seats are engineered and tested at its Commercial Airplane Products Group in Winston-Salem, North Carolina.

Multi-Disciplinary Design of an Aircraft Landing Gear with Altair HyperWorks

NAFEMS invited several software vendors to a roundtable in 2007 to demonstrate their best processes in the design of a realistic aircraft landing gear system. (Figure 1). The emphasis was on simulation processes that can make problem solving innovative, accurate and efficient. This paper explains the processes followed by engineers at Altair and should help increase awareness regarding the powerful tools available for solving realistic design problems.

PBS Professional at Chrysler: Managing 250,000 Simulations a Year

The people who design cars and trucks at Chrysler have been using computer simulation tools since the 1980s. Since those early beginnings, the use of computer-aided engineering and finite element analysis has expanded to become the powerhouse enabler for Chrysler designers that it is today.

Sheet Metal Transfer Dynamic Analysis Using Altair HyperWorks at Ford Motor Company

By applying Altair HyperWorks simulation technology, Ford Motor Company has been capable to simulate the dynamic behavior of their new generation of crossbar transfer presses. Altair solutions have been adopted to optimize the automation tooling design and the transfer motion operational parameters.

Managing 30 Teraflops of Compute Power: PBS Professional at Italy’s CILEA Consortium

With 30 teraflops of peak computing power, it has ranked as high as 135th among the Top 500 high performance computing centers. PBS Professional keeps CILEA’s processors humming.

OptiStruct Technology Application in Early Concept Design Stage Enables Weight Reduction of Cast and Forged Parts

Using Altair OptiStruct, India based Ashok Leyland was able to reduce cost and improve reliability of the components in their stride towards design an development of innovative, optimal and robust design solutions. Leveraging OptiStruct's technology was able to take quick and reliable design directions on the track rod lever.

OptiStruct Cuts Development Time to Design a Light Weight and More Durable Window Regulator Lift Plate at ArvinMeritor

Using Altair OptiStruct, ArvinMeritor was able to design a lighter weight window regulator lift plate which eased assembly. The new snap-fit design reduced the material compared to original design, without sacrificing performance and durability.

HyperForm Sheet Metal Forming Solution Provides Yield Improvement of Wheel Housing and Wheel Arch

Using Altair HyperForm, Mark Auto was able to significantly improve the material utilization for their existing production dies. Mark Auto re-designed two existing dies for wheel arch an wheel housing and was able to dramatically reduce material scrap with minimum rework in their tools while not compromising on component quality.

Biomedical Research at the Scripps Clinic: Modeling Orthopedic Implants with Altair HyperWorks

Every year, countless people — regardless of their age or level of physical activity — begin to experience the effects of osteoarthritis, a degenerative joint disease. As we age, the cartilage that cushions the joints begins to deteriorate. The head of the adjacent bones begin to break down from the friction, causing pain in the joint. When the condition worsens and non- surgical remedies are exhausted, surgeons may recommend joint replacement. Typically, titanium alloy implants are lined with plastics that act as cartilage and are fixed in place with cement or screws by the surgeon. The implants can give patients a new lease on life, dramatically reducing pain and improving mobility. However, questions naturally arise in the patient’s mind: How much range of motion will I have in the new joint? How much strength will I recover? And how long will the new joint last?

From Incremental Change to Full Design/Validation Leap: A Multidisciplinary Approach to Optimize Safety and Crash Performance

Heavy-duty mining trucks at Hitachi are designed to meet ISO ROPS and FOPS safety requirements, while structures must be as lightweight as possible. The presentation will discuss Hitachi’s design and simulation approach, which consists of an integrated multidisciplinary analysis process. Dynamic analyses, multibody dynamics simulations, including flexible bodies and dynamic simulations are methods applied to optimize performance and vehicle safety. The author will present examples such as the optimization of a trolley support structure, a kinematics model of a 100-ton truck and the analysis of a trailing arm. Finally, the author will share his thoughts on the important subject of how simulation can better impact the design.

PBS Professional at National Institute of Health

Twenty-seven institutes and centers make up the National Institutes of Health. Many of their acronyms, listed on the NIH website (nih.gov), can be as mysterious as hieroglyphics: NHGRI, NIGMS, NIAMS. Others, such as NCI (National Cancer Institute) and NIMH (National Institute of Mental Health) are familiar to most of us. By any name or acronym, this cluster of organizations in Bethesda, Maryland is a major force in health sciences research.

Altair HyperWorks Helps Joe Gibbs Racing

Using OptiStruct from the Altair HyperWorks computer-aided engineering (CAE) suite of software tools, Joe Gibbs Racing was able to significantly redistribute vehicle mass and improve ride handling characteristics to design a more competitive race car.

Driving Million Dollar Savings at Ford using Structural Optimisation

The automotive business is a very competitive industry and in today’s markets, leading manufacturers are keen to find ways of reducing costs without compromising either quality or performance. This paper will cover the process of applying OptiStruct software to the re-development of a high volume and high cost plastic PAS (Power Assisted Steering) pump bracket into a much cheaper aluminium alternative. The outcome of this was a lighter, stiffer and cheaper replacement bracket that had the potential, based on the current production engine volumes, to save Ford Motor Company over $1.1 million a year.

Topology Optimization of Aircraft Wing Box Ribs

This paper considers the application of conventional energy based topology optimization methods for design of aircraft wing box ribs. Compared to standard topology optimization work undertaken at Airbus, the topology optimization of wing box ribs posed several additional challenges, mainly due to the wing box ribs being embedded in a redundant wing box structure. Several approaches to solving this problem have been investigated and are being reported as part of this paper, including a global analysis/optimization approach and two local analysis/optimization approaches.

Optimisation Techniques Leading the Development of a Steering Wheel

The early application of structural optimisation in the design of automotive components streamlines the design process and at the same time significantly increases the potential of the final design achieving maximum performance. This paper details the use of optimisation techniques during the development of a steering wheel, to generate an optimised design for cross attribute performance. This was completed in the Altair HyperWorks environment as Altair HyperMesh combined with Altair OptiStruct enables the creation of a parametric model with a multitude of design variables (i.e. size, shape, displacement, stress and frequency) in order to satisfy NVH, manufacturability, durability and crash targets.

Balancing Manufacturability and Optimal Structural Performance for Laminate Composites through a Genetic Algorithm

This paper details the application of a specialised genetic algorithm to reduce the mass of a laminated composite wing rib. The genetic algorithm has been customised specifically to optimise the performance of polymer-laminated composites. The technology allows the mass to be minimized by the removal or addition of plies of various discrete orientations whilst satisfying the structural intent of the component. For the rib structure assessed, the structural constraints consist of limits placed on the displacement, stress (i.e. ply failure index) and buckling behaviour.

Design Optimization Applied to the Development of an Oilfield Bistable Expandable Sand Screen

This paper will cover the design, development, and testing of an expandable sand screen using bistable cell technology. In addition, the design and development of the proprietary expandable connection will be presented. The testing presented covers a wide range of structural integrity, expansion, sand retention, mudflow, and geomechanical tests performed on the screen, base pipe, and connection.

The Automatic Calibration and Robustness Assessment of a Complex Engineering Component: Airbag Inflation

This paper describes the application of new technology to achieve automatic calibration and assess the robustness of an airbag inflation model. Calibration of the kinematic response of the airbag is achieved by defining the activity as an optimisation problem. The objective is to minimise the error between the experimental test and numerical simulation curves. Once calibration has been achieved, a unique robustness assessment is performed, which utilises the optimisation technology used in the calibration exercise.

Predicting the Dynamics of Mechanical Systems in the Automotive Industry

The application of CAE tools to help design and develop mechanical systems in the automotive industry is a widely accepted practice. This paper highlights various applications of these tools, in particular, the application of MotionView and MotionSolve from Altair Engineering. Each example demonstrates the advantages of using such tools to work rapidly and seamlessly within the general design process. This results in the development of innovative designs to face challenging problems in a short time frame.

The Complete Package: Applying Altair's Technology Process to Reusable Packaging Design

This paper demonstrates the flexibility that Altair technology provides throughout the design process with tools applicable to all stages. An overview of the LINPAC design process incorporating Altair's technology is given together with examples of how and which tools are being implemented. The limitations of the traditional LINPAC approach and the use of Altair's tools is demonstrated through the use of a detailed example; without the use of Altair technology, more iterations in expensive tool modifications would have been required to achieve a satisfactory design without introducing unacceptable costs.

A New Approach to Optimizing the Clean Side Air Duct Using CFD Techniques

An integrated approach to CFD design optimization is proposed. It consists of taking an initial CAD design, meshing it using HyperMesh, analysing it using Star-CD, parameterising its key features using HyperMorph, and then shape optimizing it using HyperStudy. This approach has been applied here to the shape optimization of the compressor inlet duct of a turbo system.

Delivering World Class Chassis Design

This paper details the extensive use of CAE optimisation technology at ThyssenKrupp Automotive Tallent Chassis Ltd (TKA). There are a number of trends in the automotive business that are presenting great challenges, these include severe cost pressures from OEM’s, platform commonisation and reduced vehicle development cycle time. The use of optimisation is critical for TKA to maintain its competitiveness, this paper deals with more advanced concepts of optimisation by extending into the severely non-linear region of analysis types.

A Holistic Virtual Design Process Applied to the Development of an Innovative Child Seat Concept

There is a need to minimise product development costs and provide efficient design solutions to maintain competitiveness, so increasingly companies in the Child Restraint System (CRS) industry are turning to Computer Aided Engineering (CAE) to enhance the design and development for their products. Graco has worked with Altair Engineering to develop a group 1 CRS using an advanced CAE driven design process. The design process introduces a number of key phases in the design cycle each of which are positioned to maximize the efficiency of the structure and reduce or remove the cost involved in a traditional, iterative ‘test it and see’ approach.

Design Development of a New Consumer Personal Care Product Pack Driven by Optimization

Packaging designers must constantly inject innovations to attract consumers in a constantly evolving and highly competitive market. Keeping ahead of the competition by bringing new and exciting products to market fast, and at the necessary level of quality, presents a major engineering challenge. A new deodorant pack development process is described, which introduces advanced simulation and optimization technology into the concept development phase. Detailed predictions of interacting parts in a mechanism assembly are made possible through use of advanced simulation technology. Design optimization is then employed using the modelling as a virtual testing ground for design variants. The approach provides clear design direction and helps to improve performance and reduce uncertainty in the development process.

Simulating the Suspension Response of a High Performance Sports Car

The use of CAE software tools as part of the design process for mechanical systems in the automotive industry is now commonplace. This paper highlights the use of Altair HyperWorks to assess and then optimize the performance of a McLaren Automotive front suspension system. The tools MotionView and MotionSolve are used to build the model and then carry out initial assessments of kinematics and compliance characteristics. Altair HyperStudy is then used to optimize the position of the geometric hard points and compliant bush rates in order to meet desired suspension targets. The application of this technology to front suspension design enables McLaren Automotive to dramatically reduce development time.

HyperForm Improves Accuracy and Robustness of Tool Design and Manufacturing Process at Summit Auto Body (SAB)

HyperForm Improves Accuracy and Robustness of Tool Design and Manufacturing Process at Summit Auto Body (SAB) Leveraging HyperForm’s sheet metal forming solution, SAB designed the validation process and press tool design covering the vital areas of virtual prototyping/testing, which, in turn, reduced the time-consuming manual process drastically.

HyperWorks Process Manager Delivers Productivity and Quality Gains to Chassis Design Process

Using Altair HyperWorks Process Manager, M&M was able to implement best practices through standardization of CAE processes and minimize CAE analysis set-up time. Automated post-processing enabled through Process Manager facilitated a 40% reduction in time when compared with the manual practice of post-processing.

HyperWorks Cuts Design and Prototyping Costs for Truck Cabin Development and Testing

Using HyperWorks, Eicher Motors was able to significantly reduce the number of physical tests during the development process of their truck cabins. The numerical simulation helped in predicting the failure mode and estimating the stress level in the individual components in elastic as well as plastic zone prior to the first physical test.

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