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High Performance Computing Speeds-up Optimization Processes for Tailor Rolled Blanks at Mubea

OEMs and suppliers include every possible technique to support lightweighting in the automotive industry. It is common to use optimization techniques in order to identify and tab existing lightweight potentials as well as design tailor rolled components in a vehicle, the design optimization of which is normally based on crash simulations. Due to the large size of these simulations, a single run can take 1 to 12 hours. To conduct all the simulation runs needed for assessment and evaluation of different design concepts, the use of HPC is necessary. HWUL- VA was able to reduce the turnaround time for a lightweight study significantly at Mubea.

OptiStruct is 17x faster with the latest Dell Precision Workstation

The reduction of run times up to 17X is a direct result of more powerful hardware and the more advanced algorithms in Altair’s latest software releases.

Introduction to OptiStruct

OptiStruct is an industry proven, modern structural analysis solver for linear and nonlinear problems under static and dynamic loadings. It is the market-leading solution for structural design and optimization.

Introduction to RADIOSS

RADIOSS is a leading structural analysis solver for highly non-linear problems under dynamic loadings. It is used across all industries worldwide to improve the crashworthiness, safety, and manufacturability of structural designs.

Introduction to MotionSolve

MotionSolve can accurately simulate any mechanical system to predict forces, kinematics and dynamics of motion. The mechanical system may consist of rigid and structurally flexible bodies connected by various kinds of kinematic constraints and flexible connectors. Environmental forces and motion excitations drive the motion of the entire system.

Using Analytical Approach with Finite Element Analysis for Coupling Magnetic and Thermal Analysis for Motors

Thermal analysis is a key factor when designing motors. We propose to link the studies of electromagnetic and thermal aspects in transient application with Finite Element Method (FEM) to represent the thermal state of motor with higher accuracy. As electromagnetic response time is different of thermal response time, an original method is used for extracting average values on one magnetic period of losses (Joule and iron losses), and to use them as input for the transient thermal analysis. So, the temperature in different parts of the motor is extracted, and brought back as input for the next electromagnetic computation.

Study the Influence of Air-gap Variation on Axial Forces in Axial Flux Permanent Magnet Motor Using 3D-FEM

This paper describes the effect of air-gap variation on performance of a 28 pole axial flux permanent magnet motor (AFPM) with concentrated stator winding. The AFPM is modeled using three-dimensional finite-element method. This model includes all geometrical and physical characteristics of the machine components.

Numerical Modeling and Experimental Analysis of the Magnetic Noise of the Single-Phase Inverter-Fed Permanent Split-Capacitor Motor_Andrei NEGOITA_OPTIM

Abstract- The paper presents a FEM approach for studying the influence of the capacitor value on the magnetic noise of a network and inverter-fed permanent split-capacitor induction motor. A 4 pole, 24 stator slots and 30 rotor slots, induction motor is modeled under Flux2D Finite Element software in order to determine the amplitude and frequency spectrum of the magnetic forces acting on the stator. The effects of the inverter supply are taken into account by coupling Flux2D with Matlab/Simulink. The results are compared with those obtained from noise measurements performed on the studied motor.

Analyze Design and Control Aspects of Linear Machines Using Co-simulation

This research work describes the permanent magnet linear machines, their characteristics, control and applications. It aims to develop a linear machine model in finite element based software, Flux2D. The Finte Element Method (FEM) model consists of 8 poles and 9 slots where periodicity of poles is used to simulate inifinite travel length. The no-load and nominal load conditions are also simulated to validate the performance of the model. At no-load, the cogging force is simulated and is found to be 1.1N

Low Frequency EMC Analysis of Power Systems and Equipments

Presentation slides by Enrico Vialardi

3D Calculation and Modeling of Eddy Current Losses in a Large Power Transformer

Elimination of hot spots and reduction of eddy current losses in structural parts is one of the important constituents of transformer design. In this work, the eddy current losses in the clamping frame, transformer tank and electromagnetic shielding are calculated using a 3D finite element method. The clamping frame, transformer tank and electromagnetic shielding are modeled by surface impedance method. The paper analyses the effects of electromagnetic shielding and magnetic shunts on the eddy current loss reduction in the transformer tank.

Influence of Discrete Inductance Curves on the Simulation of Round Rotor Generator Using Coupled Circuit Method

This paper presents a study on the influence of the discretisation of the inductance curves on a detailed coupled circuit model of a synchronous generator with a damper winding and search coils. The self and mutual inductances of all coupled circuit are computed in magnetostatic with a 2D finite-element method (FEM) for different rotor positions.

Investigation of Electromagnetic and Thermal Behavior During Fast Dynamics in a PMSM Flux 2D/3D and Motor-CAD Simulation

2013 Flux Conference Presentation

Hall Effect Magnetic Sensors Design for Automotive Application

Samir GUERBAOUI – R&D Engineering

Transverse Flux Induction Heating of Magnetic Non Linear Sheets

FLUX Conference 2013 Presentation

Design Optimization of Traction Motors for EV Applications

Increasing concerns on energy security and environmental pollution by fossil fuel engines have pushed significant research in electric vehicles (EVs). The requirements for traction electrification are highly demanding in terms of efficiency, torque and power density, wid

Cal Poly Pomona Uses HyperWorks to Design a Winning Formula SAE Racecar

Cal Poly Pomona applies HyperWorks to optimize the design of a new wheel shell and analyze laminates for a SAE Formula student racecar.

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Analysis of Hybrid Motor and Drive for Automotive Application

Flux Conference 2012 Presentation

Design of Permanent Magnet Axial Flux High Power  Wind Turbines Generators (MW range)

Flux Conference 2012 Presentation

Flux API in Induction Heating Applications

2014 FLux Conference Presentation

Enhancing Surface-breaking Flaw Detection by Induction Thermography Using Flux

2014 Flux Conference Presentation

Reluctance Synchronous Motor Optimization

2014 Flux Conference Presentation

FEM Simulation Tool for Electromagnetic NDT System in Different Inspection Situation and Visualization Platform

Dr. Yasmine GABI Dr. Bernd Wolter Dr. Olivier Martins Andreas Gerbershagen

Actuator Design

For a fine design and analysis of any actuator (voice coil, electromagnet, protection relay…), Flux package features many tools to speed up the simulation and get the most accurate results, for both electromagnetic and thermal computations:

Heat Treatment Simulation

As a leader in induction heating simulation for more than 20 years, Flux has developed numerous formulations and tools to precisely model inductive, conductive and dielectric heat treatment.

PSA Groupe Discusses the Simulation of Squeak & Rattle Noise in its Vehicles

In this interview, Sebastien Gourg, CAE Methods, Expertise and Support Engineer from PSA Groupe gives us insight into his experience of working with Altair ProductDesign during the implementation and customization of the Squeak and Rattle Director (SnRD). The SnRD is used within PSA vehicle development programs today to help to quickly identify and eradicate unwanted noise from interiors, while cutting down the need for costly physical testing.

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Temperature Prediction And Thermal Management For Composite Magnetic Controllers Of Induction Coils

ABSTRACT. Temperature control of magnetic controllers (concentrators, cores, shields, shunts) is an essential part of the induction coil design. Prediction and study of the coil copper have been described in a presentation “Influence of Cooling Conditions on Induction Coil Copper Temperatures” (V. Nemkov, R. Goldstein) [1]. That study was made using Flux 2D computer simulation program.

EMC Modeling of an Industrial Variable Speed Drive With an Adapted PEEC Method

This paper presents an adapted partial element equivalent circuit (PEEC)-based methodology applied to the modeling of interconnections of power electronics devices. Although this method is already well known, the originality of this work is its use to model a device presenting an industrial complexity.

Analysis of a Tubular PM Motor with Integrated Contactless Energy Transfer

Flux Conference 2012 - 18 October 2012

Manufacturing Chain Modeling with Virfac Using HyperMesh

This webinar will be about a Virfac® modeling of an entire manufacturing chain consisting of a fusion welding stage followed by machining and heat treatment stages on a steel workpiece.

Coupling Insight+ with NVH Director to Enable Subjective Evaluation of Simulation Results

This webinar will demonstrate the workflow between NVH Director (NVHD) and Insight+ for interactive, subjective evaluation of sound and vibration in the context of full vehicle NVH. It will include worked examples to demonstrate use cases.

Inspired by Nature: Electric Motorcycle goes 3D - Combining Topology Optimization, New Materials, and Additive Manufacturing in the Development of the Airbus APWorks Light Rider Results in a Revolutionary Lightweight Design

The Airbus APWorks Light Rider is the world's first 3D printed motorcycle prototype. Altair OptiStruct® was used for inspiration of its organic structure. Using additive manufacturing, a simulation-driven design process approach and topology optimization during the process achieved optimum lightweight design.

CADdoctor Case Study: Arkal Automotive

Arkal Automotive Optimizes FEA Data Creation Workflow with HyperMesh and CADdoctor.

MBD Series: Why and How With Altair's Technology

First out of 6 multi-body dynamics webinars presented by Rajiv Rampalli. He is giving an overview over Altairs solutions and provides many examples and talks about how customers are using Altair solutions for their MBD needs.

Close Hauled with Hyperworks - Student Team of Politecnico di Torino Sails Away from Competition

The project focused on the design and construction of a skiff, a particular kind of sail boat, within the given regatta regulation. With its modeling and calculation tools, HyperWorks helped the team to significantly reduce weight while increasing stiffness, while saving time and costs.

Auburn University applies HyperWorks to Optimize the Design of Composite Suspension Components and Monocoque for a SAE Formula Student Racecar

To optimize the car performance, the Auburn University SAE Racing Team focused on selected components that were most promising in terms of mass reduction with equal or increased stiffness. HyperWorks enabled them to reduce component mass-to-stiffness ratio, thereby improving car performance, speed up development time, as well as grow in knowledge of composite material design and optimization

Predicting impact of manufacturing process on composite performance with HyperMesh, KTex Family and RADIOSS

RADIOSS already offers many material laws dedicated to composite materials. On top of that, many representations are possible thanks to shell and solid elements. However, weaving patterns of the yarns in a ply are hardly taken into account, and predicting the behavior of these yarns (orientation change but also fibre volume fraction evolution) is a main concern. In this frame, KTex Family is a group of modules, fully integrated in HyperMesh, aiming at improving the composite experience within Altair software suite.

Whitepaper: A Design-Validation-Production Workflow for Aerospace Additive Manufacturing

Additive manufacturing coupled with topology optimization allows the design-and-analysis and manufacturing iterations to be reduced significantly, or even eliminated. To ensure that the part will perform as simulated, a mid-stage validation is conducted on a standardized part before creating the final products.

HyperWorks Enables Ingeniacity to Reduce Mass of Sailing Yacht Composite Bowsprit by 65%

Altair's HyperWorks Suite provided the pre-processing, optimization and FE-solving tools to help create a new bowsprit design that was 34kg lighter than the previous model

HyperWorks for Crash: Simulation with RADIOSS

Erwan Mestres (Business Development Director) is presenting a comprehensive overview of Altair's crash solution RADIOSS, touching on basics, model setup, safety models (such as dummies and barriers), and also analysis speed-up with e.g. scaling or sub-modelling.

Mabe

The consumer goods industry is fast paced and highly competitive, with designs becoming increasingly complex while the timeline for production shrinks. Companies like Mabe must innovate and develop new products quickly in order to remain on the consumer radar, and conducting various analysis studies on their designs helps them to do so. This project addresses the tedious and time consuming task of modeling the foam within the product door that helps maintain the internal temperature and also absorbs shock in a drop situation. Modeling the foam effectively is complex and difficult due to the complicated nature of the doors and other cavities, so the step was often skipped, causing inefficiencies with the product.

CEVT Discuss Multi-Disciplinary Optimization for Vehicle Development

China Euro Vehicle Technology (CEVT) discuss the application of Multi-disciplinary Optimization (MDO) during the development of new automotive vehicle architectures.

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Adam Wais of Rolo Bikes Discusses the Working Relationship with Altair

During the development of a new carbon fiber bicycle, the design team at Sweden based Rolo Bikes, wanted to develop a frame which exhibited world leading strength and stiffness attributes while keeping weight to an absolute minimum. The team required an efficient process to design the frame and test it in a virtual world against the industry’s safety and performance standards.

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An Interview with Ben Farmer of Robot Bike Co. Discussing the Development of their R160 Bike with Altair

Robot Bike Company (RBC) is a new startup established in the UK by aerospace engineers and mountain biking enthusiasts who identified the potential of combining additive manufacturing technologies with carbon fiber to, in their own words, “create the best bike frames possible”. To deliver a customizable, lightweight, high strength bike, RBC’s frame was intended to be created from carbon fiber, a material very common in the industry. The carbon fiber tubes, as well as the bike’s other components and systems were to be joined by additively manufactured titanium ‘nodes’, manufactured based on the specification of individual riders. Altair ProductDesign’s engineering team was tasked with optimizing these joints, which included the head tube, seat post and chain stay lugs, to ensure they were as lightweight as possible and still able to withstand the forces of downhill mountain bike riding, all while being fit for the AM process.

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Gator Motorsports

Gator Motorsports utilized solidThinking Inspire to redesign its brake pedal, as well as suspension bell cranks. This resulted in increased stiffness and a reduction of weight.

HyperWorks for Crash: Model Preparation and Evaluation

This webinar will introduce the latest crash and safety capabilities in HyperWorks 14.0, working with RADIOSS, LS-DYNA and PAM-CRASH. It also reviews other powerful tools and recommended processes available in Altair’s pre- and post-processing software.

OptiStruct V14.0.210 Feature Presentations and Demo Models

The zip file contains feature presentations and demo models for all the 35 OptiStruct features released in V14.0.210

Numerical Wave Tank Analysis of Wave Run-Up On a Truncated Vertical Cylinder

J. Kin, S.Cosgrove, R. Jaiman, and J. O’Sullivan.

VIV Prediction of a Truss Spar Pull-Tube Array Using CFD

Y. Constantinides, S. Holmes, and W. Yu

CFD Based Hydrodynamic Databases for Wake Interference Assessment

D. Corson, S. Cosgrove, P. Hays, Y. Constantinides , O. Oakley, H. Mukundan, and M. Leung

Dynamic Analysis of Riser Release and Lowering

S. Atluri, N. Liu, A. Sablok, and T. Weaver

Vortex Induced Vibration Analysis of a Complex Subsea Jumper

S. Holmes, and Y. Constantinides

Automated Parameter Tuning for Optimized Vehicle Dynamics Using CarSim and HyperStudy

New vehicle suspensions need to be optimized early in the development process to position vehicle programs to meet performance and quality targets in an efficient, low-cost manner. Through the use of Altair HyperStudy, solidThinking Compose and Mechanical Simulation’s CarSim, 1D models are built and quickly tuned to achieve desired kinematic characteristics. A case of tuning a vehicle for a slowly increasing steer event to improve vehicle targets is also discussed.

Moldex3D-to-OptiStruct Workflow: The Integration Between Molding Simulation and Structure Analysis

This webinar is to show the benefit of performing an advanced structure analysis through the integration of molding simulation and structural analysis. The general workflow of Moldex3D (Injection Molding and FEA Interface modules) followed by OptiStruct FEA solver will be demonstrated.

A Minimization of Forming Loads in the Gear Driver Forging Process Using AFDEX and HyperStudy

In the webinar, there will be a presentation of the most efficient ways to optimize those process parameters encountered in metal forming processes, which are based on AFDEX, general purpose metal forming simulator and HyperStudy, Altair’s optimization tool.

Lightweight and Durable Design of Automotive Components

This webinar covers how advanced optimization techniques helped FCA Engineering India Pvt. explore the lightweight component design of a vehicle suspension system. For this purpose, the development process of a track bar bracket will be shown, highlighting how a lightweight and durable component design was achieved.

Success Story: OHB System AG

HyperWorks and the Altair Partner Alliance Streamline Development Process of Optical Satellite Components at OHB System AG.

Matereality-HyperWorks CAE Connectivity

Use Matereality to store all of your relevant material data, convert raw data in your database into formatted CAE Material files, and export your library as a Master Material file for use in HyperWorks.

OptiStruct V14.0.220 Feature Presentations Demo Models

The zip file contains feature presentations and demo models for all the 21 OptiStruct features released in V14.0.220

OptiStruct V14.0.230 Feature Presentations Demo Models

The zip file contains feature presentations and demo models for the 27 OptiStruct features released in V14.0.210

Digital Development at Hyundai Motor Group

Dr. Byungsik Kang is explaining how upfront engineering with FEA methods made a big impact at Hyundai Motor Group. He also explains the importance of designers using simulation for their own need at the early stage of development. Last but not least he is talking about the power of the solver OptiStruct to find entirely new designs.

HyperWorks for Aerospace Series: Electromagnetics

This webinar will give an overview and update on the EM simulation solutions (FEKO, Flux and WinProp) in HyperWorks for the aerospace industry and its segments covering applications and real use cases from antenna design and placement, EMC, RCS and wave propagation to electric machines, actuators and sensors and high power equipment.

HyperWorks for Aerospace: Structural Solvers

This video summarizes the latest features of OptiStruct 14.0.120 which are very relevant for aerospace engineers. The topics discussed are new stress constraints for topology optimization, a 'fast contact' algorithm, tape laying manufacturing for composites, fail safe topology optimization, and resultant forces and moments as design criteria. The webinar also touches on MotionSolve and RADIOSS as solvers for the Aerospace industry.

Optimizing Your CAE Data Preparation with HyperMesh and CADdoctor

This webinar will incorporate how CADdoctor has been a flagship product in data translation and optimization by helping users to prepare the best 3D data for their optimal CAE analysis.

APWorks Choses OptiStruct for Topology Optimisation for the 3D Printed Light Rider

Despite its skeletal appearance, the Light Rider is an extremely strong yet lightweight electric motorcycle designed by Airbus subsidiary APWorks as a showcase of what’s possible when OptiStruct's topology optimisation is coupled with metallic 3D printing. Written by Tanya Weaver from DEVELOP3D.

Using Topology Optimization with solidThinking Inspire for Improved Casted Rail Compoments

A simulation driven approach was taken using solidThinking Inspire for topology optimization, Evolve for shape refinements and HyperWorks for FE analysis for the optimization of an existing component design to be manufactured with casting/AM technologies

A Vision of Tomorrow's Architechture: Designing the LAVA Bionic Tower

Exploring design variants with OptiStruct's FE-based topology optimization to generate a free-form exoskeleton structure

Safety System Simulation with MADYMO-RADIOSS

The Webinar will outline how engineers can combine the best of both worlds in a single co-simulation environment and gain considerable time saving in vehicle developments. The Radioss-MADYMO coupling solution enables engineers to use the same MADYMO dummy and restraint models in occupant safety analysis as well as in the RADIOSS structural analysis. This removes the need to create intermediate FE models of the restraint system, which reduces development time and provides higher confidence in simulation results.

The Three-Click Workflow of nanoFluidX, HyperMesh, and SimLab

The webinar will begin by presenting FluiDyna GmbH and by giving a short introduction to the nanoFluidX (nFX) code. After that the attendees will get a more detailed description of the work flow, emphasizing the ultra-simple pre-processing capabilities of the HyperMesh 14.0.110 and upcoming SimLab 14.2, which allow particle generation with literally three clicks per element. Some details about the solver will also be presented, particularly pointing out the speed up the customer potentially gains in turn-around time for oiling simulations by using nFX on GPU’s. We shall also present the new ParaView 5.0.1 with special SPH features, as well as FieldView version (which should show up by the webinar). Finally, summary and licensing details will be provided for nFX.

solidThinking Activate and CarSim FMI Tutorial Video

This short tutorial introduces the Functional Mockup Interface and how to use solidThinking Activate and CarSim for co-simulation for coupled systems analysis.

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PolyNURBS

See how the PolyNURBS tool allows you to quickly create free-form solid geometry that is smooth and continuous.

HyperMesh 14.0 Overview

See an overview of the new features available in HyperMesh for 14.0.

HyperMesh 14.0 - Modularization & Common Model

A new part-based workflow is available, which brings modularization to HyperMesh. One of its primary benefits is that it promotes flow of data from PDM to HyperMesh.

HyperMesh 14.0 - BatchMesher Workflow

New options are available for accessing the BatchMesher. One of those methods is through the Mesh Controls Browser. In this demonstration see how to use the Mesh Controls Browser and BatchMesher in HyperMesh 14.0.

HyperMesh 14.0 - Mesh Controls

A new browser-based workflow for meshing has been implemented. This workflow utilizes the new "mesh control" entity.

HyperMesh 14.0 - Aerospace Tools Overview

See an overview of the new tools available in HyperMesh 14.0 for aerospace users.

HyperMesh 14.0 - Entity Management

Redundant entity management is enabled which provides the ability to control which FE/geometry, material, and/or property attributes are read into session.

HyperView 14.0 Overview

See an overview of the new features available in HyperView and HyperGraph for 14.0.

HyperView 14.0 - Multi Model Results Overlay

This enhancement allows users to plot and view results for multiple overlaid models in a single window without having to switch between the models (In previous releases, result plots could only be viewed on current model).

HyperView 14.0 - Top/Bottom (Z1/Z2) Contour

This new method of contouring can be used to read and contour results (for example, stress or strain) on both the top and bottom layers of a shell element simulteneously in a single plot.

HyperView 14.0 - Video Overlay Enhancements

Significant improvements have been made to Video Overlay. A clean overlay of a Model and Video/Image can be achieved by providing the properties of the camera used to capture the image or by a multi-point alignment method.

HyperView 14.0 - Visibility Control Toolbar

A new toolbar called Visibility Controls has been added to HyperView for quick visibility manipulation- Isolate, Hide, Display All/None/Reserve and Unmask. This toolbar works on both component and element selections.

OptiStruct Overview 14.0

See an overview of the new features available in OptiStruct for 14.0

Mechanical Simulation Top Use Cases

Presentation introducing a few of the top use cases for the vehicle dynamics simulation software, CarSim, BikeSim and TruckSim.

Developing a New Safety System for the Rail Industry with Sharma & Associates

Sharma & Associates (SA), a Chicago-based consulting firm that is focused on providing engineering solutions to the railroad industry, led the effort. Since 1995, SA have delivered safe, effective and efficient solutions to its customers, which include the Federal Railroad Administration (FRA), the Association of American Railroads (AAR), railroads and transit agencies, rail car builders and rail car component manufacturers. The objective of the Altair ProductDesign team effort was to develop an ‘Engineer Protection System (EPS)’ that can protect train crew in frontal collisions (a common mode of train collision) from secondary impact injuries.

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Achieving Superior Crash Performance for the Souest DX7

Analysis and optimization to improve crash performance while reducing reliance on physical tests.

HyperXtrude 14.0 Overview

See all the new features available in HyperXtrude for 14.0

Load Model

A demonstration covering the ways to load a geometry file into HyperXtude 2015.

Orient Model

This demonstration covers the tools available to orient and set the global origin of the geometry.

Extract Flow Volume

This demonstration will show how to extract the flow volume from the geometry loaded into HyperXtrude.

Extract Bearing Profile

This demonstration shows how to extract the bearing profile using HyperXtrude 2015.

Organize Flow Volume

This demonstration will show how to use HyperXtrude 2015 to organize the solid geometry in a model.

Create Billet

This demonstration shows who to create a billet in HyperXtrude 2015.

Select Materials

This demo will show how to use the material database in HyperXtrude 2015 to select a material for analysis.

Perform Simulation

This demo shows how to run the analysis in HyperXtrude 2015.

PolyNURBS

See how the PolyNURBS tool allows you to quickly create solid free-form geometry that is smooth and continuous.

Acceleration Tools

See a demonstration of the new angular velocity and accelerations tool which allows you to define the speed of rotation of the entire model and the axis about which it rotates.

Buckling Analysis

See a demonstration on how to analyze your model for buckling modes which are used to predict when a part will bend or collapse under load.

Enforced Displacements

See a demonstration on the new Enforced Displacement tool that can be used when the magnitude of a force applied to a part is unknown, but the amount that the part displaces when force is applied is known.

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