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HyperWorks at Wagon Automotive: Speeding Development Time While Cutting Prototype Costs

Wagon Automotive, a system and module supplier of components to major car builders, sought ways to accelerate product development and reduce prototyping costs while maintaining high quality. Adopting the HyperWorks suite of advanced CAE tools enabled the company to achieve both those goals. Wagon Automotive now uses HyperWorks during the entire development cycle, from concept design to optimization.

HyperWorks CAE Process Automation Accelerates Product Development at Scania

Scania chose HyperWorks – the Engineering Framework for Product Design – to automate the assembly process of virtual truck models for finite-element (FE) simulations. The new process significantly increased simulation efficiency and robustness, which are especially critical to Scania’s truck-customization process.

HyperForm Sheet Metal Forming Simulation Solution Provides Product Design Optimization of Panel Front Dome

Using Altair HyperForm sheet metal forming simulation software solution, India based Mahindra & Mahindra was able to arrive at an optimum product (BIW Part) and tooling design. The Draw Shell was simulated using HyperForm to evaluate different tooling options.

PBS Professional at Toulouse Genopole

The Toulouse Midi-Pyrénées Genopole, a research program set up in 1999 in southern France by the French Minister of Research, is part of the massive French research initiative known as the National Genopole Network. The genopole name is metaphoric. It brings to mind a magnetic pole that attracts researchers and entrepreneurs to the potential of genomic research. And it is working: the initiative has drawn together, at seven locations across France, a symbiotic mix of public laboratories, biotech companies, and educational institutions. The genopoles stimulate genomics research and may provide an incubator for biotech enterprises.

OptiStruct Drives Weight Reduction in Commercial Aircraft: Door Support Arm Design Optimization

Using OptiStruct topology and shape optimization tools, Eurocopter created an innovative new design of a door support arm for the Fairchild Dornier 728 aircraft. The company achieved a weight reduction of approximately 20 percent, using structural optimization techniques as an integral part of the design process.

HyperWorks Cuts CAE Modeling Time by Up to 50 Percent at Dunlop Aerospace

Using HyperWorks for the creation and modification of complex finite-element meshes, Dunlop Aerospace was able to dramatically cut modeling time. The software’s stability, ease-of-use and superior technical capabilities for HEX meshing contributed to the successful deployment.

Accelerating Product Development at the Nanotech Level with Altair HyperWorks

In addition to looking for a way in which to reduce product development time through simulated modeling and analysis, Zyvex Corporation wanted to be able to communicate the features and value of its MEMS product more effectively to internal and external audiences. Using the Altair HyperWorks computer-aided engineering (CAE) framework for product design, Zyvex not only accomplished its goal to significantly speed time to market, but also used HyperView’s visualization technology to prepare informative compact slide and PowerPoint presentations on the nanotechnology to various stakeholders, including Zyvex management and potential investors.

HyperWorks at Changchun Railway Vehicle Co., Ltd.: Accelerating Design and Analysis of High-Speed Railcars

Asia's largest railway vehicle manufacturer, Changchun Railway Vehicle Co., Ltd. (CRC), was looking for ways to increase development efficiency through streamlined CAE processes. By implementing HyperWorks, Altair's engineering framework for product design, CRC was able to reduce modeling cycle time by up to 50 percent. In addition, simulations were more accurate as a result of better model quality.

HyperWorks at Sea Ray: Engineering High-Performance Pleasure Boats

For Sea Ray Boats, the leading, U.S.-based manufacturer of high-end pleasure boats, CAE simulations are an integral part of the design process to achieve shorter time to market. HyperWorks is deployed for the entire analysis process of the vessel, from modeling and simulation, to visualization and reporting. By using HyperWorks, Sea Ray’s engineers can quickly model their advanced composite structures, as well as run complex inertia relief and durability load cases.

PBS Professional at TRW Automotive: A Standard Solution for European Design Centers

As a global technology company, TRW Automotive touches most of us in ways we're unaware of. And when we drive, it is practically a certainty that a TRW system with brakes, airbags, seat belts, or steering is part of the experience. A Tier One automotive industry supplier with a focus on safety products, TRW Automotive works with almost any car and truckmaker you can name, worldwide.

OptiStruct Technology Cuts Production and Maintenance Costs of Crop Harvester Reel Assembly

Leveraging OptiStruct's topography optimization capabilities, CLAAS designed an optimal reel hub reinforcement bead pattern for a crop harvester.

PBS Professional at GE's Oil & Gas business: Putting An Engineering Cluster to Work

Next time you stop to fill your fuel tank, reflect on the fact that a company on the sunny slopes of Tuscany may have helped to make it possible. Nuovo Pignone, now a key technological component of GE's Oil & Gas business, began life 100 years ago as a foundry. Today more than 20,000 machines – turbomachinery, compressors, pumps, valves, and metering and fuel distribution equipment – manufactured by this GE business are operated worldwide by major companies to keep petroleum products moving from oil rigs to storage facilities to refineries to distribution points.

PBS Professional at Boeing: Workflow Management for R & D

The Boeing Information Technology group provides a wide range of computing services to the entire corporation from its Bellevue, Washington computing campus. For the engineers who design Boeing commercial aircraft, the heartbeat of this campus is the Data Center, which houses the high performance computing (HPC) systems that they access to run engineering simulations and analyses.

Parametric Optimization of Fluid Dynamic Simulations using StarCD

HyperStudy's design optimization was combined with CFD simulation in order to optimize fluid flow.

PBS Professional at Trelleborg: An Automotive Design Group Maximizes Productivity

When you look for a new car, you probably think about style, comfort, performance, economy, or innovative electronics. You won't be thinking about the kinds of parts that Trelleborg Automotive makes. But they're there, all right, mostly unsung and out of sight, and you wouldn't want to be without them. Trelleborg, a Swedish corporation with a 100-year pedigree in engineering innovation, makes molded rubber components that damp down vibration and smooth out your ride. They cushion your engine where it meets the chassis. They buffer the mechanics of your steering column and your suspension. Almost all of them do their jobs without ever seeing the light of day – but if your floor gearshift lever has a rubber housing, that housing may have come from Trelleborg.

ExoMars Rover Airbag Design and Reliability Optimization

Astrium used HyperStudy with LS-Dyna to not only optimize the landing behavior of the ExoMars lander but also to investigate the probability of failure using HyperStudy’s stochastic engine. HyperWorks’ process automation engine helped to quickly create design variations.

Designing All-Terrain Vehicle Frames Using Topological Optimization

Upfront concept design optimization on a all terrain vehicle frame resulted in a 9% mass reduction. Using Design of Experiment (DOE) methods, peak accelerations during crash decreased by 22%.

Significant Weight Reduction by Using Topology Optimization in Volkswagen Design Development

Using Altair’s topology and topography optimization as an integrated part of their design process, Volkswagen is able to reduce mass of engine components by 20% and more

F-35 Joint Strike Fighter Structural Component Optimization

Lockeed Martin uses OptiStruct to meet the aggressive weight targets on the Joint Strike fighter project. High potential parts for mass savings include compact fittings and planar webs.

PBS Professional at TGen: Cutting Time to Discovery

In recent years, corporations and research institutions around the world have applied massive computational resources to defining the makeup of the human genome. One of the greatest challenges is to translate that knowledge into therapeutics and diagnostics – which is the mission of the Translational Genomics Research Institute (TGen), a remarkable non-profit organization founded by a joint effort between the State of Arizona, Arizona State Municipal Governments, Indian Tribal Community, educational institutions, private foundations and corporate entities. TGen's work is not only to make genetic discoveries, but also to translate discoveries into benefits for human health in the form of new diagnostic tests and therapies.

Enhanced Formability through Hydroforming

Cut sheet metal forming time and costs through simulation-based techniques.

Improving Heating Boiler Acoustics at Viessmann: OptiStruct for Bead Pattern Optimization

Altair OptiStruct can be used to generate and optimize bead patterns for the effective design of sheet metal components. By using OptiStruct’s topography and shape optimization methods, sheet thicknesses can be reduced significantly, leading to both reduced material and a lower overall cost.

Ford Motor Company: Building an Efficient HPC Infrastructure

The cars, trucks, vans and SUVs that roll off Ford Motor Company assembly lines are safer, quieter, and more comfortable than ever. Many of the intangibles that contribute to Ford quality flow from the innovative use of high performance computing (HPC) techniques. At Ford's Numerically Intensive Computing Department (NIC) in Dearborn, Michigan, engineers run simulations in codes such as NASTRAN and LS-DYNA for predictive analysis of cylinder cooling, wind noise, vibration, ride quality, crashworthiness, durability, and other characteristics that contribute to industry-leading automotive design.

Concept Design Optimization of Automotive Components

ArvinMeritor succesfully applied topology and topography optimization to various automotive components.

Breaking Barriers in High-Performance Computing

Sandia National Laboratories and Cray Inc. are partnering to develop a system that will take the supercomputing industry by storm.

Optimization Assisted Design of Military Transport Aircraft Structures

EADS Military Aircraft implemented an optimization assisted structural design process and applied it to the A400M rear fuselage design.

Putting the WHOA! into High-Performance Boats

Baja Marine dives into simulation technology, analyzing force, weight, and resistance to build speedies, and better, boats.

Fire Truck Design

Creativity and optimization technology extend fire-fighting capabilities.

Opportunities in Packaging: Innovation & Savings

Technology allows companies to efficiently develop cost-effective, high-performance packaging systems.

CAVE Sets the Stage for Real-Time Collaboration

An immersive virtual environment speeds the creation of prototypes to cut time in military product development programs.

Locking Up a Bike Rack Partnership

An innovative alliance reduces the risks of launching a new product.

Driving Performance with Optimization

Engineering enthusiasts and software tee-off to optimize club driver performance while ensuring conformance to the Rules of Golf.

Seeing Steel in a New Light

Advanced high-strength steels have emerged as one of the most sophisticated materials available for highly engineered product design.

Get the Most from Your Casting Process

By applying optimization technology to casting process design, manufacturers can produce less expensive, better-quality parts in record time.

Optimization: Taking a Different Tack

A slick design and the use of new materials make the Fila sailboat a force to contend with on the competitive boat racing circuit.

Incorporating Manufacturing Effects in Structural Design: Flex & Dent

As automotive OEM’s strive to significantly reduce development costs a common strategy has evolved, to eliminate the testing of physical prototypes and replace by virtual testing (CAE) in order to achieve low cost certification. However, for many components subjected to complex loadings, it has not been possible to achieve correlation between experimental and numerical results. It has long been postulated that the manufacturing process can have a major effect on the structural performance. However, a comprehensive software tool set has not been available to efficiently investigate this effect. This paper details the strategy for the efficient coupling between manufacturing process and structural product simulations. A key element of this strategy is a new software tool Altair HyperMap. This technology is applied to the ‘Flex and Dent’ assessment of an aluminium panel. Invaluable insight into the performance of the panel is obtained by incorporating the manufacturing effects. Correlation of the Flex resistance was substantially improved due to the inclusion of these effects.

An Advanced Method for Optimising Packaging Design

Consumer product packaging designers are faced with conflicting requirements throughout the development process. Good pack aesthetics are vital for the success of the product, whilst unit costs must be minimized and suitability for stacking and transportation maintained. This paper describes, by example, how design optimization technology can be used to enhance the design process. It is demonstrated that the technology can be employed to provide clear design information for the pack designers, facilitating definition of an attractive shape incorporating features to meet the structural and manufacturing requirements whilst minimizing cost.

Applications of OptiStruct Optimisation on Body in White Design

The application of topology and size and shape optimization for the design of efficient automotive components in terms of mass and stiffness has developed into a well practiced discipline. Subjecting a vehicle body structure to this type of development enables the analyst to optimise the size, shape and placement of load bearing members. By defining the most efficient topology, structural targets can be achieved with fewer design iterations, therefore, leading to reduced cycle times and lower development costs. The Altair OptiStruct software suite provides the analyst with an optimization environment which realises this method by providing a ‘right first time’ approach to body design. This paper presents an insight into the development of an efficient body structure subjected to various load cases. Based upon the topology of the load paths, which OptiStruct defines, the paper then details the development of the concept through to a detailed design.

Topology Optimisation Used to Achieve Frequency Targets of an Engine Bracket

Topology optimisation technology is becoming increasingly used in the design process of automotive components. This technology can be applied very effectively to simultaneously achieve static compliance and frequency targets for structural designs. The paper provides an industry perspective on how this technology is applied to a production bracket and the important role the designer and engineer play in converting the optimised material layout into a component which can be manufactured. It is demonstrated that the combination of topology optimisation and design knowledge can provide a design solution which could not otherwise have been achieved.

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