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Increasing the Customer Value of Structural Designs Using HyperStudy and Topology Optimization While Considering Manufacturing Constraints

This was a 2010 Americas HTC Presentation given by Steve Reagan from L&L Products. In the demanding environment seen in today's markets, continual innovations driving increasing levels of customer value are key. The use of topology optimization with the inclusion of manufacturing constraints was critical to the achievement seen in this project and was made possible through the close product/process integration available through the HyperWorks tool suite. In this presentation, Dr. Reagan shows how HPC, RADIOSS, HyperStudy, and OptiStruct were employed to drive material cost down while maintaining product performance.

HyperMesh and HyperView customization for thermal analysis of engine systems

This was a 2010 Americas HTC Presentation given by Emil Chouinard from GE Aviation. GE Aircraft Engines has many NPI (new product initiative) programs that rely on accurate and timely thermal analysis, as temperatures are critical to accurate estimates of hardware life. HyperMesh and HyperView have been customized as the pre and post processing tools, respectively, for thermal analysis of engine systems. The single database with relational data management greatly reduces modeling errors and results in Engineers being able to focus on the physics of the problem instead of data management.

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.

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.

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.

Migration ADAMS - HyperWorks

This is a presentation given by Magnus Olofsson, Vehicle Dynamics from Navistar. This was presented at Dynamics 2009.

HVAC DOOR KINEMATICS

This was the presentation by Binshan Ye, Senior FEA Engineer at Behr America, Inc. This was presented at Dynamics 2009.

Vertical Dynamics of an Offroad Race Car

This is a presentation made by Dirk Bordiehn and Katja Fritzsch from Volkswagen Motorsport. This was presented at Dynamics 2009.

Simulation Speeds Modular Truck Development Process

New finite element tools enable an international truck manufacturer to easily evaluate custom chassis.

Structural Innovation Takes Shape

Structural optimization plays a key role enabling Skidmore, Owings & Merrill, LLP to create buildings with unique shapes and aesthetic values.<br><br> This article was featured in the Spring/Summer 2009 issue of <i>Concept to Reality</i>. To subscribe to our <b>free</b> magazine, please <a href="http://www.altairhyperworks.com/MagazineFreeSubscription.aspx">click here</a>.

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.

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.

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)."

3D Visualization of 1D Elements in HyperMesh

Introduced in HyperMesh 10.0 is the ability to view 1D Elements with Beam sections as 3D representations.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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 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.

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.

RD-2050 Random Response Analysis of a Flat Plate

Interactive Tutorial demonstrating how to set up the random response analysis for the existing frequency response analysis model.

OS-2095 Frequency Response Optimization of a Rectangular Plate

Interactive Tutorial demonstrating the capability of frequency response optimization using OptiStruct.

RD-2020 Direct Transient Dynamic Analysis of a Bracket

Interactive Tutorial demonstrating how to perform direct transient dynamic analysis using RADIOSS.

HM-3000 Creating 1-D Elements

Interactive Tutorial demonstrating the creation of 1-D Elements.

HM-3120 2-D Mesh in Curved

Interactive Tutorial demonstrating the creation of a mesh on curved surfaces.

RD-2040 Nonlinear Gap Analysis of an Airplane Wing Rib

Interactive Tutorial demonstrating how to perform nonlinear gap analysis using RADIOSS.

OS-2080 Topology Optimization of a Hook With Stress Constraints

Interactive Tutorial demonstrating a topology optimization on a bracket-hook modeled with shell elements.

RD-2000 Direct Frequency Repsonse Analysis of a Flat Plate

Interactive Tutorial demonstrating how to import an existing FE model, apply boundary conditions, and perform a finite element analysis on a flat plate.

HM-1030 Organizing a Model

Interactive Tutorial demonstrating tools used for model organization.

RD-2010 Modal Frequency Response Analysis of a Flat Plate

Interactive Tutorial demonstrating how to import an existing FE model, apply boundary conditions, and perform a modal frequency response analysis on a flat plate.

RD-2030 Modal Transient Dynamic Analysis of a Bracket

Interactive Tutorial demonstrating how to perform modal transient dynamic analysis using RADIOSS.

OS-2070 Topology Optimization of a Reduced Model Using DMIC

Interactive Tutorial demonstrating how to reduce the finite element model using static reduction and also how to perform topology optimization on that reduced model.

HM-3200 Tetrameshing

Interactive Tutorial demonstrating the creation of a tetramesh.

HM-1010 Opening and Saving Models

Interactive Tutorial demonstrating opening and saving models.

HM-3100 AutoMeshing

Interactive Tutorial demonstrating automesh functionality.

HM-2000 Importing and Repairing CAD Models

Interactive Tutorial demonstrating CAD geometry import and repair tools.

HM-1020 Working with Panels

Interactive Tutorial demonstrating HyperMesh panels.

OS-4070 Free-Sizing Nonlinear Gap Optimization on an Airplane Wing Rib

Interactive Tutorial demonstrating how to perform free-sizing optimization using OptiStruct.

HM-3110 Meshing without Surfaces

Interactive Tutorial demonstrating meshing without surface geometry.

HM-2030 Refining Topology to Achieve a Quality Mesh

Interactive Tutorial demonstrating refining topology to achieve a quality mesh.

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.

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.

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.

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.

Intelligent Rendering Is in the Animation Pipeline

An intuitive interface for render farm management enables a global animation studio to harness the power of highperformance computing.

Wind Turbines Take a Technical Spin at Generating Electricity

Wind turbines convert kinetic energy into mechanical power. In use for centuries, they have harnessed the power of the wind to pump water, grind grain and generate electricity. While their popularity has peaked and ebbed over the years, interest in wind turbines to generate electricity is again gaining momentum. As an alternative to fossil fuels, wind energy is seen as a viable way to produce energy while reducing global warming and pollution.

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.

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.

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.

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.

Product Development Success Hinges on the Pursuit of Innovation

Introducing simulation tools into the design and manufacturing process has enabled Multimatic to transform innovative ideas into patented products.

Brushing Up on Product Functionality

Simulation and innovative product development go hand-in-hand at the Lion Corporation.

Full Speed Ahead on Welding Analysis

Simulation enables shipbuilders to automate welding procedures – saving time and money.

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?

Advanced Finite-Element Modeling Techniques

Getting the Most From HyperMesh

Shape Optimization of a Cylinderhead Gasket using HyperMorph

A mesh model of the water jacket of a certain engine is to be optimized by modifying the shape and topology of the gasket holes that connect the head and block parts

Fininte-Element Analysis of an Automatic Door Structure to Improve the Design Processes and Meet Customers’ Quality Expectations

The paper provides the overview of the main influences on the door quality and the methodology for design evaluation via finite element approach. The door design is treated as a separate product where focus is subsequently put on the integration aspect.

Accelerating Product Development through Process Automation



Paulstra’s Use of HyperWorks to Optimize Designs and Reduce Development Time

The combined tools within HyperWorks have allowed Paulstra to move away from the trial and error design method.

HyperView Automation for Post-Processing Cell Phone Drop Simulations

The cell phone design cycle within Motorola has matured to the extent that it is standard operating procedure to analyze several concepts of a specific model before physical parts are ever made. With the use of HyperWorks tools and the speed of current compute systems, pre-processing and number-crunching are no longer the bottlenecks in analyzing full assemblies during drop situations. The most time-consuming part of the analysis cycle for drop simulations has become post-processing. It is common in the analysis cycle to look at the results of 10 or more drop orientations for each concept. Each cell phone assembly is large enough that it manually takes a half- to a full day — depending on the drop orientation — to look at all the parts of interest. By teaming with Altair, HyperView has been customized to automatically produce a web-based report for a drop orientation in about 45 minutes. The report can be accessed by any member of the design team and provides a much quicker method for focusing on the critical components that need attention.

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.

A Procedure for Performing Tube Hydroforming Simulations

Tube hydroforming simulations can be challenging to perform due to the multiple forming stages involved and the shape variability between those stages. A step-by-step procedure will be presented to approach tube hydroforming projects. The author will also present tips for solving hydroforming simulations using LS-Dyna3D. The tube-bending macro within HyperForm will be leveraged, along with other capabilities within the HyperWorks suite. Some aspects of accurate material representation in hydroforming simulations will also be discussed.

CAE Process & Data Management Using Altair Hyperworks Solution

Computer-aided engineering plays a significant role in the product development process. However, with the growth in the number of simulations performed, and in the absence of process and data management tools to track these simulations, inefficiencies start creeping into the CAE process. Altair Data Manager (ADM) is a pioneer tool in addressing this need. With this insight, the CAE group at Eicher Motors Ltd. decided to implement the ADM tool before process management and data migration became a Herculean task. Eicher CAE users wanted the ADM system to help them manage the complete CAE process and improve CADCAE integration. That included automated assembly buildup of batch-meshed components; automated part library buildup; analysis iterations management; faster and consistent report extraction; centralized data storage without any data duplication; and efficient sharing of results and reports across the organization.

Sheet Metal Transfer Simulation Using Altair HyperDieDynamics

The sheet metal part transfer process in high-volume transfer press is a critical phase of stamping manufacturing operations. Thus, understanding the dynamic behavior of sheet metal during transfer from die station to station becomes an urgent task in the tooling design phase. The goal is to achieve optimum transfer motion design, avoid high-cost equipment damage and improve production uptime. The newly developed Altair HyperDieDynamics is a unique tool to analyze sheet metal transfer dynamic behavior through its intuitive graphic user interface and engineering intelligence. By introducing the flexible body property and the virtual model of the stamping press line, users can easily conduct a panel transfer dynamic analysis with MotionSolve, and visualize the in-motion blank deflections, accelerations and resultant forces. It is also a useful analytical tool to improve automation tooling design and transfer motion operational parameters.

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.

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.

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.

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.

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 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.

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.

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.

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.

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.

Step Change in Design: Exploring Sixty Stent Design Variations Over Night

Traditionally, computer analysis has been used to verify the structural performance of a proposed stent design. The stent deployment process consists of multiple stages (e.g. crimping, springback, expansion etc.) which is highly non-linear inducing material plasticity and load transfer via component contact. A single structural verification assessment would require a couple of days to compute on a PC. This paper investigates how recent developments in Computer Aided Engineering (CAE) and computer hardware combine to facilitate the rapid exploration of many stent design variations. It is demonstrated that by utilising these technologies, over sixty stent design variables can be assessed overnight provides valuable design sensitivity information and an optimum stent geometry configuration. On an example baseline geometry considered the radial stiffness was significantly enhanced with an improvement in structural performance. This represents a step change in the CAE assessment of a stent design.

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.

Simultaneous Robust and Design Optimization of a Knee Bolster

This paper introduces a practical process to simultaneously optimize the robustness of a design and its performance i.e. finds the plateau rather than the peak. The process is applied to two examples, firstly to a composite cantilever beam and then 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.

Simulation of Automotive Exhaust Noise Using Fluid Structure Interaction

Modelling the exhaust impingement noise is non trivial exercise. It requires a FSI (Fluid Structure Interaction) simulation. Furthermore, sufficient resolution of the local turbulence, complicated by the varying gas temperature and often complex geometry is necessary. The feasibility of modelling this phenomenon using RADIOSS CFD, a commercial code with both FSI and CAA (Computational Acoustic Analysis) capability has been investigated in this paper. A single skin manifold was modelled with flow boundary conditions obtained from a 1D engine simulation code. Engine test bed measurement in a semi-anechoic cell were compared with the prediction, and good correlation achieved. The method adopted provides support at an early stage in the development process.

Rapid Design Exploration to Determine Feasible FPSO and Spar Systems

The riser design process is well established and uses verified simulation tools to predict response to environmental loading. Design optimization is an established technology which has been widely used in other industry sectors including aerospace and automotive. Riser systems show inherently non-linear sensitivity to applied loading and parametric changes. For this reason response surface methods are required for optimization. The paper discusses two example riser configuration design problems and describes integration of Altair HyperWorks design optimization technology with the existing design process. The optimization proved to be efficient and repeatable. The designs produced for each configuration proved to be strong improvements over the baseline starting points and the wealth of information on sensitivity provided deeper understanding of the factors influencing design performance.

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.

Development of a Wingbox Rib for a Passenger Jet Aircraft using Design Optimization and Constrained to Traditional Design and Manufacture Requirements

The application of optimization technology is becoming increasingly widespread throughout the aviation industry, exploiting the potential to design lighter aircraft. This paper details the application of optimization techniques to reduce the mass of an aircraft wing component when optimization is used at the design initiation stage of the process. Altair OptiStruct provides an optimization toolkit to determine the most efficient load path for various constraints, then allow the designers to size the components based on the enveloping load cases. Applying this optimization technology into Bombardier existing design process enabled a saving of approximately 10% on the mass of the component.

UK Niche Vehicle Industry Joins the CAE Fast Lane

0-60 in 3 seconds! That’s fast, but it takes less than a second to be involved in an accident. This paper describes how Kent-based niche sports car manufacturer, Caterham Cars used Simpact and the Altair CAE toolset to help them radically improve the crash safety of their Seven sports car. The RADIOSS non-linear solver within HyperWorks was used to develop a new safety steering system. The project successfully concluded with the new design being certified experimentally under ECE-R12 and approved by the VCA.

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.

Targeting Composite Wing Performance – Optimum Location of Laminate Boundaries

This paper investigates the application of newly available optimization functionality available in OptiStruct to provide design guidance to generate innovative laminate composite solutions. Due to the flexibility of laminate composites, it has great potential to exhibit displacement characteristics that could significantly increase the aerodynamic performance. Free element sizing technology is used to determine concept lay-up solutions. These solutions determine the laminate make-up, thickness and the various laminate boundaries of an aircraft wing covers under multiple loading conditions which meet the required displacement targets whilst also minimising mass. These preliminary studies demonstrate that the technology can successfully achieve displacement targets for multiple load cases. Each analysis study can be completed within minutes and consequently can be utilised as a valuable concept design tool.

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.

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.

Programmable, Open-Architecture HyperWorks Helps Toshiba Design Smaller Hard Disk Drives to Meet Market Demand

Toshiba Digital Network Company, faced with increasing global competition in the hard disk drive (HDD) marketplace, set out to create an advantage through the redesign of their existing HDD product(s). To support this effort, Toshiba partnered with Altair Engineering to automate its design process. This was accomplished by leveraging HyperWorks powerful modeling, visualization and optimization software applications with Toshiba’s proprietary solver for fluid dynamics. The specific goal was to optimize the air bearing surface (ABS) of the HDD’s magnetic head slider. This unique product development process resulted in minimizing the flying height as much as possible while considering its stability. This, in turn, reduced the overall size of the HDD and increased its recording density. In addition, the new design was brought to market in significantly less time than with Toshiba’s traditional design process.

HyperWorks Tailors CAE Processes to Reduce Cell Phone Development Time at Motorola

Using HyperWorks, Motorola significantly reduced CAE cycle time by automating the process of input deck generation and results evaluation. By deploying HyperWorks’ process automation engine, analysts created a customized solution to simulate cell phone models more quickly.

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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