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White Paper: Minimization of Forming Load of Gear Driver Forging Process with AFDEX and HyperStudy

In this paper, a workflow is presented that integrates the functionalities of a metal forming simulation software, AFDEX and a multidisciplinary optimization software, HyperStudy. Using this approach, the forming load of a gear driver used in an automotive transmission is minimized and two die design parameters are optimized.

Design-Optimization of a Curved Layered Composite Panel Using Efficient Laminate Parameterization

In this paper, presented at the 2016 SAMPE Long Beach Conference, an aircraft door surround model is optimized with respect to the objectives and constraints typical for this type of component using HyperStudy and ESAComp.

Automated Parameter Tuning for Optimized Vehicle Dynamics

This paper, which was presented at the 2015 Americas ATC, demonstrates a workflow between HyperStudy, CarSim and solidThinking Compose.

The Art & Science Behind Manufacturing

Do you ever think about all the work that lies behind developing almost everything in the world around us? This article reflects on the tremendous effect the manufacturing process has on everything we use in our daily lives.

Benchmark of HyperStudy Optimization Algorithms

The objective of this paper is to assess several optimization algorithms in HyperStudy for their effectiveness and efficiency. The following sections of this paper present an overview of the optimization algorithms frequently used in HyperStudy. This is followed by benchmarking of both single objective and multi-objective optimization problems, respectively.

Seat Design for Crash in the Cloud - NAFEMS World Congress 2015

The benefit of design exploration and optimization is understood and accepted by engineers but the required intensive computational resources have been a challenge for their adoption into the design process. The HyperWorks Unlimited (HWUL) appliance provides an effective solution to these challenges as it seamlessly connects all the necessary tools together in the cloud. The aim of this study is to showcase the benefits of HWUL on an optimization driven design of a complex system. For this purpose an automotive seat design for crash loadcases is selected.

Fluid - Structure Interaction Analysis and Optimization of an Automotive Component

This paper discusses the behavior of a flexible flap at the rear end of a generic car model under aerodynamic loads. A strong bidirectional coupling between the flap’s deflection and the flow field exists which requires this system to be simulated in a coupled fluid-structure manner.

Optimization Drive Design - A Desktop Engineering Sponsored Report

Optimize every stage of product development with an integrated workflow that democratizes simulation and analysis. In this Desktop Engineering sponsored report Altair's vision for product optimization is analyzed

Optimizing Cooling Passages in Turbine Blades

Turbine blades have internal passages that provide cooling during operation in a high temperature engine. The design of the cooling passages is critical to achieve near uniform temperature of the blade during operation. The temperature of the blade is dependent on the thermal properties of the blade material as well as the fluid dynamics of the air circulating in the cooling passages. Computational optimization methods have successfully been applied to design lighter and more efficient structures for many aerospace structures. An extension of these techniques is now applied to guiding the thermal design of a turbine blade by designing the optimal cooling passage layout. Optimization methods will be applied to determine the optimum pattern of the cooling passages and then to optimize the size of the individual cooling passages. The goal is to produce a more thermally efficient turbine blade design that will produce blades with longer lives and better performance.

Weld Distortion Optimisation using HyperStudy

Distortion induced in parts due to the cooling of welds complicates automated manufacturing lines in the automotive industry. The resulting deformation leads to additional investment such as end of line machining to correct affected assemblies. Utilising optimisation software a welding pattern can be found which retains the intended performance of a part while reducing the distortion induced from welding. Weld locations may be optimised alongside welding sequence to allow process requirements to be considered within the early design stage. This leads to high performance, low distortion assemblies which can ultimately be manufactured at the lowest possible cost.

HUMOS - An FE Model for Advanced Safety and Comfort Assessments

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

Automotive Modal Testing Support and CAE Correlation Using Altair HyperWorks

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

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

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

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.

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.

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

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

Delivering World Class Chassis Design

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

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.

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