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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?

Altair HyperWorks Helps Joe Gibbs Racing

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

Driving Million Dollar Savings at Ford using Structural Optimisation

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

Topology Optimization of Aircraft Wing Box Ribs

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

Optimisation Techniques Leading the Development of a Steering Wheel

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

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

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

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

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

The 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.

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.

Fine-Tuning 300-Ton Haulers: HyperWorks at Hitachi Truck Manufacturing

Hitachi Truck Manufacturing sought ways of reducing materials costs for its mammoth mining trucks, while remaining within standard specifications. The company's first project using HyperWorks CAE tools enabled Hitachi to do this with accuracy. HyperWorks is now an integral part of the design process at Hitachi.

Rotorcraft Design Takes Flight

Optimization tools enable Boeing to balance form and function in the development of advanced aircraft.

Optimizing Aircraft Structures

Optimization technology and methods for the innovative design of efficient civilian and military aircraft.

Smart Product Packaging Pays Off

Our experts examine the challenges, advancements and trends that are changing the product packaging industry.

Putting Simulation Muscle Behind a Sporty Concept Car

Optimization technology delivers innovative suspension design for Alfa Romeo's sleek concept car.

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.

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 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.

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.

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.

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

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.

Concept Design Optimization of Automotive Components

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

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.

Opportunities in Packaging: Innovation & Savings

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

Locking Up a Bike Rack Partnership

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

Fire Truck Design

Creativity and optimization technology extend fire-fighting capabilities.

Driving Performance with Optimization

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

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.

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.

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.

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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