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Optimizing a Solar Car for Endurance and Energy Efficiency
Using Altair simulation software, Gurit supports Western Sydney University's Bridgestone World Solar Challenge team, helping them design the most efficient and aerodynamic
car possible, while ensuring driver safety
and adhering to class rules.

BMW Motorrad
By automating the crankshaft modeling process using Altair SimLab, BMW Motorrad, the motorcycle division of BMW was able to significantly reduce their model creation time, and enable accuracy in budgetary forecasting and planning. As a result of making it an inhouse resource, they were able to gain flexibility and consistency in model quality, with a high-degree of efficiency with iterations.

E-motor Design using Multiphysics Optimization
Today, an e-motor cannot be developed just by looking at the motor as an isolated unit; tight requirements concerning the integration into both the complete electric or hybrid drivetrain system and perceived quality must be met. Multi-disciplinary and multiphysics optimization methodologies make it possible to design an e-motor for multiple, completely different design requirements simultaneously, thus avoiding a serial development strategy, where a larger number of design iterations are necessary to fulfill all requirements and unfavorable design compromises need to be accepted.



The project described in this paper is focused on multiphysics design of an e-motor for Porsche AG. Altair’s simulation-driven approach supports the development of e-motors using a series of optimization intensive phases building on each other. This technical paper offers insights on how the advanced drivetrain development team at Porsche AG, together with Altair, has approached the challenge of improving the total design balance in e-motor development.


From Die Design to Defect-Free Castings: Shiva Tool Tech Achieves 80% Time Reduction with Altair Inspire Cast
Shiva Tool Tech is an automotive manufacturing focused, industrial powerhouse based in Pune, India. With over 25 years of experience in designing and manufacturing of gravity die casting (GDC), low-pressure die casting (LPDC), high-pressure die casting (HPDC) Dies, the company supports customers from manufacturing process design to the production stage. Manufacturing processes include milling, drilling, hardening, grinding, Computer Numerical Control (CNC) machining, Electrical Discharge Machining (EDM), inspection and polishing to get the final assembly of the casting die.

MDGo
Statistics on fatal vehicle accidents show that victims most often do not die during or right after a crash, but in the hours and days afterwards, with research indicating that up to 44 percent of people who died in car crashes could possibly have been saved if first responders and hospitals had
real-time, detailed information about the victim’s injuries. In an effort to transform data received from the car sensors into meaningful information about the victim's injuries, the MDGo team began applying crash simulation using Altair Radioss™. The Altair Startup program was a major help to the Israeli startup company in creating a system which automatically alerts first responders and hospitals of accidents, and reports on potential injuries.


Griiip
Israeli motorsport company Griiip has designed a new, fast and professional race car that combines efficiency in racing with a competitive purchase price and low running costs, to make it more affordable. By harnessing the power of data, Griiip has created the first smart connected race car – the G1 – and with it, an entirely new racing series. Accessing the software via Altair's new Startup Program, Griiip engineers employ several products from the Altair HyperWorks™ suite, among these Altair Radioss™ for crash simulation, Altair OptiStruct™ for structural optimization, general FE analysis as well as Altair HyperMesh™ and Altair HyperView™ for pre- and post-processing tasks in the development of race cars.

Gulplug
French startup Gulplug, located in Grenoble, France, has set out to revolutionize plug and charging technology used in today's electric and hybrid vehicles. To create new products and to drive innovation in the market, Gulplug is using Altair Flux™ and the Altair startup program. Flux helped Gulplug to model and create an innovative, clean, automatically self-plugging, magnetic based charging solution for electric vehicles.

Imperial Auto has Successfully Validated the Contact Pressure for O-Ring by Contact Analysis using Altair OptiStruct™ Solution
Established in the year 1969, Imperial Auto is one of the biggest integrated manufacturers of ‘Fluid Transmission Products (FTPs) in the world. The company has eight dedicated manufacturing and assembly plants in India. The grand vision of the company’s top management can be easily gauged from the strategic and technical alliances that Imperial has formed with major international players in their industry.

Pranav Vikas Achieves 17% Material Savings with Light Weight and Optimised Product Designs using Altair HyperWorks™ Solutions
With over 2 decades of experience in manufacturing Aluminum Heat-exchangers such as Condensers, Evaporators, Heaters, Radiators, Oil Coolers, IHX and Roof AC units, Pranav Vikas (India) Private Limited (PVL) today is one of the largest and most diversified Heat-exchanger manufacturers in India. The company currently is the only fully integrated Condenser manufacturer in India with their own state-of-the-art Micro-tube facility at Ranjangaon, Pune. PVL serves leading global and Indian Original Equipment Manufacturers (OEMs) in the Passenger, Commercial, and Off-road vehicle segments.

Sharda Motors – Usage of Altair CAE Solution for Durability Analysis
Sharda Motor Industries Limited (SMIL) is the market leader in the country in the manufacturing of exhaust systems, catalytic converters, independent suspension systems, seat frames, seat covers (two and four wheelers), soft top canopies, and stamped part for white goods products. Their state-of-the-art manufacturing facilities help them to continuously focus on new products, innovation, technology upgradation, and research & development. The facility seamlessly caters to various emission norms ranging from BS4, BS6, and Tier 4.

Andron Handling
Andron Handling needed to assess the strength of the welded fabrication and vertical clamping arms for both lifting and clamping loads. In previous analysis of this type in Altair SimSolid™, they would have removed the wheels from the model and applied reaction forces at the bottom of each of the clamp arms. In this case, Andron used a different approach that would not have been possible with previous FEA toolsets.

F.tech R&D North America
F.tech is a Tier-1 automotive systems supplier, headquartered in Japan. To help the CAE team at F.tech R&D North America overcome tedious challenges related to model build and geometry preparation for weld creation, Altair developed a customized solution. Developed using Altair’s Model Mesher Director (MMD) PSO (Packaged Solution Offering), the F.tech -Pre-processing Automation Solution (F.tech-PAS) is a streamlined toolset which aids F.tech engineers in CAE meshing and assembly from CAD to solver deck.

Fallbrook Technologies
Traction-based, patented NuVinci® transmission is a continuously variable planetary (CVP) technology enabling performance and efficiency improvements for machines that use an engine, pump, motor, or geared transmission systems. Fallbrook Technologies has been working on improving oil flow inside the NuVinci products as it affects the transmission’s efficiency, durability, power, capacity, and cost. Altair worked with Amazon Web Services (AWS), a secure cloud services platform, to provide an integrated solution to Fallbrook including advanced GPU hardware, high-performance computing (HPC) and the nanoFluidX software through industry-leading workload management and job scheduler Altair PBS Professional™.

Novum: University of Michigan Participates in Solar Car Challenges Around the World
See how Altair's Software is used to get University of Michigan's solar car, Novum, to the next level to compete in the World Solar Challenge in Australia and the American Solar Challenge - crossing an entire continent in both cases just on the power of the sun alone.

Improving Composite Design and Simulation Efficiency with Multiscale Designer
Dr. Jan-Philipp Fuhr - Managing Partner, Cikoni talks about developing a methodology to analyze and predict composite matrix and fiber failure using Altair OptiStruct and Multiscale Designer resulting in improved accuracy and simulation efficiency of their simulations.

Motorcycle Crankshaft Modeling with SimLab at BMW Motorrad
Learn about the semi-automated motorcycle crankshaft modeling process developed at BMW Motorrad based on Altair's pre- and post-processor SimLab. The scripts developed take the FE model generation time down from 2 weeks of manual work to half a day.

Minimising Interior Noise in Electric Vehicles
National Electric Vehicle Sweden (NEVS) leverages use of the Altair Squeak and Rattle Director in identifying and minimising risks of interior noise in electric vehicles.

Altair and Ziegler Instruments Combine Experience and Technologies to Identify and Eliminate Squeak and Rattle Issues
Altair has partnered with Ziegler-Instruments to enhance its Squeak and Rattle Director (SnRD), making it the most advanced and comprehensive solution on the market to predict and eradicate squeak and rattle phenomena in vehicles, aircraft and other products sensitive to Noise, Vibration and Harshness (NVH). The addition of Ziegler-Instruments’ PEM material database gives Altair’s SnRD clients access to the results for over 11,000 individual stick and slip phenomena for different materials pairs.

In this video, Patrick Schimmelbauer and Jens Herting of Ziegler Instruments give an overview of the partnership and what it means to companies needing to address squeak and rattle issues.

Developing More Accurate and Reliable Vehicle Component Models in Less Time with Software Automation at Changan Automobile
Pre-processing vehicle models is time consuming and complex, with many opportunities for error if done manually. Altair build a custom software solution to automate most of the pre-processing tasks.

Originating a safe Fun Utility Vehicle (FUV)
The challenge in the development of Arcimoto’s SRK Generation 8; an all-electric, multi-purpose/utility commuter vehicle, included creation of an optimized platform that offers
3-wheeled stability, a space frame enclosure for protection, and a rear swing arm that handles the load requirements and also follows the visual design of the vehicle. HyperMesh® provided an environment for rapid model generation allowing Arcimoto to answer queries by helping them perform the analysis in OptiStruct® in an easy, time efficient manner. Using RADIOSS® for the physics helped them achieve repeatable and accurate results, reduce simulation cycle times and allow for evaluating multiple design scenarios thus enabling better decisions.


Sujan CooperStandard Achieves Lightweighting and Performance Targets with Altair
Sujan CooperStandard manufactures (anti-vibration) NVH products for leading automotive companies. Currently, the automotive industry is under extreme pressure because of environmental norms and has to adhere to stringent government policies related to pollution control and one of the simplest ways to address these is to optimize designs and reduce weight of products and components. They began using Altair HyperWorks on the on the recommendation of their joint venture partner CooperStandard. The team decided to improvise design of their Torsion Vibration Damper using Altair solutions like solidThinking Inspire to optimize designs of the brackets and OptiStruct for structural integrity of the designs. Altair solutions have helped Sujan CooperStandard get their product designs right the first time and consistently meet their time, cost and quality targets.

Addressing Design Development Challenges Through Simulation Driven Platform
Automotive suppliers are facing many challenges in having in-house simulation capabilities compared to that of OEM’s. One of the ways to overcome these challenges is to invest in simulation technologies that require an affordable initial investment, the ownership cost of which is low, the codes are reliable & proven, and the suite of tools provide suppliers access to a broad range of solvers (a true multi-physics environment) helping them pick and choose the solvers as per their simulation requirements. In the early stage of in-house simulation implementation at Endurance Technologies, HyperWorks was being adopted primarily for pre and post processing due to its extraordinary FE modeling solutions. With constant support, Altair team has helped Endurance in exploring and implementing various HyperWorks solvers at Endurance Technologies.

Less Interior Squeak and Rattle Noise Using a Simulation Driven Design Approach
In the development of new vehicles, the PSA Group aimed to detect Squeak and Rattle (S&R) problems before availability of physical testing. This led to a collaboration between PSA’s method development engineering team and Altair’s domain experts.

U-Shin Ltd.
U-Shin is currently employing Altair Click2Cast to perform testing and optimization to create sound, redesigned automotive parts.U-Shin has seen significant time and cost savings by utilizing Altair Click2Cast.

Developing Efficient Design Procedures for Wideband, Low-profile Antennas Using Altair FEKO Electromagnetic Simulation Technology
Low profile, concealed antennas are frequently desired for diverse applications across many military and commercial vehicle platforms. A vehicle underside can be considered a viable alternative place for concealment as it provides enough space to avoid extreme antenna miniaturization. A study conducted at the Antenna Research Group (ARG) at the University of Colorado evaluated the bottom side of the vehicle as an alternative to more conventional antenna placement positions for mounting high-frequency VHF antenna systems. Altair FEKO EM field simulation methods were applied to assess antenna performance.

Subros Leverages Altair HyperWorks® to Build Optimized Product Designs While Reducing 60% Simulation Time and 40% Prototyping Costs
Subros is the leading manufacturer of thermal products for automotive applications in India and operates in technical collaboration with Denso. Being a major supplier of AC units to the predominant automotive segments and all classes of vehicles produced by global players in the country, it is very important for Subros to honor deadlines of product delivery with agreed benchmarks of quality. The Subros team has used Altair solutions such HyperMesh for FE modeling, RADIOSS and OptiStruct for structural analysis, AcuSolve for flow analysis, and solidThinking Inspire for Modal Analysis

Mando Softtech India Achieves Greater Simulation Accuracy with Altair HyperWorks®
As Manufacturers of Automotive Components such as Chassis and Brakes, Mando Softtech India has to ensure that they maintain highest performance and quality standards of the products they develop. Implementation of Altair HyperWorks solutions has helped them considerably reduce their product development time and costs, while augmenting product quality. Their overall development time was reduced by up to 30 to 40%.

ICAT Achieves Robust Structural Integrity of their Automotive Components using Altair HyperWorks®
The International Centre for Automotive Technology (ICAT) is an automotive testing and R&D centre. In their pursuit to carve a niche as a one-stop solution for the automotive industry’s needs in the areas of product design, testing and validation, the ICAT team required a very advanced suite of software solutions. They needed a software suite that would save them time, money and also help in all phases of product development. The Altair software suite has greatly helped the team in providing timely and appropriate solutions to their clients.

Daimler
Integrating antennas in windscreens has become popular due to the enhanced aesthetics and the increased antenna surface area that enables improved reception. However, the design of such antennas is a complex procedure. Antenna systems contain different antennas with mutual coupling, making it very inefficient and time consuming to optimize the FM-, DAB-, RKE- and TV antennas independently. Wanting to make the optimization process of its multi-port antenna more efficient, Daimler turned to Altair for assistance.

Ankers
Ankers performed co-simulation using a combined multibody and brake systems model in MotionView and Activate to generate more accurate results to analyze thermal and other effects on braking.

Simulation Speeds Roll Cage Design
Australian company relies on virtual tools to test the roll cage structures that keep motorsports drivers safe.

National Electric Vehicle Sweden (NEVS)
Due to a long-standing relationship with Altair and its HyperWorks suite of simulation solutions, NEVS approached Altair ProductDesign to see if the interior quality issue could be tackled with simulation. To perform the project, Altair ProductDesign worked on site alongside NEVS Interior
Simulation Team to implement Altair’s Squeak and Rattle Director (SnRD).

APWorks Light Rider: Optimization Process
First 3D-printed Motorcycle by APWorks (Airbus Group) called Lightrider. Altair's software OptiStruct was used for inspiration of the organic structure of the motorcycle.

  •  
CalsonicKansei North America
CKNA contacted Altair ProductDesign for training on the Squeak and Rattle Director, which led to more in-depth consultation on the squeak and rattle methodologies, ultimately saving the company time and money by helping them identify detrimental issues early on and by improving vehicle quality.

Lighter, farther, faster, greener: TUfast Eco team drives to success with HyperWorks
For the Shell Eco-marathon, an international contest for sustainable mobility, student teams from schools and universities all over the world design vehicles that are as energy-efficient as possible. After passing a technical check, the vehicles compete for energy efficiency. In this discipline the vehicles are evaluated for the vehicle’s reach per kWh. To compete in this category, a driver with a minimum weight of 50 kg has to drive a distance of 17.9 km in less than 43 minutes. The challenge for the TUfast Eco team was breaking the world record for efficient vehicles and participation in the Shell Eco-marathon. The Altair solution included topology optimization with HyperWorks.

LEIBER Group
LEIBER Group, which specializes in developing lightweight metal components, applied topology optimization to determine the ideal shape for a vehicle suspension beam, resulting in mass savings of over 50%

Triton Bikes
Triton Bikes utilized Altair Inspire to Increase performance, decrease the overall weight, and simplify manufacturability of a 3D printed custom bike rear yoke.

Mubea Relies on HyperWorks Unlimited™ for Automotive Component Design and Production
In performing lightweighting projects for large OEMs, Mubea is the only provider worldwide who delivers innovations of tailor-rolled blanks (TRB) which are ideal for not only vehicle body structural but also for suspension components that encounter different loads across their length. The Mubea team has worked collaboratively with Altair for over 6 years. With HWUL-PA, they are able to optimize their TRB applications more efficiently than ever before, including expanded capabilities for unlimited design exploration, reduced lead time and major cost savings over traditional hardware/software purchase

PSA Groupe Discusses the Simulation of Squeak and 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.

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.

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

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

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.

Technische Universität Dresden
The team at Technische Universität Dresden used Altair Inspire to redesign a Formula Student steering column mount that saved 35% of the weight and is produced with additive manufacturing.

Achieving Superior Crash Performance for the Souest DX7
Analysis and optimization to improve crash performance while reducing reliance on physical tests.

Optimization-driven Product Development at Volvo
Harald Hasselblad (PhD) - Senior Analysis Engineer at Volvo Car Group Sweden - talks about introducing an Optimization Culture Arena to support simulation driven development in his company.

Texas Instruments
Using Altair Embed, Texas Instruments was able to develop an embedded simulation of an entire system.

Hyundai Mobis Automotive Group Improves the EMC Analysis Process from 2D to 3D Using FEKO for Shielding Effectiveness Simulation
To analyze and optimize the shielding effectiveness of the housing in an Around View Monitor (AVM) while meeting EMC requirements, Hyundai MOBIS automotive group improves the Electromagnetic Compatibility Analysis (EMC) process from 2D to 3D using FEKO for shielding effectiveness simulation

Top Use Cases: ESAComp
Presentation introducing a few of the top use cases for the composites software, ESAComp.

Ford Battery Group Adopts Radioss Cut Methodology
In order to improve the simulation and accuracy of a high fidelity battery CAE model. Ford has turned to the cut methodology available in Radioss.

Bremar Automotion uses Altair Radioss to Design & Certify FIA Motorsport Roll Cages
“The Altair product is it for us in terms of simulation. That’s all we use. It’s great to be able to show such good correlation between the simulations and physical testing, and to have confidence in not only our approach, but also the Altair product as well. It’s a great product for us to be using, and the test results and these images just back that up for us.”

Brett Longhurst, Managing Director, Bremar Automotion

Optimized Design for 3D Printed Valve Block Sheds Weight, Size and Gains Improved Performance
Not every component or product is suitable
for 3D printing, depending on its size, form
and design as well as the quantity needed.
A valve block is very suitable for 3D printing
and has a high potential for improvement in
weight, performance, and design freedom
when additively manufactured.

Application of HyperWorks to Develop Human Body Models to Assess Injury Potential for Vulnerable Populations in Vehicle Crashes
The effects of obesity on occupant responses
in frontal collisions were investigated using
the UMTRI whole-body human finite element
models. A modeling approach was developed
and applied that allowed for rapid change of a
baseline human body model into geometries
representing adults with different BMIs without
the need for re-meshing the models.

Student Team H2polit0 of Politecnico of Torino Applied HyperWorks to Reduce Vehicle Weight and Fuel Consumption on Shell Eco Marathon Europe Competition
Student teams from around the world participate in the Shell Eco-marathon (SEM), a unique low energy consumption competition for student teams. Within the competition the teams strive to design, build and drive the most energy-efficient car. In three annual events in Asia, Americas, and Europe, student teams compete on the track to see who goes furthest on the least amount of fuel. The competition evaluates different aspects of the car, the most important of which is of course the energy consumption: the less energy the car needs, the better it will rank.

Climbing the Winner’s Podium with HyperWorks
HyperWorks allows for the option to increase the stiffness of the wheel shell through the use of OptiStruct. By applying HyperWorks to
their composite design and development process the team was able to increase the stiffness of the chosen components by 10 percent while learning how to do a structural layout of carbon fiber composites.

Using HyperWorks to Develop Human Body Models for Vehicle Crash Simulation
Wake Forest Baptist Medical Center is a leading research university in biomedical sciences and bioengineering that provides students and faculty with outstanding opportunities for personal and professional growth.

Minimising Mass and Increasing Durability of a Vehicle Suspension System Using OptiStruct
Gestamp selected Altair to develop a set of custom tools within HyperWorks, eliminating the need for an initial 'trial and error' design loop while reducing mass and increasing durability of a rear twist beam suspension system. The company achieved a reduction in lead time while producing competitive low cost, low mass RTB designs.

U-Shin Improves Product Design of Automotive Parts with Altair CAE Solutions
U-Shin is a global automotive part supplier, specializing in the development and production of automotive system appliances and mechatronics products as well as on the research of element technologies. Safety, reliability, adaptability, quality, eco-friendliness, are among the major concerns of the company.

FIAT Customer Story
FIAT chose Altair ProductDesign as a partner to perform a pilot project to investigate squeak and rattle. The project focused on studying issues on the FIAT UNO, a vehicle made exclusively for the South American market. Altair ProductDesign suggested that FIAT implement Altair’s ‘Squeak and Rattle Director’ (SNRD), a comprehensive set of services and software automations that rapidly identify and analyze design alternatives to eliminate the root causes of squeak and rattle in assemblies. With customization from the Altair ProductDesign team, the solution provides a semi-automated approach to determine relative component displacements in the time domain that can lead to undesired noise. A dedicated four day workshop facilitated a fast ramp-up of the NVH team’s knowledge of the SNRD and helped Altair to identify FIAT’s specific design process that the solution could be tailored to.

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.

Establishing Simulation-Driven Design at Scania
Mikael Thellner from Scania Trucks talks about improved design processes thanks to solidThinking Inspire. Designers can evaluate their products in earlier stages due to the ability to do analyses themselves.

Anadolu Isuzu Increases Truck Safety with HyperWorks Products
Safety Engineer Caner Kara is talking about their usage of Altair products in the design process of trucks and buses at Anadolu Isuzu.


Scania
Scania uses a simulation-driven design process including topology optimization and finite element analysis. This speeds up their design and development process and produces lighter, more efficient components.

Monash Motorsport takes advantage of optimization and additive manufacturing technologies and wins again!
Since their first Australian SAE Student Racing competition in 2000, the Monash Motorsport team has steadily improved the performance of their race car. Recently the students discovered the benefits of combining Altair‘s OptiStruct optimization technology and 3D printing. Based on an initial prototype rear hub design from the 2013 car, the team proceeded to pursue titanium front hubs and uprights to decrease the car’s unsprung mass. This was a tough challenge, since the former design was already made of lightweight aluminum. To tackle this, Monash Motorsport employed Altair’s optimization technology OptiStruct to design and optimize a titanium upright, which was then produced using additive manufacturing technology from CSIRO. As a result, the students were able to reduce the component’s weight by a further 30 percent whilst maintaining the component stiffness and reducing the development time and costs.

AAM
American Axle & Manufacturing employed topology optimization and FEA to redesign an automotive carrier to achieve a weight reduction of 20%.

Radioss Case Study with PSA Peugeot Citroën and Bull
PSA Peugeot Citroën collaborated with Altair, Bull, PRACE and others to perform a study of automotive crash rupture simulations, investigating ways to improve material failure criteria and better predict cracks.

EDAG: Developing Commercial Vehicles Inspired by Nature
As Germany's largest independent engineering
partner to the worldwide automotive industry,
EDAG is continuously seeking for new technology and for innovative processes to streamline vehicle development.

Increasing Robustness and Reliability of a Race Car Engine with AcuSolve
This study is part of Prodrive’s implementation of AcuSolve to enhance its CFD capability after many years of outsourcing these simulations.

Optimal Design Exploration Using Global Response Surface Method: Rail Crush
As design exploration and optimization methods have become commonly accepted across a range of industries, such as aerospace, automotive or oil and gas, they are frequently utilized as standard practice to efficiently produce designs and aid critical engineering decisions. The widespread acceptance of these methods coupled with the power of modern computing has led to applications across a range of design problems and ever-increasing complexity. The size and scope of this expansion continually pushes the boundaries of existing exploration and optimization methods. Furthermore, a complete exploration of the optimal design space includes computationally intensive features such as multi-objective optimization, to understand the trade-off between competing objectives, and global optimization, to avoid local extrema.


Failure Criteria for Stamping Analysis in Radioss
In this paper, several failure criteria are compared in their ability to predict necking point and failure propagation during a forming process. The paper has been presented at the 2014 IDDRG Conference in Paris, France.

Luxon Engineering Applies Optimization-driven Design to Motocross Components
The motorcycles used in motocross racing demand light weight and high strength components in order to gain a performance advantage over the competition. In this video testimonial Billy Wight, President of Luxon Engineering, presents a case study of applying Altair HyperWorks optimization techniques in the design of a motocross triple clamp assembly and rear suspension linkage.

HardMarque
HardMarque coupled topology optimization with additive manufacturing to conceptualize and refine the design of a piston. The final piston design is 23.5% lighter than the original design. 

Race Face
Race Face redesigned a bicycle crank using generative design and finite element analysis. The concept design process yielded a part with increased stiffness and strength without increasing the weight of the part.

Reducing Weld Distortion by 93% with HyperStudy
Gestamp Tallent Ltd is a world class designer, developer and manufacturer of cutting edge, chassis structural and suspension products, body in white structures, modules and systems for the automotive industry. Gestamp used the BMW MINI front subframe tower to demonstrate the weld distortion optimisation approach. The tower is particularly susceptible to distortion due to its tall and thin dimensions. The objective of this optimisation was to minimise the distortion of the tower measured by the displacement of the top of the tower as the weld sections cool. In order to further investigate weld removal optimisation they chose HyperStudy.

Scania Customer Story
Squeak and rattle phenomena are studied in the automotive industry in an attempt to reduce the cabin noise and as a result, give a better ride quality and comfort to occupants. In the case of Scania’s Cabin Development Department, this kind of simulation was not performed historically. The team had to rely on tolerance calculations as well as the choice of materials to reduce the risk of squeak and rattle. To reduce development time and cut down on iterative changes, a desirable solution was identified that enabled a simulation-driven design process during the early stages of the cabin development cycle.

HyperWorks provides flexibility and agility to development processes of Engineering Services Provider Beta Epsilon
Beta Epsilon designs racing cars and offers engineering. Beta Epsilon offers component and vehicle meshing, FEA analysis of metal and composite components, crash test simulation, optimization, and CFD simulation. Beta Epsilon uses HyperMesh, OptiStruct, HyperCrash, RADIOSS, AcuSolve, HyperView, and Virtual Wind Tunnel. With HyperWorks, Beta Epsilon could improve the quality of its products and extend its range of services.

Reducing Weight and Maximising Fuel Efficiency of a Formula Student Car with OptiStruct
Durham University Electric Motorsport (DUEM), are a UK-based team of students who design, build and race electric vehicles. In this project, DUEM wanted to demonstrate how they have applied the latest weight saving technology to achieve a faster, more efficient car by optimising an upright design for multiple load cases. As existing users of the Altair HyperWorks simulation suite, the DUEM team looked to OptiStruct to help meet this challenge.

HyperWorks Virtual Wind Tunnel on Cray: Benchmarks and Recommended Configurations
With Altair’s HyperWorks Virtual Wind Tunnel running on Cray XC30 or CS300 systems, manufacturers of all sizes can now predict a vehicle’s external aerodynamic performance without the need for numerous physical wind tunnel tests. This document includes scalability benchmarks for both small and large problems, along with Cray’s recommended system configurations to run Virtual Wind Tunnel.

When Engineering Intuition is Not Enough
A new technology helps design engineers quickly create dramatically lighter structures — and better understand the effects of material placement in whatever they’re developing.



Simulation Tools: Driving the Future of Design
The Clemson University Deep Orange 3 program introduced future engineers to analysis software, enabling them to develop a novel sports car concept architecture.



By Dr. Paul Venhovens

Concept To Reality Winter 2013 Subscribe to C2R Magazine

BASF Enlightens the Auto Industry
Continuous fiber-reinforced thermoplastic composite and virtual simulation technology enables BASF to develop an innovative and cost-neutral seat pan that is 45% lighter than its predecessor.



By Beverly A. Beckert

Concept To Reality Winter 2013 Subscribe to C2R Magazine

Toyota Motorsport
Controlling Software Costs with Altair’s Software Asset Optimization System



TMG chose Altair’s Software Asset Optimization (SAO) system to address this problem. SAO (Software Asset Optimization) enables the user easy and efficient access of the actual software usage of existing licenses in his company. He can analyze the software usage and based on this information make appropriate decisions concerning the acquisitions of new licenses and the extension of existing contracts.

Success Story: M.TEC
M.TEC Engineering Continues to Benefit and Yield New Business Due to Advantages of the Altair Partner Alliance (APA)

Polaris Reduces Weight of Snowmobile Structures Up to 40% with solidThinking Inspire and OptiStruct
Polaris, based in Roseau, Minn., is a
renowned manufacturer of snowmobiles,
and its Snowmobile Chassis Structures
Group is engaged in design and testing that supports three different platform teams with chassis solutions for each set of requirements. Computer-based design and finite element (FE) analysis are integral parts of the Polaris snowmobile development process, as engineers work to create optimal structures that reduce weight without sacrificing performance.

Dana Adopts Altair’s SimLab to Automate Meshing of Powertrain Models with Dramatic Time Savings
Dana Holding Corporation is a world
leader in driveline, sealing, and thermalmanagement
technologies that improve
fuel efficiency, reduce emissions and
lower the cost of ownership in passenger,
commercial and off-highway vehicles.
Dana's 25,000 employees operate in
27 countries within a network of some
90 engineering, manufacturing and
distribution facilities.
Computer simulation of powertrain
components—entailing the creation of
very large models with 25,000 surfaces or
more—has long been an important aspect
of Dana’s product development process.
For many years, the company’s engineers
have employed a standard industry
methodology of transforming CAD designs
into prototypes, analyzing the prototype
to observe failure points, redesigning
the prototype and retesting until the
product met specifications.

Cooper Standard Speeds Development of Next-Generation Pumps with Altair’s AcuSolve CFD Solver
With more than 22,000 employees in
19 countries, Cooper Standard supplies the vehicle industry with fluid delivery systems, sealing and exterior systems, thermal and emission systems and AVS. The company’s Electromechanical Department is an advanced research and development arm of the Cooper Standard North America division. It’s goal is to marry mechanical systems with electronic controls. This new technology improves overall vehicle efficiency by providing on-demand fluid delivery and by eliminating the power loses inherent in conventional systems.
In designing new pumps for this type of system, CAE Engineer Tom Lincoln uses computational fluid dynamics (CFD) software to simulate the flow of coolant through the device. He and his team began using CFD computer-aided engineering tools as long ago as 2003, and computer simulations have become an essential part of his organization’s product development process.

BiggerBoat Solutions Makes Waves in Auto Industry Using HyperForm to Cut Die Development Costs and Time
When the auto industry crashed in 2008
and the tool shop where Jay Weiner worked
closed its operations, he started his own
company, called BiggerBoat Solutions Ltd.
He carries out metal-forming simulations
for major tooling suppliers and originalequipment
manufacturers. With 15 years
of experience in tooling design, Weiner and
his Toronto-based practice offered a service
that no one else had perfected but that
was crucial to a key process in automotive
manufacturing: the simulation-based die
design for stamped sheet-metal parts.

CFD Advances Racing Bike Performance
Highly automated computational fluid dynamics (CFD) workflows enable the discovery of flow behaviors, improving wheel aerodynamics.



Mathew N. Godo, Ph.D. and David Corson, Ph.D.

Concept To Reality Summer / Fall 2012 Subscribe to C2R Magazine

Simulation: The Connection between Speed and Safety in Racing
Chassis manufacturer relies on simulation
and optimization to develop the fastest
– and safest – race cars on today’s circuits.


By Luca Pignacca

Concept To Reality Summer / Fall 2012 Subscribe to C2R Magazine

Altair Enables BorgWarner to Automate Process for Determining Combined Impact of Temperature and Mechanical Stress on Turbochargers
Inherently, turbochargers are adversely impacted by hot exhaust gases. This heat impacts the material strength of the turbocharger housings, resulting in degraded performance and the potential creeping or rubbing of turbine wheels. When extreme fluctuations occur, the turbocharger can suffer from premature thermal-fatigue resulting in cracking.

Gordon Murray Design
Overcoming the Challenges of Composite Design



Automotive manufacturers are utilizing lightweight materials as a method of minimizing mass and maximizing fuel economy. Automotive design company, Gordon Murray Design (GMD) believes that composite materials can play a much larger role in the manufacture of vehicles. To prove its case, the company has developed ‘iStream’, an efficient process for manufacturing low and high volume cars from lightweight material. To validate the iStream structure, GMD required an experienced simulation partner.

Automotive Weight Management Article
The automotive development process is still focused on objectives such as durability and crash safety, while weight is often limited to the very end of the design process. Through the establishment of the “Optimization Center” (OC) concept, Altair ProductDesign has developed an innovative design model combining performance features with weight reduction goals. This article describes the OC concept dealing with everything from the optimization of single components to an entire optimization process known as “CAE Weight Management”.

Altair BUSolutions
Developing the World’s First Series Hydraulic Hybrid Bus



The Federal Transit Administration (FTA) requires modern transit bus systems to provide more efficient services across America. Currently, U.S. public bus transit authorities are subsidized to meet operating budgets with State and local subsidies exceeding $19 billion per year and Federal subsidies exceed $7 billion per year. The goal of the BUSolutions project is to design and manufacturer a new bus with improved fuel economy, lower emissions and a lower life cycle cost than today’s buses.

Tallent Automotive
Customized Solutions to Reduce Chassis Mass by 25%



To meet the growing demands for lightweight, fuel efficient vehicles, Tallent Automotive required a more automated method to produce minimum mass sheet metal chassis components which took performance targets and manufacturing constraints into account.

OPEL
Improving Design Productivity through Automation



OPEL identified the design process of engine mount systems as a candidate for a process automation solution. As an objective, NVH engineers had to be able to generate input decks even without detailed load case information. Knowledge had to be captured and re-used in a standardized workflow. Automatic optimization and robustness analysis of the mount parameters had to be integrated into the process to quickly improve final product quality.

MCE-5 DEVELOPMENT uses HyperWorks Suite to optimize engine performance
MCE-5 DEVELOPMENT is developing the MCE-5 VCRi variable compression ratio engine which reduces fuel consumption and CO2 emissions from 20% to 35%. The MCE-5 VCRi engine provides a concrete technological and commercial response to the environmental, energy and economic challenges faced by the automotive industry. The MCE-5 VCRi engine combines advantages of both Diesel and gasoline.


For more information on the MCE-5 VCRi project, please visit: www.VCR-i.com.

Superior Industries Accelerates its Design Process With HyperWorks
Superior Industries was looking to identify a solution to aid in shortening the overall product design cycle through simulation. Altair HyperWorks, proved instrumental in automating some of the most tedious of tasks and dramatically impacted the design process.

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.

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