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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.

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.

Success Story: IVECO Australia

HyperWorks and the Altair Partner Alliance Streamline Testing of Truck Components at IVECO Australia

Daimler

During the development of a new vehicle variant, Daimler wanted to explore the potential of utilizing a multi-disciplinary approach to optimization (MDO), whereby several attribute performance targets are considered in a single optimization study, a technique that has the promise to deliver rapid design direction to design teams.

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.

CFD Oilsplash Simulation in Driveline CAE

A brief presentation on how GKN Driveline performs CFD Oilsplash Simulation using nanoFluidX.

Experimental and Numerical Investigation of Churning Losses in Powertrain Components

A brief presentation on how Magna is predicting and improving powertrain efficiency with nanoFluidX.

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.

Arkal Automotive Case Study Video

Arkal Automotive Optimizes FEA Data Creation Workflow with HyperMesh and CADdoctor.

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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. Bremar Automotion provides simulation, testing, validation and design optimization services.

By Beverly A. Beckert
Concept To Reality Winter/ Spring 2017
Subscribe to C2R Magazine

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).

Success Story: Toledo Molding & Die

HyperWorks and the Altair Partner Alliance improve tuning frequency predictions for induction systems at Toledo Molding & Die.

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%

Use Case: KTex Family for Manufacturing

Predicting the impact of the manufacturing process on composite materials.

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.

CADdoctor Case Study: Arkal Automotive

Arkal Automotive Optimizes FEA Data Creation Workflow with HyperMesh and CADdoctor.

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

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.

Altair Offers Flexibility and Enhancement for Casting Process Design and Optimization

The goal of the project outlined in this paper is to get the optimal gating system (size and position of ingate) to help avoid porosity and other common defects in the produced parts, achieving the final design to begin casting the component.

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.

3D Printing for Innovative Mold Making Combined with Simulation Driven Design Inspiration Push the Limits for High Performance Castings

Altair, Click2Cast, HBM nCode, and voxeljet present a technology demonstration that stands out with dramatic performance improvements and the solid potential for serial manufacturing and mass production. Bringing design optimization, fatigue analysis, casting, and 3D printing together addresses the challenges of lightweight design and enables the creation of an innovative design and manufacturing process that enhances performance and efficiency.

F.tech R&D North America

F.tech R&D North America utilizes HyperView to investigate test results, using the data to inform decisions on methods to improve designs. This data will often be used to create reports and presentations during the development process, using images and animations generated by HyperView to illustrate particular areas of a component where additional work may be required. However, exporting these assets is a highly manual process of loading in results, positioning the model and taking screenshots. To allow its engineers to concentrate efforts on exploring and interpreting the results, F.tech R&D North America wanted a way of automating this process.

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.

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.

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.

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

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.

By Beverly A. Beckert
Concept To Reality Winter 2013 Subscribe to C2R Magazine

Success Story: Mahindra Two Wheelers

Two-Wheeler Designer-Manufacturer Cuts New Component Time to Market and Optimizes Component Design with the Altair Partner Alliance

Success Story: M.TEC

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

Altair Products and Partners Offering Assist Commercial Vehicles Seat Manufacturer to Enhance its Development Process

Isringhausen applies DesignLife, Moldex3D, and Total Materia alongside RADIOSS, OptiStruct and other HyperWorks tools to optimize weight and durability of their customized seats while still meeting safety standards.

Success Story: HBPO GmbH Achieves Flexibility and Cost Efficiency in Automotive Development By Leveraging the APA

HBPO GmbH optimizes their design process by utilizing multiple products, such as Moldex3D, Total Materia and MADYMO, alongside HyperWorks products for the development of their front end modules.

Intel-Colfax-Altair Trial Cluster Testimonial: Nexteer Automotive

Nexteer Automotive used Colfax’s “Try Before You Buy” cluster trial program to run an OptiStruct simulation for design optimization. Their job ran in just 30 minutes instead of 2-3 days.

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

HyperWorks improves development processes at PSA Peugeot Citroën

Challenge: Define new process that includes accurate component data
Altair Solution: Use HyperForm and RADIOSS in development process
Benefits:
  • Reduce Development Time
  • Accelerate Innovation
  • Improve Quality and Robustness


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.

Van-Rob Expands the Scope of Its Projects, Saves Time and Money, Using Altair Partner Alliance Software in Designing Automotive Assemblies

Van-Rob, a tier-one automotive supplier headquartered in Aurora, Ontario, designs and manufactures metal stampings, modular welded assemblies, structural welded assemblies, and mechanical assemblies. Van-Rob needed upgraded its durability and fatigue technology to satisfy customer demand, but infrequent use made it difficult to justify cost. Altair’s APA licensing model allowed Van-Rob to use nCode DesignLife for durability analysis without needing to spend resources on additional licensing.

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.

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.

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.

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 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.

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.

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.

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.

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.

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.

HyperWorks Process Manager Delivers Productivity and Quality Gains to Chassis Design Process

Using Altair HyperWorks Process Manager, M&M was able to implement best practices through standardization of CAE processes and minimize CAE analysis set-up time. Automated post-processing enabled through Process Manager facilitated a 40% reduction in time when compared with the manual practice of post-processing.

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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