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Development of Reliability Analysis and Multidisciplinary Design Optimization (RAMDO) Software

In manufacturing industry and DoD, developing and producing optimized and reliable
products is the primary goal for success of business, reduction of warranty cost, and success of
military operations. As the CAD and CAE tools are advancing, the simulation-based design
process is often used to obtain an optimum design, prior to prototype development, to reduce the
product development cost. However, a design that is deterministically optimized without
inclusion of input uncertainty will be most likely only 50% reliable.

Electromagnetic Interference in Automotive and Aerospace

Both the automotive and aerospace industries face ever-increasing Electromagnetic Interference challenges. In the automotive case, new problems arise due to proliferation of electric and hybrid cars, which carry high-voltage systems, and of wireless infotainment and safety systems, which use high frequencies. The aerospace industry’s challenges are exacerbated by the use of composite materials and by the need to protect against lightning strikes.
This presentation will discuss many of the challenges and explain how they can be met with simulation. A few practical examples involving cable harnesses will be analyzed in more depth.


Topology Optimization of Nose and Forward Fuselage

The aeronautical sector is facing many concurrent challenges since OEMs have to ensure their commitments in terms of delivery, whereas eco-responsibility, eco-efficiency and sustainable development are becoming more and more significant requirements. In this environment, competition between all players of the sector increase with new comers, offering low cost capabilities and strong investments.

Performance Evaluation, Scalability Analysis, and Optimization Tuning of Altair HyperWorks on a Modern HPC Compute Cluster

Engineers from wide ranges of industries face ever increasing needs for complex, realistic models to analyze the most challenging industrial problems; AcuSolve is designed to tackle these finite element-based Computational Fluid Dynamics (CFD) simulations with superior robustness, speed, and accuracy. AcuSolve simulations are designed to carry out on large-scale computational systems effectively. The breakthrough in HPC parallel computing that allows such complex analyses to be performed that generate the high-quality results, while reducing simulation time from days to just hours. Behind this type of computational improvement that makes AcuSolve perform, it involves complex calculations and data exchanges among computational systems. The more complex simulations are being performed, the higher demands from the cluster performance are. In this analysis, the HPC Advisory Council has performed a deep investigation and profiling for the AcuSolve CFD solver to evaluate its performance and scaling capabilities and to explore potential optimizations. This study presents the optimization techniques and networking profiling results to further understand AcuSolve dependencies on the CPUs, communication networks, IO subsystems and the underlying hardware. The paper will review the effects by comparing various hardware using different simulation models.


Structural Component Design Optimization for Additive Manufacture

Additive manufacturing (AM) technology enables the possibility of realizing highly efficient, optimized structural components with configurations not achievable using conventional manufacturing methods. The Altair and Solid Thinking toolsets provide advanced capabilities to design structural topologies to minimize weight and maximize other performance criteria. However, conventional manufacturing processes require application of design constraints, such as directional access for machining, in the optimization that limit the structural efficiency of the resulting design. AM can remove many of these constraints to allow for more efficient configurations under the applied loading conditions. Case studies show the potential to reduce weight up to 30% for components with applied bending and torsional loads by allowing increased complexity configurations that could only be manufactured additively.

Teaching Aerospace Design Optimization

Engineers develop design and analysis skills through application of principles, methods, and tools to the solution of complex, often ill-defined problems. Engineering training that focuses on simple, focused component-level applications teaches some portion of the skills needed to execute real world problems but is incomplete. Altair has experience both deep and broad in applying optimization technologies and has developed a training curriculum aiming to teach engineers more comprehensive design optimization skills and knowledge in aerospace applications. The Altair Aerospace Optimization Academy has been developed as a series of online modules to develop deep design and optimization knowledge and skills in engineers that have basic structural analysis and finite element experience. The training curriculum leads students through complete design cycles using Altair’s advanced optimization technologies and explores the different approaches that engineers can use to develop aerospace designs for a variety of metallic and composite components and configurations.

Accurate Simulation of Short-Fiber-Reinforced Automotive Parts

For fiber reinforced automotive parts the consideration of anisotropic material behavior is required to receive reliable results. In the scope of this fact a procedure is described how to consider these effects in terms of process-structure interaction and how to achieve possible benefits such as weight reduction and shorter development cycles. The procedure is outlined with practical applications from company Valeo Ligthing Systems and another industrial partner project that is currently still in progress.

Lead Time Reduction using Automatic Reporting Director (ARD) for MAHLE

Mahle is one of the top automotive suppliers and one of the top 3 piston suppliers worldwide. With the recent advancements in numerical simulation and computing power, the FEA process has become a major tool to look at the reliability of different design variants. With these advancements, the reporting aspect remained a relatively unchanged process of manually creating pictures and tables with all of the different results. This presentation will look at the collaboration work between Mahle and the Altair Product Development (PD) team to customize the Automatic Reporting Director (ARD) for Mahle's requirements. The goal was to use to better utilize the engineers time by automatically generating a report with standard formats, pictures, and tables. By using the ARD tool, Mahle was able to reduce the lead time for a report from over 4 hours down to less than 1 hour.

Forming Simulation of Woven Composite Fibers and Its Influence on Crash Performance

The automotive industry, in its constant quest for weight reduction, is increasingly considering composite materials as a substitute for sheet metal components to meet future fuel consumption standards. However, composite forming processes are expensive and difficult to control because of the complexity of the material behavior with fiber and matrix layers or plies and its dependency on many parameters, such as non-linearity of tensile stiffness, effect of shear rate, temperature and friction. Hence, numerical simulation could be a viable approach to predict material behavior during composite forming. The objective of this study is to highlight capabilities of RADIOSS™ to simulate forming simulation of composite plies made from woven fibers, each ply modeled as a layer of woven fibers along two directions of anisotropy, warp and weft. For validation the well-known double dome model published in NUMISHEET’05 proceedings is used. The compared result is the shear angle after stamping that is, the final angle between warp and weft fibers, at several prescribed points on the ply. The variation of this angle has a strong impact on material characteristics which severely deteriorates when a critical value is reached. Hence, a study on crash simulations is performed, after mapping fibers angles from stamping simulation.

Meshing the Human Lumbar Spine

HyperWorks customer Jeff Harris from NuVasive has used HyperMesh to solid hybrid mesh consecutive human vertebrae and discs from a patient bone scan. The meshing, set up in Hypermesh, is simulated using Ansys for motion limits, stiffness, and disc material correlation. Once a model is correlated, disc implants are modeled and simulated with the goal of replacing degenerate discs.

Advances in EM Simulations

This paper introduces some of the recent extensions to the computational electromagnetics code FEKO as released in Suite 7.0. The FDTD (Finite Difference Time Domain) method was added to the selection of available solvers. MLFMM (Multilevel Fast Multipole Method) and PO (Physical Optics) were hybridized for electrically large applications. The RL-GO (Ray-Launching Geometrical Optics) solver was extended and improved in terms of speed and accuracy, and a new interface to import measured near-field antenna data from MVG/Starlab will be presented.

An Automated Head Impact Process Setup for Automobile Instrument Panel (IP) Application

FMVSS 201 procedure originally rolled out in 1968 by Federal Motor Vehicle Safety Administration to protect the automobile occupants from fatal injury during the crash. Since the beginning of the law, the automobile interior safety has become considerably more challenging for manufacturer to meet FMVSS 201 standard criteria. During the course of instrument panels (IP) development, engineers are heavily relied on computer simulation to optimize the design for a more robust design. Based on FMVSS 201, there are an infinite number of target points on the instrument panels that must be tested for head impact performance. Therefore, this becomes not only costly but it is impossible for the manufacturer to test all possible target points using the current conventional process.

The Use of Suimulation (FEKO) to Investigate Antenna Performance on Mobile Platforms

Wireless technologies have proliferated onto automotive platforms as part of infotainment, telematics and active safety initiatives. These wireless solutions present engineers design challenges in the area of applied electromagnetics in terms of antenna design, antenna placement, electromagnetic compatibility and wave propagation. The Applied EMAG and Wireless Lab at Oakland University possesses an outdoor vehicle-level antenna range (80 MHz - 6,000 MHz) and full-wave electromagnetic field solvers with high end computers to solve these issues. This presentation will highlight some of the past and recent research projects conducted in my lab that relied on a full-wave electromagnetic field solver to investigate the issue and subsequently be validated with measurements.

Motivations, Opportunities and Challenges of Additive Manufacturing for Space Application

Additive manufacturing (AM) technologies have progressed rapidly in the last years. Supported by the recent developments of design optimisation tools and manufacturing capabilities, components and parts produced using AM are emerging more and more into the focus of space industry.
The aim of this presentation is to show why AM can be seen a promising manufacturing technique for space industry and in particular for satellite application?
Opportunities and challenges that have to be faced to make 3D printed components “flying” on spacecraft are presented and discussed.
The re-engineering and qualification approach of the already existing Antenna Support Bracket, that is part of the Sentinel-1 spacecraft, is discussed as a case study to bring this topic into the more tangible context of an industrial project.


A Multifunctional Aerospace Smart Skin Emerges from Computational Models and Physical Experiments

The capability to assess the current or future state of the health of an aircraft to improve safety, availability, and reliability while reducing maintenance costs has been a continuous goal for decades. Many companies, government agencies, and academic institutions have become interested in Integrated Vehicle Health Management (IVHM) and a growing effort of research into “smart” vehicle sensing systems has emerged. Methods to detect damage to aircraft materials and structures have historically relied on visual inspection during pre-flight or post-flight operations by flight and ground crews. More quantitative non-destructive investigations with various instruments and sensors have traditionally been performed when the aircraft is out of operational service during major scheduled maintenance. Through the use of reliable sensors coupled with data monitoring, data mining, and data analysis techniques, the health state of a vehicle can be detected in-situ.

Pure Michigan. We run on Brainpower

A presentation on Michigan’s automotive industry. An overview of the automotive strategy that was developed by the Michigan Economic Development Corporations automotive office and the continued work in the area of talent development including the new “We run on brainpower” campaign.

Altair NVH Solutions - Americas ATC 2015 Workshop

This Workshop Presentation on NVH was conducted by Jianmin Guan at the Americas ATC on May 5, 2015. This workshop introduced Altair full frequency and multi-physics solutions for solving the most pressing problems in the NVH field. It provided an overview of Altair’s solutions designed to facilitate the best in class NVH design process at automotive OEMs, coupled with real-time demonstrations of key product features. The focus of the workshop is on effective NVH problem resolution.


Electromagnetic and Mechanical Analysis Using the Coupling between Flux and Vibro-acoustics

The purpose of this presentation is to show the different steps of the vibro‐acoustic study of a rotating machines with the new coupling between Flux 2D/3D and ANSYS

ATCx - Multi-objective Optimization of a Heat Sink for a LED Device using SC/Tetra and HyperStudy

Presentation from Yuya Ando that was given at ATCx West on June 18, 2014

ATCx - Structural Optimization of Turbine Engine Components for a Competitive Advantage

Presentation on Structural Optimization of Turbine Engine Components for a CompetitiveAdvantage by Don Holcomb, Staff Engineer, at Honeywell. This was presented at ATCx West on June 18, 2014

ATCx - A Structural Stress Method for Weld Fatigue in both Shell and Solid Finite Element Models

Presentation on "A Structural Stress Method for Weld Fatigue in both Shell and Solid Finite Element Models." This was presented by Jeff Mentley, DesignLife Specialist, HBM-nCode, at ATCx West on June 18, 2014

ATCx - Inspire 2014 Overview

Presentation of "Inspire 2014 Overview." This was given by Russell Vernon, Application Engineer, solidThinking, at ATCx West on June 18, 2014.

ATCx - Altair Solvers Overview

An Altair solvers overview presentation given by Uwe Schramm, Chief Technical Officer, Altair, at ATCx West on June 18, 2014.

ATCx- Hyperviscoelastic Coefficient Determination of a Spherical Impacter using HyperStudy Optimization William Giannetti, Sr. Research and Development Engineer, Swift Engineering

A presentation on "Hyperviscoelastic Coefficient Determination of a Spherical Impacter using HyperStudy Optimization." This was presented by
William Giannetti, Sr. Research and Development Engineer, Swift Engineering, at ATCx West on June 18, 2014.


ATCx - OptiStruct: Modern Solver Technology for Innovative and Lightweight Design

Presentation on "OptiStruct: Modern Solver Technology for Innovative and Lightweight Design." This was presented by Warren Dias, Business Development Manager – OptiStruct, Altair at ATCx West on June 18, 2014.

An Application of Using HyperWorks® Partner Alliance Software for Solving a Structural Problem with Anisotropic Material Properties

Jake Xu, Senior CAE Specialist, Van-Rob

In nowadays automotive industry, innovative materials are demanded to replace traditional metals for a variety of structural components in order to make the vehicle lighter. Meanwhile, there is no compromise of related performance requirements.

Improved Quality Prediction of Injection Molded Fiber Reinforced Components by Considering Fiber Orientations

Sascha Pazour, FEA Specialist, PART Engineering GmbH

For fiber reinforced parts the consideration of anisotropic material behavior is required to receive reliable results. In the scope of this fact a procedure is described how to consider these effects in terms of process-structure interaction and how to achieve possible benefits such as weight reduction and shorter development cycles shown for examples of the industry .


Evolving Trends in the Structural Optimization of Aircraft Gas Turbine Engines

Brian Cottrell, Chief Engineer of Structures, Honeywell Aerospace

The history of aircraft gas turbine engine design generally has not included significant optimization of the structural layout of engines. This optimization gap has been driven by the pace of engine layout during the concept development phase and by the extreme complexity of the problem. Therefore the initial selection of the structural system concept has tended to be anchored in experience and in simple parametric trade studies seeking to provide a sound configuration from the perspectives of strength, weight, cost, and modularity.

Optimization and Automation for the Naval Shipbuilding Industry

Raj Bishnoi, Account Manager, Altair (on behalf of General Dynamics Electric Boat)

In the Ship building industry, foundation design and verification is a very time consuming task, especially with the repetitive loops of design and validation. If we also include weight savings and shorter turnaround times into the equation, the task becomes even more daunting.

Resolving automotive EMC/EMI problems before they occur

Dr. Martin Vogel, Sr. Application Engineer, EMSS (USA), Inc.

The trend towards more electronic systems in cars continues unabated. Ever more electronic devices, some of them communication devices that radiate intentionally, have to co-exist in an automobile. Cable bundles carrying a multitude of signals in the car body lead to many possible EMC/EMI problems that have to be resolved early in the design stage.

Simulation Driven Weight Saving in Stamping

Dr. Subir Roy Director - Industry Solutions, Altair

With increasing regulation on fuel consumption and emission standards, weight saving has become one of the most important topics for automotive sheet metal design. Advanced high strength materials are becoming more prevalent for new vehicle models to reduce weight while enhancing structural performance.

Simulation for cabin noise inside a car due to external turbulent flow using AcuSolve and OptiStruct

Dilip Mandal (USA), Babak Emami (USA), and Robert Snadboge (Sweden), Altair

We present a new simulation procedure for evaluation of automotive cabin noise caused by external turbulent flow. A methodology for coupled simulations of flow noise sources and structural vibrations has been developed within the AcuSolve and Optistruct solver framework of Altair.

Building and Validating the Finite Element Model for an Expandable Liner Hanger

Ganesh Nanaware, Sr. Project Engineer, Baker Hughes

Expandable liner hangers used for wellbore construction within the oil and gas industry are complex mechanical systems. An expandable liner hanger is a revolutionary technology that is getting special attention during wellbore completion due to its unique capabilities of hanging liner weight under extreme conditions and problematic environments.

Integrated Composites Design with ESAComp and HyperWorks

Markku Palanterä and André Mönicke, Componeering Inc.

The design process of composite structures involves tasks that require special attention and which are not typically covered by general finite element simulation tools.

Validation and Optimization of Fiber-reinforced Plastic Parts, from Design to Manufacturing

Wilson Wang, Robin Wei and Venny Yang, CoreTech System (Moldex3D)

With increasing demands on weight reduction, fiber-reinforced thermoplastics have been a popular composite used in injection molding process due to its superior mechanical properties and high heat distortion temperature.

More innovation using Cradle CFD software

Yuya Ando, General Manager, Cradle North America Inc.

CAE software, including CFD, has been extensively used in R&D in many industries and becoming indispensable tools. However, each simulation is merely one of many aspects an engineer needs to consider about. Therefore, ideally, each tool utilized for R&D is easy, fast, robust, accurate, reliable and being able to interact with other tools to aid the innovation in onefs design.

Virtual and Real Testing to Evaluate Load Security for Heavy Products

Masahiro Takagi, Founder & CEO , eXcearch Corporation

Heavy packages cannot be easily tested in the lab to check the effectiveness of their securements against tip over accidents. We will demonstrate how virtual testing by Altair MotionSolve supported by real testing can be utilized to simulate a real-world tip over accident for examination and improvement.

Fatigue Due to Random Loadings

Jeffrey Mentley, Senior Engineer, HBM nCode

Fatigue damage is traditionally determined from time signals of stress or strain using the Rainflow method to extract fatigue cycles. This approach is satisfactory when the damaging events are deterministic and are represented by short data samples of extreme transient loads such as aircraft landing, or automobile potholes.

Development of a New Altair Customized Database of Advanced Material Properties

Dr. Viktor Pocajt, CEO, Key to Metals AG - Zürich, Switzerland

Key to Metals is a vast database which contains the properties of metallic – and more recently non-metallic materials, providing a turn-key solution for the global engineering community.

Optimization Driven Design Applied to Motocross Steering and Suspension Components

Billy Wight, President, Luxon Engineering

The motorcycles used in motocross racing demand light weight and high strength components in order to gain a performance advantage over the competition. A case study of applying Altair HyperWorks optimization techniques, this presentation focuses on the design of a motocross triple clamp assembly and rear suspension linkage.

From Concept to Design Verification in Half the Time

Rick Kerner, Staff Engineer, CAE Structures

Concept ideation on clean sheet designs can consume considerable time on the front end of a new project. From training-in new designers/engineers to collaborating with offshore contract firms, a significant amount of time is sunk into building momentum in a new program.

Scripting with HyperMesh to Automate the Process of Connector Creation and Realization at Tesla

Singai Krishnamoorthi, Technical Specialist, Tesla Motors

The paradigm of using connector entities within HyperMesh is a powerful method of quickly modeling various welds and other connections without having to manually define their finite element representation every time you need to build or update a model.

Free Size Optimized for a Doubler Repair of a Gouge Type Defect on Uniaxially Loaded Composite Sandwich Structures

Timothy Harrell, Structural Analyst, United Launch Alliance

Doublers are commonly used to repair composite sandwich facesheet defects, such as gouges or depressions, because they locally increase the strength of the facesheet in the area of the repair.

Consideration of uncertainties in forming simulation using HyperWorks

This was a 2013 European ATC presentation given by Markus Reinert from DTE Werkzeugtechnik GmbH & Co. KG. In the automotive industry, the lightweight is an increasingly important issue. This leads to the increased use of high strength steels and aluminum. These materials decrease the process capability of forming of many automotive components than conventional materials. It becomes more difficult to predict the feasibility of CAE methods.

Prediction of warpage in welded assemblies

This was a 2013 European ATC presentation given by Dr. Amin Sedighiamri from SABIC. Long glass fiber reinforced polypropylene (PP-LGF) is a material often used in semi-structural automotive components, such as front-end module carriers, door modules, dashboard carriers and hatch back doors. Main process for the production of these parts is injection molding, which generates complex glass fibre length and orientation distributions during processing.

Sequentially Cold Forming Simulation of Complex Shaped Heavy Plates

This was a 2013 European ATC presentation given by Dipl.-Ing. Steffen Garke from Universität Rostock. Swept lines and derived double curved shapes are not only satisfying an esthetic concept, particularly in ship and offshore structure their implementation is essential for certain aspects like drag of the hull. In ship building it is often about one of a kind or miniseries manufacturing. Therefore the demand for a flexible production process for complex formed plates is at hand.

Process Simulation of Tube Stamping on HyperWorks Platform

This was a 2013 European ATC presentation given by Metin ÇALLI from Coskunöz Metal Form . The main targets of automotive industry can been represented by (a) the reduction of the vehicles environmental impact (pollutions, fuel consumption, CO2 emission), (b) the increase of safety (impact absorption performance, crash resistance, pedestrian safety, etc.), and (c) the improved accuracy and quality for easier, cheaper and more reliable joining and assembly of final components.

Fatigue Due to Random Loadings

This was a 2013 European ATC presentation given by Frédéric Kihm from HBM United Kingdom Limited. Fatigue damage is traditionally determined from time signals of stress or strain using the Rainflow method to extract fatigue cycles. This approach is satisfactory when the damaging events are deterministic and are represented by short data samples of extreme transient loads such as aircraft landing, or automobile potholes.

Sensitivity Evaluation of Welding Seams in Durability Analysis with FEMFAT

This was a 2013 European ATC presentation given by Axel Werkhausen from Manager FEMFAT Support. Modelling of welding seams is very different in most of the FE-codes. Some swear to the detailed modelling with every little detail – totally impractical with long weldseams. Some others like the idea to keep it simple, like FEMFAT users, who describe the seam by coincident nodes of two shell meshes.

DSHplus and AcuSolve - Fluid Power System Simulation Hand in Hand

This was a 2013 European ATC presentation given by Dr. Heiko Baum from FLUIDON Gesellschaft für Fluidtechnik mbH. Today the dynamic behavior of complex fluid power systems is typically simulated with 1D system simulation programs such as DSHplus. But, if accuracy requires modeling details at component level this technique comes to its limits. The representation of pressure losses of complex flow channel geometries, such as the bores in hydraulic manifold of heavy machinery or the customized pipe layouts in automotive applications or aerospace applications, cannot be achieved with a series connection of 1D system components.

Fan Optimization in Automotive Industry

This was a 2013 European ATC presentation given by Dr Macoumba N’DIAYE from Fluorem. SC/TETRA is an all-in-one general purpose Computational Fluid Dynamic (CFD) software using unstructured mesh. It was developed with the specific purpose of "Easily enabling calculation of complex geometries".

Automotive is among the area which mainly use CFD calculation, like at Valeo, an automotive Tier 1 supplier whose thermal system department is responsible for the design, the development and the sale of fan systems for engine cooling (among others components for cooling systems).

Vibration Behaviour of External Payload on Rotorcraft

This was a 2013 European ATC presentation given by David Schmid from RUAG Schweiz AG. The RUAG developed ISSYS Pod (Integrated Self Protection System Pod) is an external countermeasure dispenser / threat sensor system designed to protect the rotorcraft from incoming surface-to-air and airto-air missiles.

Detection & Analysis of Barely Visible Impact Damage & its Progression on a Composite Overwrapped Pressure Vessel

This was a 2013 European ATC presentation given by Valentina Dolci from Thales Alenia Space/Politecnico di Torino. To ensure structural integrity and reduce repair and maintenance cost, in-service health and usage monitoring techniques are employed in many engineering areas.

In this context this dissertation, developed in Thales Alenia Space, has the purpose to create and test an automatic procedure to detect and monitor the damage occurred on a COPV (Composite Overwrapped Pressure Vessel) obtained by filament winding.

Study on structural behavior of an atmospheric re-entry vehicle during ditching

This was a 2013 European ATC presentation given by Dr. Maurizio Coltro from Altran Italia SPA. Water impact phenomenon plays an important role in the context of a controlled ditching in the final phase of an atmospheric reentry vehicle mission. Loads generated by contact against fluid are radically different from those that would generate in the case of a ground impact; it’s therefore appropriate to accurately assess forces distribution to be able to careful predict the impacting body structural response.

Airframe Engineering Process at CASSIDIAN

This was a 2013 European ATC presentation given by Gunnar Clemen from CASSIDIAN. Airframe engineering is supported by several commercial software suites for analysis, design and optimization. The structural strength and stability analysis & verification is usually done by semi-analytical analysis methods taken from HSB (Handbuch Strukturberechnung), ESDU, MIL-handbook etc., which have been developed and validated over a long period of time. These analysis methods are often processed by Excel- or Mathcad-sheets which are fed with geometry data, loads and/or stresses as well as material data, in order to determine structural reserve factors.

Unlock 55+ Partner Applications with Your HyperWorks Units

This was a 2013 European ATC presentation given by Stephanie Scapa from Altair.Traditional licensing schemes do not promote the discovery of technology or offer the flexibility of choice. To combat this, Altair utilizes its unique subscription-based licensing model to extend the HyperWorks Suite with its partners' complimentary products.

NovaFlow&Solid CV - Improved casting quality and strength using casting process simulation efficiently

This was a 2013 European ATC presentation given by Hakan Fransson from NovaCast Systems AB. NovaFlow&Solid CV can make casting process simulations with much fewer mesh elements, enabling much faster simulations. This allows making more variants of a specific casting layout and considerably optimizes the casting. The technology enables simulations of virtually any type of casting, even extremely thin-walled or complex.

Improved Strength Prediction of Injection Molded Fiber Reinforced Components by Considering Fiber Orientations

This was a 2013 European ATC presentation given by Sascha Pazour from PART Engineering. For fiber reinforced parts the consideration of anisotropic material behavior is required to receive reliable results. In the scope of this fact a procedure is described how to consider these effects in terms of process-structure interaction.

Coupled thermal, structural, and CFD simulation using RadTherm and HyperWorks

This was a 2013 European ATC presentation given by Antti Jussila from Thermoanalytics. Many automotive applications involve complex heat transfer in which all three modes (conduction, convection, and radiation) are important. The high thermal loads generated in these cases (e.g. engine waste heat, braking heat) can also cause thermal stress in the parts involved. Coupled thermal and structural analysis can be used to predict potential problems due to either material temperature thresholds or mechanical stresses.

Development of a New Altair Customized Database of Advanced Material Properties

This was a 2013 European ATC presentation given by Viktor Pocajt from Key to Metals AG. Key to Metals is a vast database which contains the properties of metallic – and more recently non-metallic materials, providing a turn-key solution for the global engineering community. Designed to help a broad range of engineering professionals, Key to Metals is specialized in helping to find and source similar and equivalent materials worldwide, getting easy-to-use and accurate material properties, and navigating through international standards.

Damage and Failure Mechanism Study of Composite/hybrid Crush Tubes during Axial Crush through Progressive Failure Dynamic Analysis

This was a 2013 European ATC presentation given by Dr. Angelo De Fenza from AlphaSTAR Corporation. Carbon fiber reinforced polymer (CFRP) and hybrid metal/composite are considered to be a good candidate for energy absorption due to their high specific energy absorption (SAE) as the ratio of energy absorbed by the tube mass.

CAE-driven design methodology for semi-autonomous product development for the next generation light weight vehicle structures

This was a 2013 European ATC presentation given by various presenters from German Aerospace Center. Passenger cell assembly makes up a large percentage of the overall structural weight of the BIW-design, and hence has a high lightweight potential. The structure of the passenger cell not only ensures a “rigid-like” behavior in different crash scenarios, it also contributes to comfort and driving characteristics with a high torsional and flexural stiffness.

Topology optimization of a prototype race car rear wing pillar

This was a 2013 European ATC presentation given by Elias AMRO from ADESS AG. The design optimization of race car structural parts becomes more and more popular in the motorsport industry. Companies involved in the design and development of race cars subjected to the technical and safety regulations are looking forward implementing this tool as an important part of their design process. The principal objective here is to maximize the stiffness to mass ratio of the part by optimizing the material distribution ultimately leading to an overall enhancement in performance.

A design approach for lightweight car body construction with an example on the micro-car “ec2go”

This was a 2013 European ATC presentation given by various presenters from Imperia GmbH Abstract. With increase in demands for special purpose vehicles such as electric vehicles, small series production is gaining more importance in automotive industry. However due to restricted amount of resources available, these manufacturers have to face a number of challenges, high development costs, longer design-optimization loops, high manufacturing costs are some to name. Additionally, no compromise can be made with the passive safety and lightweight characteristics of the vehicle design.

Strengths and Weaknesses of the Different Contact Formulations Available in Explicit Software

This was a 2013 European ATC presentation given by Gérard Winkelmuller from Altair Development France. I will present some comparison of these formulations to analyze the strengths and the weakness of the different approaches. This evaluation will not only be based on classical comparison of these different formulations but will also analyze the interaction with other RADIOSS options

Numerical simulation of liquid sloshing and fluid-structure interaction (FSI) inside closed volumes

This was a 2013 European ATC presentation given by Ralf Euser from Femto.The presentation will have two different aspects. First, showing how to analyze the nonlinear sloshing motion of free-surface flows inside closed volumes, with respect to contact pressure and liquid height. In addition to this it will be demonstrated how to simulate real fluid-structure interaction (FSI) between liquids and solids.

Experimental and Numerical Simulation of Laser Driven Shock Waves in Water

This was a 2013 European ATC presentation given by Dr. Ekaterina Mazanchenko from ENSMA-PPRIME. In order to test the ability of RADIOSS code to simulate shock waves propagation into water and interaction of these shocks with materials, experiments were carried out using two modes of laser shocks driven into water. It was achieved by direct laser interaction on aluminum plate immerged into water and by laser acceleration of aluminum splashing then in water to generate the shock.

Rat brain injury mechanism identification through indentation experiment FE reconstruction

This was a 2013 European ATC presentation given by Dr. Daniel Baumgartner from University of Strasbourg. The rat head Finite Element Model of the Strasbourg University is composed of three main features: a brain, a rigid skull and a layer of solid elements figuring the interface between the former two features. In order to simulate indentation, a cylinder was meshed and added to the original model. The lower part of the cylinder was positioned so as to match the position of the indentor in the experimental setup.

Digital Photonic Production - Optimization potentials by Laser based manufacturing

This was a 2013 European ATC presentation given by Dipl.-Wirtsch.-Ing. Simon Jens Merkt from Fraunhofer-Institut für Lasertechnik ILT and Christian Hinze from
RWTH Aachen. Digital photonic production enables us to produce nearly any component or product directly from digital data. Due to a fundamental change in the cost function laser based manufacturing technologies hail a new technological revolution. One of the most promising laser based manufacturing methods is Selective Laser Melting (SLM).

Structural Optimization and Laser Additive Manufacturing in lightweight design: barriers and chances

This was a 2013 European ATC presentation given by Dipl.-Ing. Jannis Kranz TUHH Technische Universität Hamburg-Harburg iLAS Institut für Laser- und Anlagensystemtechnik. With resource prices rising and becoming more and more volatile, lightweight design is getting more important than ever before. Against this background structural optimization tools saw an increased usage in the recent years.

Multi-Scale FEM Simulation of Selective Laser Melting Process

This was a 2013 European ATC presentation given by Nils Keller, Group Leader from ALMJ Universität Bremen and Prof. Vasily Ploshikhin from Airbus Stiftungsprofessor. Simulations using the method of Finite Elements (FEM) allow predictions of residual stresses and distortion. Through high temperature gradients, Selective Laser Melting processes have lots of process-related thermal issues what can be investigated with numerical simulation.

Multibody Analysis of a Vending Machine

This was a 2013 European ATC presentation given by Dr. Marco Morone from Altran. It was performed a MB analysis of a vending machine. The aim of analysis was to analyze and optimize a cam in order to reduce the friction a acceleration peaks. A rigid MB model in Motion view was generated with contacts. From model results were optimized the cam profile was improved.

Alternative Model Order Reduction in Elastic Multibody Systems

This was a 2013 European ATC presentation given by Dipl.-Ing. Philip Holzwarth from Institute of Engineering and Computational Mechanics University of Stuttgart. Reliable and fast simulations are of crucial nature in the modern development process of technical products. Two frequently used methods in structural dynamics are the finite element method (FEM) and the method of elastic multibody systems.

Optimized Design for Vehicle Underbody System

This was a 2013 European ATC presentation given by Emanuele Santini from Autoneum Management AG. Underbody systems are defined as parts, which are added below the body of a car, with aerodynamic functions and with the aim of improving its protection and acoustic performances. Underbody parts are subject to a variety of loads during vehicle operation, which degrade their original performances.

Optimization Center – Consistent Integration of Structural Optimization in the Development Process of Passenger Cars

This was a 2013 European ATC presentation given by Dr. Karsten Bohle, Dr. Bernhard Wiedemann, Dr. Boris Kuenkler, and Prof.-Dr. Lothar Harzheim. Since many years the use of numerical structural optimization is an integral part of the development process in the automotive industry and helps in the design of load-specific and mass-efficient components. Due to higher requirements for cars, regarding performance and costs it becomes increasingly important to leverage structural optimization consequently during the entire development process.

Shape Optimization of Engine Moving Components with Hyper-Study Integration

This was a 2013 European ATC presentation given by Mr. SANGWOO CHA from Hyundai motors company. Computer aided optimization techniques find broad application recently in order to search for structural optimized design. Engine components such as cylinder head, cylinder block and bed plate are subjected to many optimization studies, since the loading conditions are clearly defined and easy to evaluate as a unique characteristic constraint or objective.

HyperCrash Dummy Positioning Using RADIOSS Fast and Accurate Innovative Features

This was a 2013 European ATC presentation given by Fabien Breda & Lionel Morançay from Altair. Dummy positioning needs more and more precision and sometimes moving a leg will create source of troubles or inaccuracy due to intersections at the beginning of the safety study. To avoid such troubles and increase the accuracy of the safety analysis, a process has been developed in HyperCrash based on RADIOSS simulations.

Stamping Process Integration of Composites in Crash Analysis

This was a 2013 European ATC presentation given by Cécile DEMAIN from Solvay Engineering Plastics. Thermoplastic composites (TPC) developed by Solvay Engineering plastics are composites based on polyamide 6 or 6.6 as a matrix and can be reinforced with glass fibers or carbon fibers. The two main interests vs. TPC. thermosetting composites are cycle time and recyclability. The development of TPC PA66 or short fiber hybrid structures / TPC PA66 is today's challenge.

Humanetics Anthropomorphic Test Device News and Radioss Model Developments

This was a 2013 European ATC presentation given by Robert Kant from Humanetics Europe GmbH. Main stream finite element models of ATDs see continuous improvements to keep the models up-to-date to the latest hardware, latest solver codes and to make them more predictive. New validation tests are continuously being designed to gain more insight in the understanding of the ATD. Furthermore, more knowledge is obtained on variability which plays a role in the attempt to make highly reliable models.

Impact of a new regulation for Child Restraint Systems on the crash simulation

This was a 2013 European ATC presentation given by François Renaudin and Sylvaine Pormente from DOREL. Injuries to children involved in car collisions can be significantly reduced if they use a suitable car seat. All Child Restraint Systems CRS (or car seats) sold in the EU must conform to the United Nations Regulation. A new regulation on CRS, known as the “I-Size regulation”, will be adopted in 2013 by the UNECE.

Multidisciplinary Optimisation of Business Jet MED Hinge for Production by Additive Manufacturing

This was a 2013 European ATC presentation given by Martin Muir, Jonathan Meyer, and Alex Diskin from European Aeronautic Defence and Space Company (EADS). Additive Manufacturing (AM) using Powder Bed Fusion (PBF) processes is a novel and rapidly expanding manufacturing field which eliminates many conventional constraints from the manufacturing process. With the reduction of design inhibitors such as tool paths, AM becomes an ideal process for the fabrication of topology optimised (TO) structural designs.

Topology Design of a Metallic Load Introduction Bracket Manufactured by ALM

This was a 2013 European ATC presentation given by Wolfgang Machunze from EADS Innovation Works. The usage of numerical optimization within the development process for aircraft structures enables the engineer to reduce cost and weight for new airplanes. Next to the evolution of optimization methods also manufacturing approaches are enhanced, like e.g. the ALM (Additive Layer Manufacturing) process.

Sustainability approach by Design Optimization for Advanced Layer Manufacturing

This was a 2013 European ATC presentation given by Udo Behrendt from EOS GmbH - Electro Optical Systems. Sustainability and environmental compatibility are one of the major facts in the aero industry to achieve with new optimized designs, light weight construction and last not least cost reduction. That is a key driver for the engine manufacturer to increase efficiency and reduce fuel consumption of their product´s.

From Incremental Change to Full Design/Validation Leap: A Multidisciplinary Approach to Optimize Safety and Crash Performance

Heavy-duty mining trucks at Hitachi are designed to meet ISO ROPS and FOPS safety requirements, while structures must be as lightweight as possible. The presentation will discuss Hitachi’s design and simulation approach, which consists of an integrated multidisciplinary analysis process. Dynamic analyses, multibody dynamics simulations, including flexible bodies and dynamic simulations are methods applied to optimize performance and vehicle safety.

The author will present examples such as the optimization of a trolley support structure, a kinematics model of a 100-ton truck and the analysis of a trailing arm. Finally, the author will share his thoughts on the important subject of how simulation can better impact the design.

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