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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.

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.

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.

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.

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 consists 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.

Imagining a World that Works
To create products and processes that are well-adapted to life, innovators are turning to a new design discipline called biomimicry. Biomimicry consults nature for inspiration, design ideas, and standards. Life has been on Earth for 3.8 billion years—the same planetary conditions in which we are trying to build our homes, grow our food, make our materials, run our businesses. Life has already done everything we want to do, but at a lot less cost to the planet. Realizing this, scientists and designers are now consciously emulating life’s genius. Explore biomimicry as both a philosophy and a practical methodology with examples of groundbreaking innovations and their role in ensuring the success of a new industrial revolution that is greener and more sustainable over the long haul.

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