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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.

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