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



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


Magnet Weight Minimization of PMM over Multiple Operating Points
Magnet Weight Minimization of Electric Traction Interior Permanent Magnet Motor Over Multiple Operating Points

This paper describes the process of using Altair tools such as Flux for synchronous permanent magnet motor EM FEA analysis and HyperStudy to minimize the weight of the NdFeB magnets of a typical IPM motor for electric traction application such as the IPM motor of the Toyota Prius 2010.

Maximizing the joint strength of a clinching process using AFDEX and HyperStudy
In this white paper, a suitable FE model of a joining process(clinching) is built using the metal forming simulator AFDEX and then the process is optimized using the multidisciplinary optimization software HyperStudy from Altair.

Seat Design for Crash in the Cloud
The benefit of design exploration and optimization is understood and accepted by engineers but the required intensive computational resources have been a challenge for their adoption into the design process. The HyperWorks Unlimited (HWUL) appliance provides an effective solution to these challenges as it seamlessly connects all the necessary tools together in the cloud. The aim of this study is to showcase the benefits of HWUL on an optimization driven design of a
complex system. For this purpose an automotive seat design for crash loadcases is selected.

Magnet Weight Minimization of Electric Traction Interior Permanent Magnet Motor Over Multiple Operating Points
This paper describes the process of using Altair tools such as Flux for synchronous permanent magnet motor EM FEA analysis and HyperStudy to minimize the weight of the NdFeB magnets of a typical IPM motor for electric traction application such as the IPM motor of the Toyota Prius 2010.

Snap-Fit Optimization for Achieving Desired Insertion and Retention Forces
Snap-fits are ubiquitous engineering features used to quickly and inexpensively assemble plastic parts. The geometric, material, and contact nonlinearities associated with snap-fit problems can present modeling challenges. Quasi-static solutions with explicit solvers are commonly used to analyze snapfits; however, OptiStruct’s nonlinear solver now possess the ability to solve these highly nonlinear problems implicitly. The first part of this study discusses an effective approach to using OptiStruct for the implicit finite element analysis of snap-fits. Once an accurate simulation model has been created, engineers typically make design changes in order to achieve desired insertion and retention forces. The second part of this study details how HyperMesh morphing and HyperStudy can be used to optimize the snap-fit design, resulting in desired insertion and retention forces while minimizing mass and ensuring structural integrity. The approach documented in this report can reduce the design time, material use, and failure rate of snap-fits used in industry.

Multi-physics Electric Motor Optimization for Noise Reduction
In an electric machine, the torque is generated by electromagnetic forces which also create some parasitic vibrations of the stator. These vibrations excite the mechanical structure on which the motor is fixed and generate sound. When designing the electric machine, this aspect has to be taken into account from the start since it depends on the harmonic content of the currents that feed the machine, on the shapes of the rotor and stator, and on the interaction of the electric frequencies with the natural mechanical modes of the structure.
To simulate this phenomenon, a coupling between electromagnetic calculations and vibration analysis has to be set-up. Some optimization procedure can also be added in order to reduce the noise.
In what follows, it is shown how Altair HyperWorks suite; specifically FluxTM, OptiStruct®, HyperMesh® and HyperStudy® products have been successfully used to perform a multi-physics optimization for noise reduction in a fuel pump permanent magnet motor.

RAMDO - HyperStudy & OptiStruct Example
This step-by-step tutorial details how to use RAMDO with HyperStudy and OptiStruct.

White Paper: Minimization of Forming Load of Gear Driver Forging Process with AFDEX and HyperStudy
In this paper, a workflow is presented that integrates the functionalities
of a metal forming simulation software, AFDEX and a multidisciplinary optimization software, HyperStudy. Using this approach, the forming
load of a gear driver used in an automotive transmission is minimized and two die design parameters are optimized.

Design-Optimization of a Curved Layered Composite Panel Using Efficient Laminate Parameterization
In this paper, presented at the 2016 SAMPE Long Beach Conference, an aircraft door surround model is optimized with respect to the objectives and constraints typical for this type of component using HyperStudy and ESAComp.

Benchmark of HyperStudy Optimization Algorithms
The objective of this paper is to assess several optimization algorithms in HyperStudy for their effectiveness and efficiency. The following sections of this paper present an overview of the optimization algorithms frequently used in HyperStudy. This is followed by benchmarking of both single objective and multi-objective optimization problems, respectively.

Seat Design for Crash in the Cloud - NAFEMS World Congress 2015
The benefit of design exploration and optimization is understood and accepted by engineers but the required intensive computational resources have been a challenge for their adoption into the design process. The HyperWorks Unlimited (HWUL) appliance provides an effective solution to these challenges as it seamlessly connects all the necessary tools together in the cloud. The aim of this study is to showcase the benefits of HWUL on an optimization driven design of a complex system. For this purpose an automotive seat design for
crash loadcases is selected.

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.

Optimization Drive Design - A Desktop Engineering Sponsored Report
Optimize every stage of product development with an integrated workflow that democratizes simulation and analysis. In this Desktop Engineering sponsored report Altair's vision for product optimization is analyzed

Optimizing Cooling Passages in Turbine Blades
Turbine blades have internal passages that provide cooling during operation in a high
temperature engine. The design of the cooling passages is critical to achieve near uniform
temperature of the blade during operation. The temperature of the blade is dependent on the thermal properties of the blade material as well as the fluid dynamics of the air circulating in the cooling passages. Computational optimization methods have successfully been applied to design lighter and more efficient structures for many aerospace structures. An extension of these techniques is now applied to guiding the thermal design of a turbine blade by designing the optimal cooling passage layout. Optimization methods will be applied to determine the optimum pattern of the cooling passages and then to optimize the size of the individual cooling passages. The goal is to produce a more thermally efficient turbine blade design that will produce blades with longer lives and better performance.


Weld Distortion Optimisation using HyperStudy
Distortion induced in parts due to the cooling of welds complicates automated manufacturing lines in the automotive industry. The resulting deformation leads to additional investment such as end of line machining to correct affected assemblies. Utilising optimisation software a welding pattern can be found which retains the intended performance of a part while reducing the distortion induced from welding. Weld locations may be optimised alongside welding sequence to allow process requirements to be considered within the early design stage. This leads to high performance, low distortion assemblies which can ultimately be manufactured at the lowest possible cost.

HUMOS - An FE Model for Advanced Safety and Comfort Assessments
Biomechanics modelling is becoming increasingly accepted as a tool for enhance assessment of vehicle safety, in particular in the field of injury assessment and virtual testing. Firstly, a generic RADIOSS model for safety applications (HUMOS2) is presented and applications are demonstrated. Important tools associated with the scaling, and positioning of the model is also described. Secondly, an innovative model for scaling of human organs (individualization) is presented. The method which employs optimization techniques, identifies critical (optimal) anatomical control points which allow for a best scaled model of the HUMOS2 representing an individual. Finally, some remaining challenges for future human models are discussed and solution paths are described.

Automotive Modal Testing Support and CAE Correlation Using Altair HyperWorks
To derive the natural frequencies and mode shapes of a given structure, the test Engineer has to decide on excitation positions that will efficiently excite all the modes of the structure in the frequency range of interest. Excitation positions are usually decided upon from experience or trial and error methods which can be time consuming and still not capture all of the modes in the selected frequency range. Using Altair HyperStudy and Radioss (bulk), Pre-test CAE analysis has been carried out to identify effective excitation positions before the commencement of modal testing, thereby significantly reducing pre-test lab time.

The Application of Process Automation and Optimisation in the Rapid Development of New Passenger Vehicles at SAIC Motor
As a relatively young automotive company, SAIC Motor has drawn on the expertise of its UK Technical Centre to help in its objective to bring a new range of vehicles to market in an aggressive time frame. CAE has formed an integral part in doing this and the UK technical centre has worked closely with Altair Product Design amongst others to utilise its Engineers’ skills as well as the Hyperworks suite of software.

The paper aims to showcase what has been achieved to date, on the Roewe 550 medium car programme - currently on sale in China - and on another current vehicle programme, where processes have been developed further. Several interesting optimisation examples are highlighted in the development of the body structure as well as some key process improvement methodologies which have been jointly developed between SAIC and Altair to streamline the design process.

A New Approach to Optimizing the Clean Side Air Duct Using CFD Techniques
An integrated approach to CFD design optimization is proposed. It consists of taking an initial CAD design, meshing it using HyperMesh, analysing it using Star-CD, parameterising its key features using HyperMorph, and then shape optimizing it using HyperStudy. This approach has been applied here to the shape optimization of the compressor inlet duct of a turbo system.

Delivering World Class Chassis Design
This paper details the extensive use of CAE optimisation technology at ThyssenKrupp Automotive Tallent Chassis Ltd (TKA). There are a number of trends in the automotive business that are presenting great challenges, these include severe cost pressures from OEM’s, platform commonisation and reduced vehicle development cycle time. The use of optimisation is critical for TKA to maintain its competitiveness, this paper deals with more advanced concepts of optimisation by extending into the severely non-linear region of analysis types.

Simulating the Suspension Response of a High Performance Sports Car
The use of CAE software tools as part of the design process for mechanical systems in the automotive industry is now commonplace. This paper highlights the use of Altair HyperWorks to assess and then optimize the performance of a McLaren Automotive front suspension system. The tools MotionView and MotionSolve are used to build the model and then carry out initial assessments of kinematics and compliance characteristics. Altair HyperStudy is then used to optimize the position of the geometric hard points and compliant bush rates in order to meet desired suspension targets. The application of this technology to front suspension design enables McLaren Automotive to dramatically reduce development time.

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