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From Die Design to Defect-Free Castings: Shiva Tool Tech Achieves 80% Time Reduction with Altair Inspire Cast
Shiva Tool Tech is an automotive manufacturing focused, industrial powerhouse based in Pune, India. With over 25 years of experience in designing and manufacturing of gravity die casting (GDC), low-pressure die casting (LPDC), high-pressure die casting (HPDC) Dies, the company supports customers from manufacturing process design to the production stage. Manufacturing processes include milling, drilling, hardening, grinding, Computer Numerical Control (CNC) machining, Electrical Discharge Machining (EDM), inspection and polishing to get the final assembly of the casting die.

Serapid
Serapid, the developer and manufacturer of the original Rigid Chain, designs and manufactures telescopic mechanical actuators for the horizontal and vertical movement of heavy loads. See how they use Altair SimSolid to aid in gravity loads of complete structure simulation.

Optimization of Photovoltaic (PV) Mounting Structures – Savings on Material and Cost
Photovoltaic specialist Thesan, a subsidiary of global manufacturer Savio S.p.A, manufactures, and distributes mounting structures, consisting of a so-called Purlin, a Rafter, and a Pole (and Hat), designed to withstand potentially occurring loads from wind and snow, as well as dead loads. Drawing on the Savio Group’s competence in the design of steel and aluminum structures and thanks to a team of over 40 engineers, they are to satisfy every construction requirement of photovoltaic power plants at all altitude and climatic conditions, using any specific fixation requirements. For a recent project requiring optimization of a mounting structure of a medium sized PV field with a power of 5 MW, engineers used HyperWorks. The benefits included reduced material usage, reduced manufacturing and transportation costs and improved competitiveness for Thesan.

APEL Extrusions
APEL Extrusions employs die extrusion simulation software to test die extrusion performance. This allows APEL to greatly speed up the design process and test multiple simulations per week.

APWorks Choses OptiStruct for Topology Optimisation for the 3D Printed Light Rider
Despite its skeletal appearance, the Light Rider is an extremely strong yet lightweight electric motorcycle designed by Airbus subsidiary APWorks as a showcase of what’s possible when OptiStruct's topology optimisation is coupled with metallic 3D printing.


Written by Tanya Weaver from DEVELOP3D.

Haier Redesigns Air Conditioners and Packaging with Altair HyperWorks to Eliminate Drop Damage
Haier Group is one of the world’s largest manufacturers of home appliances and consumer electronics. The company is the leader of its industry in China, where it is headquartered.



Haier ships its products all across the globe and in more than 100 countries, so well designed product packaging is crucial to the company’s ability to deliver products without damage to even the farthest destinations.



Download the Case study to see how Altair was able to reduce costs of physical testing and eliminate drop damage using simulated drop testing with HyperWorks.

DECKED
The huge capacity of a pickup comes at the expense of storage. The loading area is often a simple box with no ability to store smaller items safely or secure them from theft. After spotting an opportunity in the marketplace, entrepreneur, Lance Meller, started work on a well-built alternative. Lance founded DECKED with his business partner, Jake Peters, with a shared determination to create an innovative, robust and useful storage solution for both commercial users and private owners alike. The system had to be able to withstand a load of 2,000 lbs, fit it into a wide range of pickup models including those from Ford, GM, Chrysler, Toyota and Nissan and be manufactured for a compelling retail target price. DECKED selected Altair ProductDesign as it needed a partner that was able to deliver conceptual design work along with advanced engineering and prototyping services.

Combining topology optimization with laser additive manufacturing reveals new potential for lightweight structures
Challenge: Development of design and optimization methods to improve components made with laser additive manufacturing methods.

Altair Solution: HyperWorks, OptiStruct, Simulation Driven Design Process

Benefits: increased material efficiency, lighter and stiffer structures, less user training required, flexible and adaptable manufacturing process


Fully automated in a single process: Optimization and manufacturing of CFRP components
Use of HyperWorks and adapted threestep optimization process for Composite materials integrated in the production process

Benefits:
  • process suitable for large volume series
  • flexibility in production
  • short learning curve for users
  • light and yet stiff components


Increasing Robustness and Reliability of a Race Car Engine with AcuSolve
This study is part of Prodrive’s implementation of AcuSolve to enhance its CFD capability after many years of outsourcing these simulations.

Accurate Simulation Modelling of Sports Impact Scenarios using HyperWorks
One of the key research activities within the institute is concerned with the development of enhanced human surrogate models for sports personal protective equipment (PPE) research. Impact surrogates are used to provide a representation of a living human which can then be impacted under injurious loading conditions such as a ball impacting the thigh to understand the response behaviour.

Failure Criteria for Stamping Analysis in RADIOSS
In this paper, several failure criteria are compared in their ability to predict necking point and failure propagation during a forming process. The paper has been presented at the 2014 IDDRG Conference in Paris, France.

Empire/Renishaw
Renishaw and Empire Cycles utilized generative design to conceptualize the world's first metal additive manufactured  bicycle frame. This resulted in a 33% weight reduction of the bicycle.

HardMarque
HardMarque coupled topology optimization with additive manufacturing to conceptualize and refine the design of a piston. The final piston design is 23.5% lighter than the original design. 

Intel Solution Brief: Maximize Performance and Scalability of RADIOSS on Intel® Xeon® Processor E7 v2 Family-Based Platforms
This paper summarizes the findings of a benchmark study with RADIOSS and Intel® Xeon® processors. In the study, Altair benchmarked RADIOSS using a modified crash simulation model on a single-node platform -- RADIOSS was able to easily take advantage of all 60 cores, running the workload 2.75X faster than on a comparable 24-core platform.

Reducing Weld Distortion by 93% with HyperStudy
Gestamp Tallent Ltd is a world class designer, developer and manufacturer of cutting edge, chassis structural and suspension products, body in white structures, modules and systems for the automotive industry. Gestamp used the BMW MINI front subframe tower to demonstrate the weld distortion optimisation approach. The tower is particularly susceptible to distortion due to its tall and thin dimensions. The objective of this optimisation was to minimise the distortion of the tower measured by the displacement of the top of the tower as the weld sections cool. In order to further investigate weld removal optimisation they chose HyperStudy.

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

Assa Ashuach uses solidThinking Inspire to Optimise 3D Printed Stool Design
Industrial Research and product design consultancy Assa Ashuach Studio, design and manufacture lifestyle products and also limited edition studio pieces using new design and production methods to achieve unique forms and aesthetic qualities.

Evenflo Juvenile Products
Evenflo employs topology optimization and generative design simulation for “sustaining engineering” where fast turnaround is essential for functional improvements of  infant car seats design.

BiggerBoat Solutions Makes Waves in Auto Industry Using HyperForm to Cut Die Development Costs and Time
When the auto industry crashed in 2008
and the tool shop where Jay Weiner worked
closed its operations, he started his own
company, called BiggerBoat Solutions Ltd.
He carries out metal-forming simulations
for major tooling suppliers and originalequipment
manufacturers. With 15 years
of experience in tooling design, Weiner and
his Toronto-based practice offered a service
that no one else had perfected but that
was crucial to a key process in automotive
manufacturing: the simulation-based die
design for stamped sheet-metal parts.

Quality Driven by CAE
Advanced CAE tools enable companies to design quality into their products.

Creating a Virtual Press to Optimize the Extrusion Process
Today's advanced computational tools increase productivity and quality, as well as lower energy consumption in the design and fabrication of extrusion dies.

Simulation Links Welding Data to Structural Analysis Models
A robust modeling process greatly aids the design of lower cost and higher quality welded structures.

Get the Most from Your Casting Process
By applying optimization technology to casting process design, manufacturers can produce less expensive, better-quality parts in record time.

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