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Injecting Innovation in Performance Engine Design with Altair HyperWorks
MAHLE Powertrain outsourced model generation of large complex parts such as heads and
blocks to low cost countries to ensure sufficient mesh quality could be produced for their
automotive engine designs. The third party’s improved capabilities proved valuable but
ultimately MAHLE Powertrain wished to bring the process back in-house to maintain control
and reduce external expenditure. To achieve this a new pre and post-processing solution was
needed. HyperWorks was selected as the new platform as it afforded the required increase in
productivity through its automatic mesh creation and batch processes.

Simultaneous Robust and Design Optimization of a Knee Bolster at Jaguar & Land Rover
Jaguar Cars needed a practical process to simultaneously optimize the robustness of a design
and its performance. Altair HyperStudy is applied to the design of an automotive knee bolster
system whereby the design is optimized to account for different sized occupants, impact
locations, material variation and manufacturing variation.

Sheet Metal Transfer Dynamic Analysis Using Altair HyperWorks at Ford Motor Company
By applying Altair HyperWorks simulation technology, Ford Motor Company has been capable to simulate the dynamic behavior of their new generation of crossbar transfer presses.
Altair solutions have been adopted to optimize the automation tooling design and the
transfer motion operational parameters.

OptiStruct Technology Application in Early Concept Design Stage Enables Weight Reduction of Cast and Forged Parts
Using Altair OptiStruct, India based Ashok Leyland was able to reduce cost and improve reliability of the components in their stride towards design an development of innovative, optimal and robust design solutions. Leveraging OptiStruct's technology was able to take quick and reliable design directions on the track rod lever.

OptiStruct Cuts Development Time to Design a Light Weight and More Durable Window Regulator Lift Plate at ArvinMeritor
Using Altair OptiStruct, ArvinMeritor was able to design a lighter weight window regulator lift plate which eased assembly. The new snap-fit design reduced the material compared to original design, without sacrificing performance and durability.

HyperForm Sheet Metal Forming Solution Provides Yield Improvement of Wheel Housing and Wheel Arch
Using Altair HyperForm, Mark Auto was able to significantly improve the material utilization for their existing production dies. Mark Auto re-designed two existing dies for wheel arch an wheel housing and was able to dramatically reduce material scrap with minimum rework in their tools while not compromising on component quality.

Altair HyperWorks Helps Joe Gibbs Racing
Using OptiStruct from the Altair HyperWorks computer-aided engineering (CAE) suite of software tools, Joe Gibbs Racing was able to significantly redistribute vehicle mass and improve ride handling characteristics to design a more competitive race car.

Driving Million Dollar Savings at Ford using Structural Optimisation
The automotive business is a very competitive industry and in today’s markets, leading manufacturers are keen to find ways of reducing costs without compromising either quality or performance. This paper will cover the process of applying OptiStruct software to the re-development of a high volume and high cost plastic PAS (Power Assisted Steering) pump bracket into a much cheaper aluminium alternative. The outcome of this was a lighter, stiffer and cheaper replacement bracket that had the potential, based on the current production engine volumes, to save Ford Motor Company over $1.1 million a year.

Optimisation Techniques Leading the Development of a Steering Wheel
The early application of structural optimisation in the design of automotive components streamlines the design process and at the same time significantly increases the potential of the final design achieving maximum performance. This paper details the use of optimisation techniques during the development of a steering wheel, to generate an optimised design for cross attribute performance. This was completed in the Altair HyperWorks environment as Altair HyperMesh combined with Altair OptiStruct enables the creation of a parametric model with a multitude of design variables (i.e. size, shape, displacement, stress and frequency) in order to satisfy NVH, manufacturability, durability and crash targets.

The Automatic Calibration and Robustness Assessment of a Complex Engineering Component: Airbag Inflation
This paper describes the application of new technology to achieve automatic calibration and assess the robustness of an airbag inflation model. Calibration of the kinematic response of the airbag is achieved by defining the activity as an optimisation problem. The objective is to minimise the error between the experimental test and numerical simulation curves. Once calibration has been achieved, a unique robustness assessment is performed, which utilises the optimisation technology used in the calibration exercise.

Predicting the Dynamics of Mechanical Systems in the Automotive Industry
The application of CAE tools to help design and develop mechanical systems in the automotive industry is a widely accepted practice. This paper highlights various applications of these tools, in particular, the application of MotionView and MotionSolve from Altair Engineering. Each example demonstrates the advantages of using such tools to work rapidly and seamlessly within the general design process. This results in the development of innovative designs to face challenging problems in a short time frame.

HyperForm Improves Accuracy and Robustness of Tool Design and Manufacturing Process at Summit Auto Body (SAB)

HyperForm Improves Accuracy and Robustness of Tool Design and Manufacturing Process at Summit Auto Body (SAB)

Leveraging HyperForm’s sheet metal forming solution, SAB designed the validation process and press tool design covering the vital areas of virtual prototyping/testing, which, in turn, reduced the time-consuming manual process drastically.

HyperWorks Process Manager Delivers Productivity and Quality Gains to Chassis Design Process
Using Altair HyperWorks Process Manager, M&M was able to implement best practices through standardization of CAE processes and minimize CAE analysis set-up time. Automated post-processing enabled through Process Manager facilitated a 40% reduction in time when compared with the manual practice of post-processing.

HyperWorks Cuts Design and Prototyping Costs for Truck Cabin Development and Testing
Using HyperWorks, Eicher Motors was able to significantly reduce the number of physical tests during the development process of their truck cabins. The numerical simulation helped in predicting the failure mode and estimating the stress level in the individual components in elastic as well as plastic zone prior to the first physical test.

HyperWorks CFD Optimization Helps MTU Improve Diesel Engine Compressor Blade Performance
To increase turbo charger efficiency, global diesel engine supplier MTU Friedrichshafen GmbH
combined Altair’s HyperWorks computer-aided engineering (CAE) software suite with a
computational fluid dynamics (CFD) solver. Combining the morphing capabilities of HyperMesh (the
pre-processor for finite-element [FE] analysis and CFD) with HyperStudy (the solver-neutral design
study and optimization tool), MTU redesigned the shape of the compressor blades to improve
pressure gain and efficiency. The redesign, in turn, increases the fuel efficiency of the engine.

Where Is Your Performance Data?
A new data management system lets engineers easily manage, share and leverage simulation and test data.

Putting Simulation Muscle Behind a Sporty Concept Car
Optimization technology delivers innovative suspension design for Alfa Romeo's sleek concept car.

HyperWorks at Wagon Automotive: Speeding Development Time While Cutting Prototype Costs
Wagon Automotive, a system and module supplier of components to major car builders,
sought ways to accelerate product development and reduce prototyping costs while maintaining high quality.
Adopting the HyperWorks suite of advanced CAE tools enabled the company to achieve both those goals.
Wagon Automotive now uses HyperWorks during the entire development cycle, from concept design to optimization.

HyperWorks CAE Process Automation Accelerates Product Development at Scania
Scania chose HyperWorks – the Engineering Framework for Product Design – to automate the assembly process of virtual truck models for finite-element (FE) simulations. The new process significantly increased simulation efficiency and robustness, which are especially critical to
Scania’s truck-customization process.

HyperWorks’ Simulation Technology Enables Godrej to Streamline Sheet Metal Tooling Processes
Using Altair HyperForm, HyperWorks’ stamping simulation technology, Godrej was able to design and
fine-tune a successful tool for a rear fender, while minimizing die testing time by reducing physical
trials. Leveraging numerical analysis, Godrej was also able to predict the size, shape and location of
the blank accurately. HyperForm’s ability to visualize failure in incremental simulation enabled them to
finalize the draw bead location and characteristics.

HyperWorks’ Stamping Simulation Technology Helps Reduce Front Housing Development Time at OMAX Auto
Using Altair HyperForm, India-based OMAX Autos was able to significantly reduce production
costs and maximize productivity by redesigning the manufacturing process for front housings.
Leveraging HyperForm’s simulation capabilities, OMAX Autos reduced the three-stage forming
process to a single-stage process.

HyperWorks Structural Optimization Reduces Suspension Design Time at Alfa Romeo
Using Altair HyperWorks, Italy-based Alfa Romeo was able to significantly reduce design time by
integrating multibody dynamics (MBD) with structural optimization. The resultant suspension
design showed superior performance characteristics.

Ford Motor Company: Building an Efficient HPC Infrastructure
The cars, trucks, vans and SUVs that roll off Ford Motor Company assembly lines are safer, quieter, and more comfortable than ever. Many of the intangibles that contribute to Ford quality flow from the innovative use of high performance computing (HPC) techniques. At Ford's Numerically Intensive Computing Department (NIC) in Dearborn, Michigan, engineers run simulations in codes such as NASTRAN and LS-DYNA for predictive analysis of cylinder cooling, wind noise, vibration, ride quality, crashworthiness, durability, and other characteristics that contribute to industry-leading automotive design.

SmartWorks optimizes fleet management at Boyaca
Boyacá has been handling the daily delivery of newspapers and magazines in Spain for more than 35 years. Fulfillment of time schedules is essential for customer satisfaction and late deliveries can result in additional costs. Boyacá needed to have direct real-time information on arrival and departure times at each hub of the distribution chain in order to control costs with the lowest possible investment. Several hundred trucks are used for delivery every day.

Transformative Flight Transportation
Advances in energy storage, motor efficiency, and flight control systems have us on the potential cusp of a revolution in air mobility. This comes at a time when many traditional transportation infrastructures are saturated and new modes of mobility are desperately needed.

Terrafugia highlights recent developments in urban- and extended-air-mobility, and the hurdles that must be overcome, not only technical obstacles but also challenges in regulations, societal acceptance, and business.

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