Altair OptiStruct™

Optimization-enabled Structural Analysis

Multidisciplinary Workflow to Assess Modal Fatigue Results of a 4-Cylinder Crankshaft with EXCITE-OPTISTRUCT-FEMFAT

The crankshaft of an engine is a highly dynamically loaded component that is continuously optimized and optimized in terms of design and production technology. In order to be able to reproduce this in the simulation, the essential influences must be considered. This includes the dynamically behaviour in combination with the engine, the material properties and the application of the loads and their transfer to other parts (bearings). The modal approach has established itself as a proven method here, whereby a modal basis is determined in the FEM so that the crankshaft is integrated as a flexible body in the MKS model of the engine, and so that an entire engine run-up can be simulated. The modal participation factors are obtained from the MBS simulation, which are used together with the modal stresses for the safety factor calculation. This workflow requires the combination of different simulation tools. The challenge is to organize the data transfer between the tools efficient and correct. In this example, the workflow is realized using Optistruct from ALTAIR for FEM calculation, EXCITE from AVL as MKS tool and FEMFAT from ECS as Fatigue solver. This makes it possible to simulate a complex engine run-up with consideration of the ignition bearing forces and to calculate the fatigue life of the crankshaft in FEMFAT. This live webinar, details of the simulation workflow of the 4 cylinder crankshaft will be presented and the effects of several influencing variables on the fatigue life will be studied.

Webinars

Development of A new vehicle front sub-frame using Altair Inspire topology optimization

Presentation by Edan Lazerson, CAE Engineer, Plasan. The Stormrider is a new vehicle which was designed from scratch and developed by Plasan. Altair Inspire was used for Topology optimization In order to find the ""best"" design for the vehicle front sub frame. The available volume (design space), 5 different load cases and target mass were specified and the optimization software calculated geometry to maximize stiffness. The optimization results were complex to manufacture with traditional technologies; the simulation and design teams collaborated on designing a manufacturable front sub frame assembly. The new design was simulated to ensure it will withstand all the required loads. The front sub frame was implemented and tested on the prototype vehicle. The optimized front sub frame proved mechanically sound, while satisfying the mass and geometrical requirements. The early stage optimization reduced the development time, by creating a valid geometry however, the topology to manufacturable design process is not trivial. In this presentation, we will present the mentioned development stages and compare the test results to the simulation predictions. Presentation at the ATCx in Israel, Netanya on October 30, 2019.

ATC Presentations

The Increased Importance of BIW & Powertrain Integration in Electric Vehicle Development

Jamie Buchanan, UK Technical Director at Altair presents at the 2019 UK e-Mobility Seminar. Global Review of the EV Architecture. Integration Opportunities (e.g. Battery System Packaging, BIW / Battery Tray Integration)

Presentations, Videos

The Challenges Associated with the Electrification of Motorsport Platforms

Michael Gascoyne, CEO of MGI Technologies presents at the UK e-Mobility seminar 2019.

Presentations, Videos

The C123 Process - A Rapid Simulation Process to Optimise the Weight & Performance Attributes of a BIW Structure

Dr. Stuart Bates, Concept Technical Specialist at Altair presents at the UK e-Mobility seminar 2019. Rapid Exploration of Packaging Alternatives e.g. Battery System Layout, Battery Frame / BIW Integration. Developing Balance Design (Weight vs Attribute Performance), Target Setting using Simulation.

Presentations, Videos

Scaling Up Your Nonlinear Analysis Solver Throughput with HyperWorks Unlimited

In this webinar, you'll learn about OptiStruct's nonlinear analysis performance at scale as well as Altair's powerful and cost-efficient solutions for on-premise or virtual compute clusters.

Webinars

Nonlinear Analysis Buyer's Guide

We created this guide to help managers of CAE budgets navigate the multifaceted decisions companies must make when choosing a nonlinear analysis software vendor. Additionally, we’ve compiled some tips and best practices for successfully managing these deployments to satisfy the needs of growing engineering teams while extracting maximum return on investment.

Brochures

Human Plus Machine: How Sarcos is Revolutionizing the Future of Work with Industrial Robotics

With the prospect of increasing labor shortages among a wide variety of industries, combined with the significant costs of occupational injuries and the ever-increasing pressure to increase productivity, leading robotics company, Sarcos is in a unique position to deploy industrial robotics designed to increase productivity while eliminating injuries, by augmenting rather than replacing human workers. Chris Beaufait, COO of Sarcos, discusses the current robotics landscape, why automation is not the right solution to the problems industries are facing, how Sarcos and its product lineup - including the full body, fully powered Guardian XO exoskeleton - will play a critical role in defining the workforce of tomorrow, and his vision for the robotics industry over the next five to 10 years.

ATC Presentations

An Efficient and Automated Design Strategy for Multi-physics E-Motor Development

This presentation introduces an application of a unique, highly automatic, multi-physics design strategy for E-motors, based on a current program at Mercedes-AMG GmbH. The strategy considers essential development requirements including electromagnetics and thermal requirements, NVH, stress and durability. It accommodates for DOE, multi-objective optimization and design exploration methods to be used to explore and find feasible motor designs. The presentation will show how the strategy adds efficiency to the E-motor development process and how it impacts the total costs of development.

ATC Presentations

Fast Forward Your Nonlinear Analysis with OptiStruct and HyperWorks Unlimited

Take home a modern nonlinear solver and state-of-the-art compute cluster to start revolutionizing your engineering decision-making on day one. Make agile design decisions, boost throughput, and reduce time-to-market by combining the modern nonlinear solver capabilities of OptiStruct with Altair’s HyperWorks Unlimited appliance.

Brochures

Design for Additive Manufacturing with Topology Optimization

Presentation by Avishai Warszawski, Mechanical Designer at IAI, Israel Aerospace Industries at the ATCx in Israel, Netanya on October 30, 2019. The goal of this project is to design a lightweight and stiff support bracket for delicate coaxes which are attached to an electronic unit. The machining design of this bracket, although very light in weight, did not provide the required stiffness and was also very expensive to manufacture. The best approach for design was only realized after the AM team was requested to find a solution. Topology optimization with Altair tools was used to define the best shape that provides the best solution. Finally, the bracket was printed in an SLM machine from AlSi10Mg. In the near future it will be qualified by dynamic tests in accordance with the defined environmental loads.

ATC Presentations

What’s the State of Nonlinear Simulation?

Engineering.com audience survey of nonlinear simulation practices

Technical Papers

Analysis Origins: OptiStruct

This article, featured in the October 2019 issue of NAFEMS BENCHMARK Magazine, chronicles the origins and legacy of OptiStruct, an early pioneer of simulation-driven design. Features quotes from Altair CEO Jim Scapa and other influential voices from the early days of Altair's history. Article originally published in Benchmark Magazine by NAFEMS, the International Association for the Engineering Modeling, Analysis & Simulation Community. Find out more at nafems.org.

Articles

Fast Forward Your Nonlinear Analysis with OptiStruct

Simulate the effects of large displacements, material nonlinearity and advanced contacts with Altair OptiStruct™. OptiStruct is the industry standard for the optimization of topology, composites, mechanisms and additive manufactured parts, but over the past three decades, it has evolved into a comprehensive linear and nonlinear analysis solution, delivering the functionality that customers of traditional nonlinear implicit codes expect coupled with the high performance they need. Watch this webinar to learn about how OptiStruct is being used to reduce software cost, simulate faster, and improve design process efficiency.

Webinars

Battery & Motor Thermal Management for Electric Vehicles

The key element of an electric vehicle (EV) is the battery and batteries are known to produce heat during their charge-discharge cycle. An efficient thermal management system (TMS) is of paramount importance. The battery TMS affects the cost, life, and range of the EV. A battery TMS study or an EV TMS study involves the use of thermal and fluid physics and Altair’s AcuSolve (Computational Fluid Dynamics based Simulation Technology), was used to carry out this study. The importance of finding new methods for effectively and accurately designing TMS that control temperature and optimize the performance of Li-ion batteries. This can be used to study and optimize the Battery Thermal Management System and other Thermal Management requirements arising in an electric vehicle which involves both active and passive cooling. A similar issue of heat (unwanted) exists in Motors as well, in this, we shall cover the Multiphysics simulation of Motors which shall include both electromagnetics and CFD Thermal studies of both air and liquid coolant motors.

Webinars

Traction Motors Design & Multidisciplinary Optimization

Traction Motor play key role in the electric vehicle/hybrid electric vehicle (EV/HEV) development process. The design of a High-Performance e-Motor is a complex undertaking. Engineers have conflicting constraints to consider including efficiency, temperature, weight, size, and cost. To explore more ideas, better understand their designs and improve performance, Altair HyperWorks™ has a workflow to guide motor designers through an efficient process of Simulation-Driven Design. This analysis and optimization solution supports multi-disciplinary teamwork and reduces design times.

Webinars

Cost Optimization in Composite Structures

Cost optimization is a driving force in all fields of industry, with every manufacturer competing to provide a cost-effective solution to the end customer. The paper addresses how to perform an early-stage design of components with emphasis on cost optimization and without consuming too much of a construction designer's precious time. The main objective of this paper is to generate a proposal for a car seat design, based on free size optimization and cost optimization using Altair OptiStruct commercial engineering software.

Technical Papers

10 Things You Didn't Know You Could Do In Altair OptiStruct

You know Altair OptiStruct as the leader in topology optimization, but did you know that the use of OptiStruct for nonlinear structural analysis has been increasing rapidly at leading companies? Teams are benefiting from a modern solver technology with linear and nonlinear capabilities – backed by Altair’s industry leading support – while reducing costs through the unique value of HyperWorks Units.

Videos

Heavy Equipment Simulations: Multi-body, Hydraulics & DEM

Presenter: Ronald Kett, Technical Specialist, Altair

For a Stewart-Gough-Platform (Hexapod), various software tools were used to study and design highly dynamic hydraulic drives together with an overall system control. Calculation of Eigenfrequencies, control design and comparison, hydraulic system design, and overall simulation control were done in Altair Activate, the mechanics of the Stewart-Gough-Platform was taken from a CAD model into Altair Inspire Motion. The co-simulation between control + hydraulics and mechanics was performed using Activate and Altair MotionSolve. Altair HyperView and HyperGraph were used to analyze and visualize the results. With the highly integrated solutions, the results could be achieved within a very short time. The different types of models (linear/simplified/full mechanics/hydraulics) made it possible to start with fast development cycles and finally achieve reliable results.

ATC Presentations, Videos

Integrated Systems Simulation from Requirements

Ed Wettlaufer, Technical Manager Mechatronics Group, Altair [on behalf of NAVAIR]

Government solicitations for proposals, or RFPs, for aircraft and airborne systems require preliminary designs with enough fidelity to accurately predict performance, in order to prove the design's ability to meet the Governments performance requirements. Modern high-performance computing provides the leverage to execute previously expensive analyses in areas such as computational fluid dynamics. The results of these high order analyses can be used to populate parameters in 1D systems models which can be easily coupled to medium order models from other disciplines. These capabilities allow the design engineer to rapidly iterate to levels of model maturity and accuracy not achievable years ago, resulting in high levels of confidence in the designs performance predictions in unprecedented time. Moving forward, Altair engineers will employ Multiphysics and co-simulation to execute the Engineering and Manufacturing Development phase (EMD) for one subsystem of the preliminary design developed in the afore mentioned pre-acquisition phase.

ATC Presentations, Videos

Experience the Sound of Your Future EV Before it is Built

Achieving the targeted brand image in a short development cycle time with minimal or zero prototypes is a major challenge faced by EV companies. To overcome this challenge, Altair, HBK and Romax have jointly developed a simulation driven process coupled with capabilities to virtually experience the noise and vibration characteristics, giving engineers a way to obtain real time performance feedbacks as the vehicle is being developed. This joint presentation on the proposed NVH development process covers a wide range of topics, including benchmarking, target setting, full vehicle and motor gearbox simulation loadcases, troubleshooting, optimization and stochastic analysis, and playback of simulation results for subjective evaluations, with a number of new technologies representing the global best practice in sound and vibration design and development. Join us to explore ways to control the sound and vibration characteristics of the vehicle, achieve the right sound, and avoid common NVH pitfalls, while accelerating time to market utilizing and experiencing virtual NVH prototypes.

ATC Presentations

eBook: Learn Dynamic Analysis with Altair OptiStruct

This study guide aims to provide a fundamental to advanced approach into the exciting and challenging world of Structural Analysis.

eBooks, Training Materials

eBook: Introduction to Nonlinear Finite Element Analysis using OptiStruct

This study guide aims to provide a fundamental to advanced approach into the exciting and challenging world of Nonlinear Analysis.

eBooks, Training Materials

eBook: Learn Thermal Analysis with Altair OptiStruct

Examples in the eBook – Learn Thermal Analysis with Altair OptiStruct

eBooks

eBook: Learning Fatigue Analysis with Altair OptiStruct

The focus of this study guide is on Fatigue Analysis. As with our other eBooks we have deliberately kept the theoretical aspects as short as possible.

eBooks

Optimizing a Solar Car for Endurance and Energy Efficiency

Using Altair simulation software, Gurit supports Western Sydney University's Bridgestone World Solar Challenge team, helping them design the most efficient and aerodynamic car possible, while ensuring driver safety and adhering to class rules.

Customer Stories

eBook: Practical Aspects of Structural Optimization

This study guide aims to provide a basic introduction in the different optimization methods. Designed for users who are interested to learn more about the “inspiring” world of optimization.

eBooks

Five Common Mistakes made Running Topology Optimization

Topology optimization is an approach that optimizes the material distribution within a given design space, for a given set of loads and boundary conditions, to meet a set of performance targets. Using topology optimization at a concept level can help you achieve the best performing design while saving time by replacing costly design iterations.

Articles

Magneto Vibro Acoustic Design of PWM Fed Induction Machines

Induction Motors (IM) are widely used in various industries. To ensure their speed control, IM will be supplied with pulse width modulation (PWM). This kind of supply, can impact efficiency of the motor and degrade its vibro-acoustic behavior, generating noise nuisance. To tackle these technical challenges and ensure best-in class acoustic comfort for users, it is necessary to design a quiet e-motors at the early stage of design. The first aim of this paper is to show a new method to reduce noise and vibration due to PWM supply of induction machine. The proposed approach allows the passive reduction of air-gap flux density harmonics in an induction machine. The second interest, is to show a new method to analyze the vibro-acoustic behavior of a PWM-fed IM. The method is fully finite element (FE) computation. Finally, the third interest of this article, is to compare noise and vibration results between the proposed FE method, magneto-vibro-acoustic coupling and measurements. Good agreement between measurements and computation will be shown.

Technical Papers

Drivers...Start Your Simulation? University of Texas – Arlington uses Altair SimLab™ and Altair Optistruct™ to design an adjustable pedal box for their Formula SAE racecar

Formula SAE is a collegiate design series run by Society of Automotive Engineers (SAE), which challenges students to design, build and compete with an open wheel style car across various events. The competition pitches various teams across different static events focusing on the teams engineering design decisions, cost planning, marketing strategies and vehicle inspections. The teams also have to compete under various dynamic events like acceleration, skid-pad, autocross and the endurance run where even the fuel economy is checked.

Customer Stories

OptiStruct – Nonlinear Axisymmetric Analysis

Nonlinear axisymmetric analysis with OptiStruct.

Tips & Tricks

OptiStruct – Mode Tracking and Rotor Energy from Complex Eigen Value Analysis

OptiStruct – Mode Tracking and Rotor Energy from Complex Eigen Value Analysis

Tips & Tricks

OptiStruct – Key Performance Indicator Output

OptiStruct – Key Performance Indicator Output

Tips & Tricks

OptiStruct – Section Force Output from Pretension Bolt

OptiStruct – Section Force Output from Pretension Bolt

Tips & Tricks

Hyperworks X: Morphing Examples on a Turbine Blade

This brief demo shows the easy accessibility to morphing in HyperWorks X. Different examples are shown to explain, how to take advantage of Altair's morphing technology.

Videos

Hyperworks X: Design Space Management

Altair HyperWorks X introduces a very intuitive and powerful workflow to quickly generate design and non-design space for optimization runs. It also provides a library for automotive related non-design spaces, such as engine, seats, engine, sunroofs, and wheel arches. The results can be quickly altered with manipulators.

Videos

Generative Design and Topology Optimization Report

This special report by engineering.com covers two of the most talked-about trends in the product design community today: Generative Design and Topology Optimization. These simulation techniques allow customers to design lightweight and performative parts using a simulation-driven design approach.

Technical Papers, Use Cases

Multiphysics Optimization of Traction Motors For E-mobility

Multiphysics Optimization of Traction Motors For E-mobility Vincent Leconte, Sr. Director, Global Business Development-EM Solutions, Altair

ATC Presentations

What's New in OptiStruct 2019

Find out what's new in Altair OptiStuct 2019, THE solver for linear and nonlinear analysis.

Webinars

Welcome - Simulation Magic

Dr Royston Jones, Managing Director of Altair UK delivers and opening presentation for the country's 11th Altair Technology Conference 2019.

ATC Presentations

Aircraft Radome Multiphysics Using Simulation

Watch this webinar to see a demonstration of a multiphysics simulation approach using the Altair HyperWorks platform for the analysis of airborne radomes for electromagnetic , structural, aerodynamic, and bird strike performances.

Webinars

Taking on the Shell XPRIZE with Help from a Digital Twin

Chris Wilkinson, CTO at SMD speaks at the UK Altair Technology Conference 2019. An XPRIZE challenge is designed to source new approaches to solve difficult problems thereby disrupting existing markets or creating new ones. Our oceans cover over 70% of the planet with only 5% explored. The ocean environment is hostile and technically challenging to operate within. The Ocean Discovery XPRIZE competition was established to seek cheaper and faster solutions to survey the world’s oceans. This presentation is about one of the teams that entered the competition with a disruptive solution for ocean survey. The emerging role and importance of a digital twin is explored to support the solution as it scales from proof of concept to one that is fully industrialised.

ATC Presentations

Solving Problems in Product Design in Aerospace

Robert Fox, Engineering Associate Fellow at Rolls-Royce presents at the UK Altair Technology Conference 2019. This presentation provides some background on Rolls-Royce products and how CAE has changed the way in which such complex products are certified as being safe to fly. The presentation then moves on to outline some ways in which CAE is now being employed earlier in the design process to develop the next generation of aircraft engines. It concludes with some background on how Rolls-Royce engages with students and Universities engaging in CAE projects.

ATC Presentations

Development of Carbon Fibre Floor Structure for the NIO Electric SUV

NIO are a global automotive startup producing electric vehicles for the China market. Our second vehicle, the ES6, was unveiled in December 2018 in Shanghai. It features a lightweight carbon fibre rear floor body structure, which will become the first high volume CFRP production part in ASIA. This presentation describes the CAE activities undertaken to develop the composite body structure. It explains the approach that was taken to construct and validate the material cards and the various material tests involved. It explores the various CAE activities used to develop and optimise the design of the parts and the layups of composite layers, and then the successful validation of the parts.

ATC Presentations, Presentations

Using Advanced Simulation to Design Leading Motorcycles

Rod Giles, Group Manager CAE & CAD presents at the UK ATC 2019. Royal Enfield has and is undergoing a massive transformation, not only in the sales and manufacturing departments, but also in the way the motorcycles are designed and developed. Leading the way in the development of all new motorcycle platforms is the use of advanced Computer Aided Engineering (CAE) tools. At Royal Enfield we use a wide array of different tools and techniques. The primary tool for model preparation and analysis is Altair Hyperworks. Rather than trying to cover the vast range of analyses carried out, today I will concentrate on some examples where advanced techniques have helped the design process including using smooth particle hydrodynamics (SPH) in explicit analysis to evaluate fuel tank integrity, using NVH director to evaluate and improve transfer path analysis (TPA) to aid the rider comfort, using topology optimisation to reduce mass and improve structural performance of engine and chassis components, and using MotionSolve to understand complex mechanism dynamics.

ATC Presentations

Empowering Designers with Predictive Simulation Technology

Jon Heath, Lead Mechanical Engineer at Brompton Bicycle presents at the UK ATC 2019. The Brompton bicycle has been engineered over many years using very much traditional engineering development methods. Introducing FEA tools and methods into the development process has allowed Brompton to reduce development time and improve early stage design robustness.

This presentation details how the company has implemented the Altair Inspire, SimSolid and HyperWorks suites into its development process, enabling its design team to find problems quickly and correct them before prototyping.

ATC Presentations

Additive Manufacturing, Lattice Structures and Advanced Simulation: the Good, the Bad & the Ugly

Simon Jones, Technical Director at HiETA presents at the UK ATC 2019. Additive Manufacturing (AM) offers huge potential to create structures and designs that are not realisable through conventional manufacturing methods, and deliver real engineering benefit. HiETA will talk about our experience of developing complex thermal management structures using AM, some of the potential benefits and opportunities it affords, and how new advanced simulation software from Altair is addressing some of the industry needs around it.

ATC Presentations

Development of the Next Generation Civil Tiltrotor

Leonardo’s Product Roadmap and the Associated Design Challenges. The Multi-Disciplinary Requirements of Tiltrotor & Other Lightweighting Studies.

This is a keynote presentation from the UK Altair Technology Conference 2019 by David Matthew, Lead Engineer at Leonardo. David joined Westland Helicopters as an undergraduate trainee in 1990, studying Mechanical Engineering at Imperial College and joining the Stress Office following graduation. Since then, David has worked within the airframe structure system group on a range of military and civil helicopter projects including the AW101 and AW189 helicopters, becoming a lead specialist in fatigue and damage tolerance, structural analysis, testing, and qualification. On the AW189 project, he led the analysis and qualification activities from preliminary design through to certification.

For the last year, David has been the Structures Lead Engineer for the Next Generation Civil Tilt Rotor project. This is a collaborative research project, which is part of the European Union Clean Sky 2 programme. This project is to develop technologies to support a large tiltrotor aircraft and to demonstrate these on a test demonstrator aircraft.

ATC Presentations

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