Altair OptiStruct™

Optimization-enabled Structural Analysis

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

FREE 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

FREE 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

FREE eBook: Learn Thermal Analysis with Altair OptiStruct

Examples in the eBook – Learn Thermal Analysis with Altair OptiStruct

eBooks, Training Materials

FREE 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, Training Materials

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

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

Revolutionizing Simulation-Driven Design with Altair SimSolid, A Technology Disruptor

Revolutionizing Simulation-Driven Design with Altair SimSolid, A Technology Disruptor! – Warren Dias, Director, Global OptiStruct Business Development, Altair SimSolid Case Study Presentation Ashish Mishra, Head-Simulation COE & Gaurav Regmi, Manager, Durability Simulation, Ather Energy

ATC Presentations

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, Videos

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, Videos

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, Videos

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, Videos

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, Videos

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, Videos

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, Videos

Build, Verify & Optimise a Body-in-White Structure in a Working Day

Dr. Tayeb Zeguer, Group Tech Leader APD, Advanced CAE at Jaguar Land Rover presents at the UK Altair Technology Conference 2019. A Design exploration, loadpath studies, material selection and heavy usage of Optimisation are key to the development of a lightweight and efficient Body-In-White (BIW) structure. Nevertheless, the fast pace of vehicle development makes it a challenge to do such CAE work fast enough to drive the design and the decision making. This is why the C2 phase of the Altair C123 process is the ultimate weapon to drive the design in a fast and reliable manner. By using low fidelity models, the C2 phase allows quick iterations, large DOEs and complex optimisation studies to be executed within minutes and have a large impact on design and strategy decisions.

The natural starting point for the C2 process is the supply of a C1 layout model with associated CAD packaging data. However, another entry point is the availability of a high fidelity finite element model from a previous program. The initial activity is the rapid development of a C2 model which can generate a reliable and good quality results. This is the reason why Altair has developed various tools to ease the process of creating “ready to optimise” low fidelity models. Thanks to a highly automated series of tools combined with highly advanced optimisation technology, it is now possible to build, verify and optimise a BIW model for Noise, Vibration and Harshness (NVH) and Crash in a single working day.

ATC Presentations, Videos

OptiStruct - Equivalent Plastic Strain Response for Optimization

Equivalent plastic strain can be used as an internal response when a nonlinear response optimization is run using the equivalent static load method. This is made possible through the use of an approximated correlation between linear strain and plastic strain, which are calculated in the inner and outer loops respectively, of the ESL method.

Tips & Tricks

OptiStruct - Contact Pressure, Force as a Response for Optimization

Contact Pressure can be used as an internal response when a model with contact and optimization is run. Contact pressure response is activated using RTYPE=CNTP option. The PTYPE should be set to CONTACT and the corresponding CONTACT Bulk Data ID(s) can be referenced on the ATTi field.

Tips & Tricks

OptiStruct - Failure Response for Topology Optimization

Factor of Safety (FOS) and margin of safety (MOS) optimization responses are now available for Topology optimization. It is calculated using NORM approach on design domain. All optimization types are now supported including Topology.

Tips & Tricks

OptiStruct - Neuber Optimization Response in Nonlinear Subcase

Neuber Stress and Neuber Strain sensitivities are supported for optimization in small displacement NLSTAT. It was already supported for optimization in FASTCONT analysis. It is supported only for small displacement analysis, it is not supported for large displacement. Once Neuber response is defined, the material will be treated as linear and MATS1 props are used only for Neuber correction. It is supported for solids as well as shells. It is supported for all optimization types except topology & freesize optimization.

Tips & Tricks

OptiStruct - Manufacturing Constraints for Composite Optimization

Certain manufacturing constraints are important when designing composite laminates, like balancing of plies, thickness of plies, etc. ln OptiStruct, manufacturing constraints can be defined during free size optimization, shuffling optimization for a better manufacturability and desired stacking sequence. The following are some of the manufacturing constraints which can be used depending on the requirement.

Tips & Tricks

Guerrilla Gravity

For pioneering a new material application and technology without a road map, Guerrilla Gravity used Altair OptiStruct in the early design design phase. The result was the development of lightweight, high-performance bikes, that are 300% more impact resistant than other frames on the market that use traditional carbon fiber materials, at significant cost savings and shortened timelines.

Customer Stories

Altair HyperWorks Defense Brochure

HyperWorks is a wide-ranging set of engineering analysis and optimization tools that is used throughout every major industry. See how HyperWorks is used for Defense in this brochure.

Brochures

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.

Customer Stories, Technical Papers

5 ways to optimize your design

Gauge optimization, size and shape, and shell optimization, can be used to improve an existing design without altering its overall architecture. 3D topology optimization can be used when a significant re-design is desired because it identifies the optimal load paths of a structure and recommend material reduction. The material layout produced in the 3D topology is then interpreted into a concept design which is dimensioned and fine-tuned with the gauge, size, and shape approaches resulting in a final structure. Do you want to learn how to execute all the techniques mentioned? Step-by-step tutorials are available now for download!

Tips & Tricks

A Unique Car Concept for Urban Space

Udi Meridor, Chief Innovation Officer at Israeli startup, City Transformer, talks about the thinking behind the design of this revolutionary design for urban transport. They have decided to rethink the future of the city car and create a cleaner world.

Customer Stories, Videos

Duratec

Czech company Duratec Ltd. develops handmade bike frames using both aluminium and composite materials. For a recent project at Duratec presenting the latest approach in development of carbon fiber optimization of the bike frame, Altair HyperWorks was used for model creation in Altair HyperMesh, optimized via the Altair OptiStruct code and evaluated in Altair HyperView in the development and optimization of a lightweight composite racing bike frame.

Customer Stories

Griiip

Israeli motorsport company Griiip has designed a new, fast and professional race car that combines efficiency in racing with a competitive purchase price and low running costs, to make it more affordable. By harnessing the power of data, Griiip has created the first smart connected race car – the G1 – and with it, an entirely new racing series. Accessing the software via Altair's new Startup Program, Griiip engineers employ several products from the Altair HyperWorks™ suite, among these Altair Radioss™ for crash simulation, Altair OptiStruct™ for structural optimization, general FE analysis as well as Altair HyperMesh™ and Altair HyperView™ for pre- and post-processing tasks in the development of race cars.

Customer Stories

Flat Panel Post-Buckling Analysis with Implicit Method using OptiStruct

Many commercial aircraft are designed so that fuselage skins can elastically buckle below limit load and continue to operate safely and efficiently. This design regime makes for a very lightweight semi-monocoque structure compared to a non-buckling design. Therefore, predicting the local buckling, post-buckling behavior, and failures are critical to design and optimization of this kind of structure. The local panels buckle in a combination of compression and shear. Excess compression is redistributed to surrounding axial members (frames and stringers) and shear is continued to be carried by the buckled panels via tension parallel to the buckle waves. The compression redistribution and diagonal tension put special strength considerations on all involved structural components. This post-buckling behavior and the analysis method are both called intermediate diagonal tension (IDT).

Technical Papers

Improving E-Motor Acoustics with Seamless Multiphysics Simulation

Discover Altair SimLab's automated workflow for coupled electromagnetic and vibration analysis. SimLab uses Altair Flux for electromagnetic analysis and Altair OptiStruct for vibro-acoustic simulation.

Webinars

HyperWorks for Aerospace Applications v2017

The HyperWorks for Aerospace self-paced course covers the critical processes used in the creation of FEA models in the Aerospace industry. This course contains 12 modules covering aspects from model setup to post processing. Each module contains background information on the tools used and practical exercises with recorded demonstrations to help you get familiar with the tools and processes. Note: This course requires a login to Connect to view.

eLearning

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