optistruct

First Time Right Machine Design with CAE Simulation

G.S. Vidyaprakash presents how Lakshmi Machine Works Ltd. drives the design process with simulation. In his presentation First Time Right Machine Design with CAE Simulation, he discusses reliable simulation techniques to predict & prevent failure modes.

ATC Presentations, Customer Stories, Customer Testimonials, Presentations, Use Cases

Failing Fast is not an option! Develop world's first robotic car storage service with accurate virtual prototypes

Benoit Pelourdeau presents how Stanley Robotics SAS drives the design process with simulation, to develop the world's first robotic car storage service. Learn from him how the interdisciplinary mechatronic product development team succeeds with accurate virtual prototypes.

ATC Presentations

Faster evaluation of real-world machines - Improve the Design with Studies and Design Exploration

Simon Zwingert, Technical Consultant, gives a Demo Sessions on Altair Simulation Solutions for faster evaluation of real-world machines, explaining how, to improve the design with studies and the design exploration on the complete assembly to perform weld line optimization.

ATC Presentations, Tutorials

Faster evaluation of real-world machines - Vibration Reduction with topology optimization

Daniel Jauss, Application Engineer CAE, gives a Demo Sessions on Altair Simulation Solutions for faster evaluation of real-world machines, explaining how to realize vibration reduction with topology optimization performing a modal analysis & Optimization of a machine portal, identifies economic manufacturing alternatives, and conducts a topology optimization for sheet metal constructions.

ATC Presentations, Tutorials

From CNC Jobshop to the largest manufacturer of CNC Rotary tables

Indradev Babu, Managing Director, UCAM PVT LTD, explains how he developed a CNC Jobshop to the largest manufacturer of CNC Rotary tables—presenting different development examples, he explains how Simulation Driven Design helps him to differentiate and what simulation Strategies he implements in the customer-centric development for the following generation Machine Tools at UCAM.

ATC Presentations

Simulation along product life cycle – The future is now From motivation to customer value

Industry expert Dennis Baum presents how Weber Maschinenbau applies simulation, how simulation can be used along product lifecycle and which benefits arise to customers and internal processes.

ATC Presentations

Simulation as a central element of Mayer & Cie’s digital development strategy More efficient machine generations thanks to virtual product development

Mayer & Cie. GmbH & Co. KG sets simulation as a central element of the digital development strategy and leverages virtual product development for more efficient machine generations. Marcel Wohlleb presents simulation applications and illustrates how customers of the world market leader in circular knitting benefit.

ATC Presentations

Economic CNC machine design through structural optimization

Mr. Vijay Zala and Mr. Pragnesh Zala present development methodologies for new economic machine generations and showcase why Jyoti CNC Automation Ltd. sets simulation at the core of the development strategy.

ATC Presentations

ATCx E-Powertrain - E-Motor Panel Discussion

A recording of the electric motor development panel discussion as part of the ATCx Electric Powertrain virtual event in March 2021. The panel features insight from Cleef Thackwell, Lead Motor Design Engineer at Jaguar Land Rover; Dr. Lars Fredriksson, VP Global Automotive at Altair; James Eves, Team Manager at Altair; Jonathan Stevens, Senior Development Engineer at Equipmake; Andy Jones, Innovation Program Manager at HiETA Technologies; Sergi Riba, Design Engineer at Safran Ventilation Systems; and Vincent Leconte, Senior Director of Global Business Development, Electromechanical Solutions at Altair.

Presentations

The Digital Approach to Industrial Machinery Design

Chad Jackson, CEO of Lifecycle Insights, describes the digital approach to industrial machinery design and explains strategies how companies creating equipment that increases cycle speed and improves yields in this technical report.

Technical Papers

Battery Part 1: Developing Predictive Electro Thermal Cell Models for Pack Level Deployment

Martin Kemp, Regional Manager at Altair, Dr. Denis Cumming, a Senior Lecturer at The University of Sheffield, John Milios, CEO at Sendyne, Dr. Gregory Offer, Reader at Imperial College London and finally Professor Jun Xu, Director of Vehicle Energy & Safety Laboratory at The University of North Carolina, present - Developing Predictive Electro Thermal Cell Models for Pack Level Deployment. This presentation will focus on the simulation of the battery cell to represent its complex thermal and mechanical behaviour. The thermal behaviour requires the simulation of the electric behaviour within the cell which leads to the generation of heat. Managing the thermal behaviour is fundamental to the long term health of the battery. The talk provides an overview of the technologies used to simulate battery behaviour, commencing with the understanding of the battery structure including the simulation of electrode manufacture. Both electrochemical and equivalent circuit models will be discussed with the advantages and disadvantages of both methods presented. Finally, machine learning technology is used to create an intelligent cell model which retains accuracy whilst delivering computational efficiency which can be used in Part 2.

Presentations

Battery Part 3: Simulation Technology Facilitating Battery Pack Range Optimization

Dr. Richard Boyd, Technical Specialist at Altair take us through his presentation, Simulation Technology Facilitating Battery Pack Range Optimization. Richard will take the battery module presented in Part 2 and create a full 3D model of the module - the duty cycle, event and optimization is repeated in this environment. This is performed efficiently in a Finite Element environment. In addition, a link to a 3D Computational Fluid Dynamics solver is highlighted if additional verification is required.

Presentations

Multi-Physics Design of e-Motors Using Optimization with Examples from Porsche and AMG

Dr. Lars Fredriksson, VP - Simulation Driven Innovation at Altair, presents the multi-physics design of e-motors with a particular focus on optimising performance including efforts to maximize torque and power under defined driving conditions while keeping rotor stresses, motor vibrations and motor temperature within certain limits. We’ll also see some specific examples of this process as applied to e-motor development at both Porsche and AMG.

Presentations

Creating the World’s Most Power Dense Electric Motor

James Eves, Team Manager at Altair, Jonathan Stevens, Senior Development Engineer at Equipmake and Andy Jones, Innovation Program Manager at HiETA Technologies, discuss AMPERE, a joint project to produce an extremely lightweight, efficient but low-cost electric motor with an extremely high continuous power density. The consortium will present some of the engineering challenges that designing such a high performance motor has posed, and how these challenges have been overcome through advanced manufacturing technology and simulation driven design.

Presentations

Delivering the Electric Revolution with Intelligent Simulation Technologies

Dr. Royston Jones, CTO and Dr. Anthony Hahnel, Technical Director, give their keynote presentation during the ATCx Driving Innovation in Electric Powertrain 2021.

Presentations

Accelerating Turbofan Structural Design with Altair HyperWorks

Ross Atherton is a Structural Systems Design Engineer in the Rolls-Royce Civil Aerospace Future Programmes Engineering department. After a period of supporting Rolls-Royce’s growing large engine fleet, Ross turned to future products; and has since led a small team designing, assessing, and enhancing the conceptual product architecture of future market opportunities. Ross’ presentation will go into detail on how Rolls-Royce have deployed the Altair Hyperworks toolset to enhance the structural efficiency of their UltraFan engine, covering: rapid model and mesh creation; new insights from structural optimisation and robust design; integrated post-processing; and the resulting acceleration of the engineering design iteration cycle.

Presentations

OptiStruct for Linear Analysis v2021

The purpose of this self paced course is to cover the basic topics for OptiStruct Linear Analysis. The Setup sections will use the See It, Do It methodology to cover the concepts. See It allows you to watch a video demonstration of the exercise covered in the section.

eLearning

Efficient Engineering Based Modeling of Layered Composite Structures

This presentation is by Program Manager Rob Jopson. It’s a given that the simulation models we build are intended to capture and predict physical behavior, the data used to create them is not always representative of the manufacturing process used to build the physical part. For layered composite parts in particular, this mismatch can cause significant overhead in managing the simulation data as the model is created and evolves. To solve this problem, Altair’s ply-based modeling methodology strives to maintain a 1:1 relationship between the simulation data and the manufacturing process, independent of solver. The latest developments of this methodology will be presented as a workflow in the new Composite Browser, available in HyperWorks. The recording is about 18 minutes long and was originally presented at the 2020 ATCx Composites.

ATC Presentations

End-to-end Workflow for Modeling Layered Composites in HyperWorks

This workshop on end-to-end workflow for modeling layered composites in HyperWorks was conducted by Program Manager André Möenicke. The recording is about an hour and 37 minutes long, and and was first presented at the 2020 ATCx Composites.

ATC Presentations

Molding and Structural Simulation of Injection Molded Parts

This workshop on molding and structural simulation of injection molded parts was conducted by Frank Ehrhart, EMEA Technical Specialist - Material Engineering/Multiscale Designer. The recording is a little over an hour long, and and was first presented at the 2020 ATCx Composites.

ATC Presentations

VABS: Modeling Composite Beam-like Structures with 3D FEA Fidelity

Variational asymptotic beam section (VABS) is a unique technology continuously funded by the US Army since 1988 and it has become a tool of choice in the helicopter and wind turbine industries for modeling composite rotor blades. With analysis of a finite element meshed cross section, VABS can compute the best set of beam properties for 1D beam analysis and also accurately recover 3D stress/strain distribution over the cross section. VABS has been integrated with HyperWorks and OptiStruct for Altair users to take advantage of this powerful technology for better design and analysis of composite beam-like structures.  The recording of the presentation by Dr. Wenbin Yu, CTO of AnalySwift, is almost 20 minutes long, and was originally presented at the 2020 ATCx Composites.

ATC Presentations

End-to-end Workflow for Modeling Layered Composites in HyperWorks

This workshop on end-to-end workflow for modeling layered composites in HyperWorks was conducted by Program Manager Rob Jopson. The recording is about an hour and 32 minutes long, and and was first presented at the 2020 ATCx Composites.

ATC Presentations

Material Characterization / Virtual Testing

This workshop on material characterization/ virtual testing was conducted by Jeff Wollschlager, VP of Composites Technology. The recording is about an hour and 32 minutes long, and and was first presented at the 2020 ATCx Composites.

ATC Presentations

Outstanding Scalability at NIAR - Advanced crash analysis solution proves twice as fast as leading competitor

To support its goal of accelerating the development cycle, early in 2020 NIAR commissioned a study to assess the scalability of Altair Radioss™, Altair’s structural analysis solver for highly non-linear problems under dynamic loadings. Regular support from an Altair engineer ensured swift familiarization with Radioss. The study was performed on Oracle Cloud Infrastructure (OCI). OCI with its bare metal HPC shapes that use low latency RDMA interconnect provided highly scalable infrastructure-as-a-service (IAAS) for Radioss.

Customer Stories

Composites at Altair

This presentation is by Markku Palanterä, Director Composites Business Development, Altair The composites design and simulation suite by Altair is actively developed with a holistic view to cover all stages of the process from material modeling all the way to the certification of composite structures. On the material modeling side, the focus is on continuous further development of Altair’s multiscale modeling technology for continuous fiber composites and injection molded plastics, but not forgetting further application areas, such as additive manufacturing. The ply-based composite modeling in Altair HyperWorks has recently undergone a major update to achieve an improved, more efficient modeling workflow. This together with planned further developments tie the modeling even better with the manufacturing to create realistic models of composite components as built. Altair’s solver technology for implicit and explicit analyses can utilize multiscale material models to accurately describe composite material nonlinear behavior up to failure. Altair’s unique composites optimization technology is being enhanced with the repeat laminate concept that provides added efficiency and user control over lay-up design. To further complement the idea of an integrated system with all the necessary composites capabilities, the Composite Stress Toolbox has been introduced in HyperWorks to support design and certification. The recording is about 22 minutes long and was originally presented at the 2020 ATCx Composites.

ATC Presentations

Multiscale Methods: from Theory to Practice

In this presentation, Dr Jacob Fish, Professor, Columbia University, introduces some of the key concepts and approaches in multiscale modeling, highlights recent advances aimed at developing practical multiscale tools, and survey the current landscape in multiscale modeling ranging from linking atomistic-to-continuum and continuum-to-continuum scales, physics and data-driven multiscale approaches, and applications in automotive, aerospace and biomedical industries. The recording is about 41 minutes long and was originally presented at the 2020 ATCx Composites.

ATC Presentations

Improved Workflow with Integrated Composite Stress Toolbox and Certification

This presentation is by André Mönicke, Program Manager Classical composite analysis and certification methods continue to be used in a significant share of the composite design process. In particular, applying classical methods early in design, and integrating them with finite methods as soon as possible can allow faster decisions which will be rewarded when it comes time for certification. Altair’s latest developments to respond to those needs will be presented, covering the Integrated Composite Stress Toolbox and a Certification framework available in HyperWorks. The recording is about 20 minutes long and was originally presented at the 2020 ATCx Composites.

ATC Presentations

Increasing the Efficiency of Damage Modeling for Filament Wound Pressure Vessels through Multiscale Simulation​

This presentation is by Dávid Migács, R&D Engineer at CIKONI GmbH. A key design issue for new hydrogen-based vehicle drive systems is assuring safety of the start-of-the-art polymer lined, carbon fiber overwrapped vessels working at pressures over 700 bar. Cikoni will describe how a multiscale approach gives a better estimation of burst pressures and insight into damage mechanisms for different laminate layups, at both the macroscopic and micromechanical levels, to validate simulation models for structural optimization of layups, along with life predictions. The recording is about 28 minutes long and was originally presented at the 2020 ATCx Composites.

ATC Presentations

Guide to Consumer Electronics Design and Packaging

To get a beautifully designed electronic product safely delivered to your customer, the work must start at the product design phase. Leveraging simulation-driven design, manufacturers are gaining greater insight and control over the development of innovative products, consistent manufacturing processes, and cost-effective, sustainable packaging.

Brochures

Curing, Cracking and Distortions in Epoxy Composites. Simulating Manufacturing Processes using Finite Element Approach

This presentation is by Dr. Tomasz Garstka and Graham Barnes, LMAT Ltd. Manufacturing induced deformations and residual stresses are an unavoidable consequence of processing composites at elevated temperatures. A number of mechanisms have been identified causing residual stresses and distortions, including mismatch in the thermal expansion, cure shrinkage of the resin, consolidation and tool-part interaction. These mechanisms usually act collectively through the curing process and may lead to severe changes in the laminate characteristic. When cured and exposed to natural environment moisture swelling, as well as subsequent stress relaxation mechanisms lead to further geometrical changes. A novel cure simulation solver is demonstrated here with the application to typical aircraft components. The recording is about 10 minutes long and was originally presented at the 2020 ATCx Composites.

ATC Presentations

Boosting U.S. Army Vehicle Payloads - Altair enables dramatic reductions in component weight for the GVSC

Payload is a key performance measure for military vehicles, determining how many personnel and/or goods can be carried. Reflecting this, the US Army Ground Vehicle Systems Center (GVSC) is engaged in a project to reduce the curb weight of vehicles, and thereby boost payloads, by redesigning and replacing existing components with lighter alternatives. Specifically, GVSC is combining topology optimization with additive manufacturing to realize significant weight savings, without compromising other critical requirements. Altair was contracted for external expertise to create new component designs. The results included achievement of 67% mass reduction for an alternator bracket, and cheaper costs than the current machined baseline.

Customer Stories

To what extent has the Taiwan Unmanned Vehicle System been on track from MIRDC's perspective

In this presentation, MIRDC’s Bionic Intelligent Automatic Guided Vehicle (BI-AGV) is introduced. This “collaborative handling module” has three characteristics of wireless intelligence, flexible use and flexible movement. Through the wireless intelligent collaborative handling system, it can control several automatic guided vehicles (AGVS) in real time, and several vehicles can conduct remote control and serial connection to carry out handling tasks. At the same time, the 360-degree mobile omni-directional wheel design framework is adopted. It has the advantages of flexible use in the area where the traditional unmanned vehicle cannot run smoothly in the indoor narrow space.

ATC Presentations

Hydraulic Systems Optimization for Heavy Machinery

Create detailed hydraulic circuits & actuation systems as part of your multi-disciplinary system simulations, especially for heavy machinery & agricultural equipment, in combination with multi-body systems (Altair MotionSolve®) and granular material systems (Altair EDEM®).

Videos

Sound and Simulation: Designing a Smart Speaker

Speaker design and analysis, especially for a more complex product, system, or component, often requires building multiple simulation models. The loudspeaker development process involves multi-physics and multiple sources in parallel, to multiple simulation runs for prototyping, testing, and validation. This results in separate models for nonlinear analysis of strength, thermal analysis and stiffness, noise, vibration, and acoustics. Even though each model isn’t always built from scratch, typically the use of different solvers for each attribute will require that models need to be converted from one solver format to another. This practice is not only time consuming but frequently error prone resulting in an inefficient use of engineering time.

Technical Papers

SIMULATION DRIVEN ANTENNA DESIGN TO MEET ENVIRONMENTAL SPECIFICATIONS

In this paper, we illustrate a simulation-driven workflow process using Altair HyperWorks Suite for antennas to meet environmental specifications during the design process so time taken for test and certification can be minimized and thus, cost savings and faster product development cycles.

White Papers

Cool Runnings: E-Motor Design at DEF

The idea for its cooling technology for electric motor systems was born at high-tech start-up Dynamic E flow (DEF), when the founders first experienced an overheated engine of an electrical car. The existent development process at DEF used analytical methods and physical testing to confirm results. With increasing customization, that process was not flexible enough to handle various design possibilities. With the need for a simulative design approach, DEF employed Altair software to tackle its multi-physical design challenges, and to meet all the customer requirements for their unique motors, test hundreds of variants, and to check the feasibility of the customized product.

Customer Stories

Lightweight Mining Haulers Optimized

Truck dynamics, control system, thermal, and fatigue analyses all need to be completed when designing a new truck design. Using Altair HyperWorks, Hitachi achieves a 10% weight reduction in the main frame and rigid body, while maintaining product quality.

Customer Stories

The Future Needs Computational Science and Engineering

Professor Karen Willcox, Director of the Oden Institute for Computational Engineering and Sciences, University of Texas at Austin discusses the role of computational science in the future of engineering and science. Data Science. Artificial Intelligence. Machine Learning. Across science and engineering, these terms are on the minds of academics and practitioners alike. Harnessing our growing amounts of data provides tremendous opportunities to drive solutions to some of society's most pressing challenges. But for many frontier science and engineering challenge problems, a purely data-focused perspective will fall short -- these problems are characterized by complex multi-scale multi-physics dynamics, high-dimensional uncertain parameters that cannot be observed directly, a relative sparsity of data, and a need to issue predictions in support of high-consequence decisions that go beyond the specific conditions where data may be available. Instead, a synergistic combination of data and predictive physics-based models is essential. This talk will discuss the critical role of Computational Science -- an interdisciplinary field that at its core involves mathematical models and simulations to understand physical and natural systems -- in a data-intensive future for engineering and science. The recording is about 22 minutes long, and was presented at the 2020 Global Altair Technology conference.

ATC Presentations

It’s Time to Stop Operating in the Margins and Harness the Full Potential of Simulation

Dr. Royston Jones, Global CTO, Altair Consultancy, discusses how the global pandemic has been a catalyst for companies to harness the potential of simulation by reconfiguring their established design processes and traditional organizational structures. Technologies and methods that can deliver design feedback at the speed of development are already available; reducing expensive physical testing while injecting innovation into a company’s product. The rapid evolution towards a connected everything is having a huge effect on design. From autonomous and electric mobility to smart consumer products with new business models, development teams must now integrate simulations of controls systems into complex multi-physics models enriched by data captured by sensors in the field. Especially during concept development when rapid exploration of design ideas is essential, a full embrace of simulation will be essential to compete. The recording is about 19 minutes long, and was presented at the 2020 Global Altair Technology conference.

ATC Presentations

The Future of Design, Simulation and Optimization

Dr. Ming Zhou, Sr. Vice President for software development at Altair provides his perspective on the future of design, simulation and optimization. Traditionally product design starts with CAD, typically inheriting design concepts largely from previous product generations. Topology optimization inverts the process by driving design concept creation through simulation. This puts CAE in front of CAD in the product development life cycle, transforming the design process from evolution to innovation. Remarkable results have been achieved on many iconic products, including the Boeing 787, Airbus 380, and 350, that everyone of us have touched firsthand. As we reflect up on recent technology advancements, let’s take a longer view into the future and imagine what a engineer’s day may look like in 20, 50 and 100 years. The recording is about 19 minutes long, and was presented at the 2020 Global Altair Technology conference.

ATC Presentations

Guide to Urban Air Mobility

Urban air mobility (UAM) is a point of convergence for automotive and aviation organizations. This presents opportunities for collaboration between the industries, with air taxis being of particular interest. Intended to transport a few customers at a time, avoid congested streets over short distances, and reduce pollution, this category of aircraft is often envisioned as an electric vertical take-off and landing (eVTOL) vehicle. Startups and established OEMs alike have begun moving past ideation and into the development stage for these next-generation aircrafts.

Brochures

TEAMTAO Engineers the Future of Deep-Sea Exploration

At the end of 2015, the XPRIZE foundation launched the Shell Ocean Discovery competition, a three-year global challenge to advance deep-sea exploration using autonomous subsea drones. Teams competed to develop underwater robots that could fully map 500 km2 of seafloor at a 4 km depth in less than 24 hours with no human intervention. One of the competing teams was TEAMTAO, a collaboration of Newcastle University, SMD (Soil Machine Dynamics Ltd), and UK Research and Innovation. Altair joined the project as a technical design partner and provided the team with simulation expertise to virtually simulate, optimize, and test the devices. Altair simulation specialists followed a simulation-driven design approach in order to save on development time and physical prototyping.

Customer Stories

Single Model Multi-attribute Analysis and Optimization

The analysis of a design, especially for a more complex product, system, or component, often requires building multiple simulation models.

Technical Papers

OptiStruct Optimization 2020

The purpose of this self paced course is to cover the basics of OptiStruct Optimization. The course contains modules introducing the basic optimization types and giving an over of each. Many exercises are available in the modules that use the See It, Try It methodology. See It allows you to watch a video demonstration of the exercise covered in the section, while Try It gives you a pdf and model to try it in the software on your own.

eLearning

Improving the Shipbuilding Block Assembly Method: An Engineering Approach

Block construction is a modern shipbuilding method which involves the assembly of prefabricated modular sections. Cross-sections of the superstructure are pre-built in a shipyard, taken to the building dock, then hoisted into position and attached. Block splitting and lifting schemes are largely devised after the ship design phase is completed, relying on empirical data and expertise to avoid costly and potentially dangerous failures during build-up. Advances in computer-aided engineering (CAE), however, now make it possible to plan ship build-up in the principal design phase, giving designers greater insights into block assembly process outcomes and reducing downstream risk through simulation.

Technical Papers

ATCx Poland 2020 - Composite Optimization in OptiStruct - Demo

A demonstration about Composite Optimization in OptiStruct presented by Panagiotis Natsiavas, Technical Coordinator, Eastern Europe, Altair

Presentations

ATCxPoland2020

ATCx Poland 2020 presented by Channel Partner DesArt

Webinars

Power Transformer under Short-circuit Fault Conditions: Multiphysics Approach to Evaluate the Robustness

Transformers’ windings experience mechanical loads from electromagnetic forces due to the currents they carry. Power transformers can suffer from high sudden short-circuit currents. These short-circuit currents are a significant threat, not only from an electrical but also from the structural integrity point of view. In this paper, coupled electromagnetic and structural mechanics simulations are carried out to evaluate short-circuit fault risks in a comprehensive and accurate way.

Articles