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Arup Uses the Latest Simulation Technologies for Architectural Design
Arup has determined the anticipated conditions throughout the interior of a complex architectural space through computational fluid dynamics (CFD) modeling. In this video Caroline Lama, Façade Engineer at Arup NY, explains how HyperMesh has been used to develop an efficient meshing scheme for this challenging geometry.

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

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

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

Race Face
Race Face redesigned a bicycle crank using generative design and finite element analysis. The concept design process yielded a part with increased stiffness and strength without increasing the weight of the part.

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

Peter Macapia, LabDORA
Architect Peter Macapia aims to change perceptions of how buildings can look; generative design software aids in imaginative engineering and architecture projects, integrating design and testing in the same space.

Scania Customer Story
Squeak and rattle phenomena are studied in the automotive industry in an attempt to reduce the cabin noise and as a result, give a better ride quality and comfort to occupants. In the case of Scania’s Cabin Development Department, this kind of simulation was not performed historically. The team had to rely on tolerance calculations as well as the choice of materials to reduce the risk of squeak and rattle. To reduce development time and cut down on iterative changes, a desirable solution was identified that enabled a simulation-driven design process during the early stages of the cabin development cycle.

HyperWorks provides flexibility and agility to development processes of Engineering Services Provider Beta Epsilon
Beta Epsilon designs racing cars and offers engineering. Beta Epsilon offers component and vehicle meshing, FEA analysis of metal and composite components, crash test simulation, optimization, and CFD simulation. Beta Epsilon uses HyperMesh, OptiStruct, HyperCrash, RADIOSS, AcuSolve, HyperView, and Virtual Wind Tunnel. With HyperWorks, Beta Epsilon could improve the quality of its products and extend its range of services.

Sundog Eyewear
Sundog Eyewear accelerates design times through the use of conceptual design softwarewhile improving visualization of the final product using integrated rendering.

Reducing Weight and Maximising Fuel Efficiency of a Formula Student Car with OptiStruct
Durham University Electric Motorsport (DUEM), are a UK-based team of students who design, build and race electric vehicles. In this project, DUEM wanted to demonstrate how they have applied the latest weight saving technology to achieve a faster, more efficient car by optimising an upright design for multiple load cases. As existing users of the Altair HyperWorks simulation suite, the DUEM team looked to OptiStruct to help meet this challenge.

Aircraft Carrier Alliance
Creating a Structurally Efficient Design for the Queen Elizabeth Class Aircraft Carrier

When making key decisions at the concept and preliminary design phases of a naval ship project, the designer is often obliged to work with limited data on the major structural design drivers for the vessel. This can lead to a largely subjective design approach which can result in inefficiency and even structural problems being locked-in from the start. To solve any issues, increased material use, weight and unnecessary complexity, as well as high design and manufacture costs can be introduced to the end product. To evaluate the potential of simulation-driven design under the unique requirements of naval ship design, the ACA partnered with Altair ProductDesign.

Northwestern University Success Story
Using HyperWorks for Teaching Computational Optimization Methods in Engineering Design at Northwestern University

HyperWorks Virtual Wind Tunnel on Cray: Benchmarks and Recommended Configurations
With Altair’s HyperWorks Virtual Wind Tunnel running on Cray XC30 or CS300 systems, manufacturers of all sizes can now predict a vehicle’s external aerodynamic performance without the need for numerous physical wind tunnel tests. This document includes scalability benchmarks for both small and large problems, along with Cray’s recommended system configurations to run Virtual Wind Tunnel.

When Engineering Intuition is Not Enough
A new technology helps design engineers quickly create dramatically lighter structures — and better understand the effects of material placement in whatever they’re developing.



Using Analysis to Innovate with New Materials
Analysis and optimization tools enable Samsung engineers to reduce
the cost of appliances without sacrificing performance.



By Beverly A. Beckert

Concept to Reality Winter 2013 Subscribe to C2R Magazine

Simulation Tools: Driving the Future of Design
The Clemson University Deep Orange 3 program introduced future engineers to analysis software, enabling them to develop a novel sports car concept architecture.



By Dr. Paul Venhovens

Concept To Reality Winter 2013 Subscribe to C2R Magazine

BASF Enlightens the Auto Industry
Continuous fiber-reinforced thermoplastic composite and virtual simulation technology enables BASF to develop an innovative and cost-neutral seat pan that is 45% lighter than its predecessor.



By Beverly A. Beckert

Concept To Reality Winter 2013 Subscribe to C2R Magazine

Aerodynamic Development of a Road Cycling Helmet with AcuSolve - LX Sim
LX Sim uses HyperWorks Suite and select Partner Alliance programs from Altair to help build an aerodynamic cycling helmet.

Toyota Motorsport
Controlling Software Costs with Altair’s Software Asset Optimization System



TMG chose Altair’s Software Asset Optimization (SAO) system to address this problem. SAO (Software Asset Optimization) enables the user easy and efficient access of the actual software usage of existing licenses in his company. He can analyze the software usage and based on this information make appropriate decisions concerning the acquisitions of new licenses and the extension of existing contracts.

DSM Success Story
Thermal Analysis of LED Lamps using AcuSolve

DeWalt Optimizes Power Tools with HyperWorks
The development of modern electric power tools requires special attention to be simultaneously paid to both the efficiency and user comfort of the tool, as well as the robustness and durability of the devices. For the fulfillment of these two groups of attributes, computer-aided simulations using HyperWorks has become central to the development process of Stanley Black & Decker Deutschland GmbH.

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

Case Study Sogeclair
Case Study about Sogeclair's use of HyperWorks

Industry: Aerospace interiors

Challenge: Development of new flooring concept to fix the cabin seats while realizing a lighter structure, adjustable panels for all types of aircraft, and an easier installation and
maintenance.

Altair Solution: Use of HyperWorks, especially HyperMesh and HyperView as a pre- and postprocessor, OptiStruct for optimization issues, RADIOSS for linear and nonlinear simulation, and solidThinking Evolve/Inspire for concept modeling

Benefits:
  • Saving development time and costs

  • Use a new approach in the design leveraging optimization

  • Reduce product weight through structural optimization of composite components



LG Electronics Success Story
LG Electronics Performs Smartphone Drop-Test Simulation in Less than 24 Hours with New Automated Approach

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

Renault
Carmakers the world over are investing heavily in the development of lighter vehicles and more economical engines that can go further on less fuel. Renault’s powertrain division wanted to further decrease the weight and increase the performance of existing and in-devolopment engines by redesigning key components to use a minimum amount of material. As an existing user of Altair’s simulation solutions, Renault approached Altair ProductDesign to assist in the development of the required optimization design methods and processes for use
at component and sub-system levels.

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

Panasonic Ecology Systems Shortens Development Time of Indoor Air Quality Products by Applying Virtual Product Validation with HyperWorks
They began by drop-testing
a single component, then moved on to
a combination of several components,
an assembled product and a packaged product. At each step, the team employed Altair’s RADIOSS solver to calculate the drop-test impact.

Toyota Motorsport GmbH uses Altair‘s SAO System to better control software costs in its commercial Software tools
License monitoring delivering information about the actual scope of software usage with Altair’s SAO solution, improving decisions on software renewal and acquisition.

PBS Professional Wins at NCI Raijin, Largest Supercomputer in Southern Hemisphere
Australia’s National Computational Infrastructure (NCI) chose PBS Professional to manage workload for its ‘Raijin’ cluster from Fujitsu, the largest supercomputing system in Australia with over 1000 users.

HyperWorks Optimization Capabilities Integrated into Packaging Design Process Help Unilever Cut Costs and Development Time
Unilever reduced the time required for
simulation and significantly lowered costs
by working with Altair HyperWorks suite
of computer-aided engineering tools.

Railcar Manufacturer Speeds Design Modifications with HyperWorks
American Railcar Industries, headquartered
in St. Charles, Mo., designs and manufactures
commercial railroad cars, producing
every part of the car above the wheels.
Customers use the company’s railcars to
transport all sorts of liquid and solid raw
materials, including oil, coal, cement, sand,
grain and other substances. Their designs
include boxcars, gondolas and hoppers,
among other styles.

Polaris Reduces Weight of Snowmobile Structures Up to 40% with solidThinking Inspire and OptiStruct
Polaris, based in Roseau, Minn., is a
renowned manufacturer of snowmobiles,
and its Snowmobile Chassis Structures
Group is engaged in design and testing that supports three different platform teams with chassis solutions for each set of requirements. Computer-based design and finite element (FE) analysis are integral parts of the Polaris snowmobile development process, as engineers work to create optimal structures that reduce weight without sacrificing performance.

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

Creactive Design
Using Optimization to Improve the Design of a Classroom



Product design consultancy and structural engineering partner, Creactive Design, wanted to explore the possibility of utilizing optimization technologies to improve the design of a cross-functional roof for an innovative new classroom environment. The classrooms, under development at architecture firm, Future Systems, would be prefabricated in glass reinforced plastic (GRP) to a high standard, making them energy efficient, durable and eminently replicable. The ambitious project was called the “World Classroom”. Creactive approached Altair ProductDesign, to assist in this explorative project due to Altair’s reputation for developing the market leading optimization software solution, OptiStruct.

The Successful Application of HyperWorks at Lenovo
To increase efficiency, improve the quality of meshing and shorten CAE simulation time, Lenovo engineers needed to own a powerful pre-processing tool, one that would really meet the demands of scientific research and engineering innovation. For this task, they chose HyperMesh, an important component of the Altair HyperWorks suite.

Samsung Uses OptiStruct to Redesign Washing Machine Component for Optimized Weight and Material Usage
To carry out optimization on the pulley, Suzhou Samsung chose OptiStruct, a key
component of Altair’s HyperWorks suite of computer-aided engineering tools and a
modern structural analysis and optimization solver. “OptiStruct provided us with important optimization features,” said Mr. Cheng, “such as topology, size and shape optimization. We were particularly interested in topology optimization to obtain the most efficient
structure or distribution of material used in the structure.”

HyperWorks Enables Global Appliance Manufacturer to Use New Material for Stronger, Lower-Cost Product
To qualitatively and quantitatively analyze the stress on the door cover during thermal expansion and contraction, the engineers used HyperMesh, a high-performance finite element pre-processor and RADIOSS, a modern structural analysis and optimization solver, both of which are part of Altair’s HyperWorks suite of computer-aided engineering tools. With these tools, engineers created a computerized simulation of the refrigerator door cover temperature field, employing HyperMesh to create a finely meshed model of the upper and lower covers, while shell elements were used to mesh the steel plate and interior lining, along with solid elements for the foaming material.

Clemson University Chooses PBS Professional for HPC Workload Management
Clemson University's IT department, Clemson Computing and Information Technology (CCIT), selected PBS Professional over open-source alternatives for mission-critical workload management. "We were looking to fulfill two requirements that our open source scheduling tool could not handle – reliability/scalability and technical support. After evaluating workload management vendors, Altair’s PBS Professional scheduling software came out on top as the solution that met our HPC needs."

HyperWorks, especially OptiStruct is one of the central tools supporting the CAE efforts of BASF Engineering Plastics
Mathematical optimisation methods can provide significant support in virtual CAE part development. In the early phases of the project topology optimisation affords valuable clues to the design of the geometry of the part.

Dana Adopts Altair’s SimLab to Automate Meshing of Powertrain Models with Dramatic Time Savings
Dana Holding Corporation is a world
leader in driveline, sealing, and thermalmanagement
technologies that improve
fuel efficiency, reduce emissions and
lower the cost of ownership in passenger,
commercial and off-highway vehicles.
Dana's 25,000 employees operate in
27 countries within a network of some
90 engineering, manufacturing and
distribution facilities.
Computer simulation of powertrain
components—entailing the creation of
very large models with 25,000 surfaces or
more—has long been an important aspect
of Dana’s product development process.
For many years, the company’s engineers
have employed a standard industry
methodology of transforming CAD designs
into prototypes, analyzing the prototype
to observe failure points, redesigning
the prototype and retesting until the
product met specifications.

Dante Sanchez Discusses the Optimization of Mabe's White Goods Packaging
For white goods manufacturer Mabe, the quality of the design and engineering of their home appliances is paramount. The objectives of this project were to simulate the effect of the distribution environment events to a washer and dryer product and perform optimization to improve product protection while reducing material costs and weight.

Investigating Aeroelastic Performance of Multi-MegaWatt Wind Turbine Rotors Using CFD
Recent trends in wind power technology are focusing on increasing power output through an increase in rotor diameter. As the rotor diameter
increases, aeroelastic effects become increasingly important in the design of an efficient blade. A detailed understanding of the fluid elastic
coupling can lead to improved designs; yielding more power, reduced maintenance, and ultimately leading to an overall reduction in the cost
of electricity. In this work, a high fidelity Computational Fluid Dynamics (CFD) methodology is presented for performing fully coupled Fluid-
Structure Interaction (FSI) simulations of wind turbine blades and rotors using a commercially available flow solver, AcuSolve. We demonstrate
the technique using a 13.2 MW blade design.

Faster Design Changes with HyperWorks’ Morphing Technology
In the development of engine components PSA determines the lifetime of the intake manifold with a complex thermo mechanical calculation. Since the development process is distributed between PSA itself and a supplier, a design change of the intake manifold takes three weeks to be evaluated. For the supplier it has always been hard to correctly interpret the design improvements suggested by the PSA CAE engineers. Due to the three weeks of time, the iteration between OEM and
supplier takes, and because the overall development time is limited, the process just allowed a few design changes. Therefore the design of the manifold can become a critical task in the
engine development. With HyperWorks’ morphing technology (HyperMorph) it is possible to quickly implement design changes and hence to avoid intermediate CAD changes. With this process, only a single final CAD revision is needed when all improvements have been done. The new
workflow with HyperWorks’ morphing technology allows for a much faster evaluation cycle of two days instead of three weeks with the former process.

Improved Mechanical Performance and Reduced Cost of a Solar Panel System with HyperWorks
HyperWorks proved to be exceptionally valuable in Luxon’s work for a major producer of a large-scale industrial panel system, which measures approximately 50 x 70 feet and rotates to track the sun. The company had a system in production but sought to lower the cost of manufacturing. Additionally, Luxon’s customer wanted to expand the geographic locations where the system could be installed successfully, so it asked Luxon to develop
a more robust support structure to ensure that the system would survive the seismic,
wind and snow loading that the product was likely to encounter in various parts of the world.

Ron Mendell
Hollywood concept artist Ron Mendell converts sketches to fully rendered digital 3D models, incorporating real world materials, dimensions and constraints.

TokyoFlash
TokyoFlash is a world leader in the design and sales of unique watches. They use Altair Evolve to speed product development.


Pininfarina Extra
Pininfarina Extra blends the use of industrial design, modeling and topology optimization software to achieve the brand's values of elegance, essentiality and innovation outside of the automotive industry.

Automotive Lighting
Automotive Lighting uses free-form modeling software to create concepts for customers in a fast and flexible way. Concepts are presented visually  in daytime and nighttime conditions using photorealistic rendering.

Novellini
Novellini applies industrial design and modeling software to set the pace of innovation for the manufacture of bathroom solutions and wellness products in Europe.

Bros Manifatture
Bros Manifatture is a "superbrand" in the world of fashion jewelry and watches with over 200 new products each year.


XOX Audio Tools
XOX Audio Tools utilizes high design and advanced technologies to create cutting-edge musical instruments.


Korg Italy
Korg utilized 3D modeling and rendering simulation to manage the frequent design modifications that occur during the product development process. 

Customer Story: Peter Macapia
Dr. Peter Macapia discusses solidThinking's part in reinventing structural systems and rethinking what a building is.


HyperWorks - Intel-Colfax-Altair Trial Cluster Testimonial: Suncoke Energy
Suncoke used Colfax’s “Try Before You Buy” cluster trial program to run an AcuSolve simulation for analyzing the flow dynamics of a system under negative pressure and extreme temperatures. Their job ran over 16x faster on the cluster.

Weizmann Institute Case Study: Switching to PBS Professional for HP Clusters
The Weizmann Institute replaced Moab with PBS Professional to manage a 3,096-core HP cluster shared among hundreds of users. The transition process was easy, thanks to Altair’s excellent customer services and support. Now, the Institute enjoys higher cluster usage rates and greater productivity from their award-winning scientists.

Cooper Standard Speeds Development of Next-Generation Pumps with Altair’s AcuSolve CFD Solver
With more than 22,000 employees in
19 countries, Cooper Standard supplies the vehicle industry with fluid delivery systems, sealing and exterior systems, thermal and emission systems and AVS. The company’s Electromechanical Department is an advanced research and development arm of the Cooper Standard North America division. It’s goal is to marry mechanical systems with electronic controls. This new technology improves overall vehicle efficiency by providing on-demand fluid delivery and by eliminating the power loses inherent in conventional systems.
In designing new pumps for this type of system, CAE Engineer Tom Lincoln uses computational fluid dynamics (CFD) software to simulate the flow of coolant through the device. He and his team began using CFD computer-aided engineering tools as long ago as 2003, and computer simulations have become an essential part of his organization’s product development process.

Body-In-White Design for a Six-Passenger Sports Car Architecture: Maximizing Body Stiffness and Meeting Strength Requirements Using HyperWorks
The Deep Orange Program has partnered with Altair to apply advanced computational simulation methods to their vehicle designs. Altair-sponsored internships and fellowships have enhanced student learning through
providing webinar-based and on-sight instruction of Altair HyperWorks simulation technologies. An example of these simulation-based design applications is the CUICAR Deep Orange 3 Program,the third generation vehicle prototype designed and engineered by the Clemson engineering graduate students. Deep Orange 3 features a load-bearing structure based
on innovative sheet-folding technology and a unique 3+3 seating configuration package in a sports car architecture. The following describes this design and summarizes the application of Altair HyperWorks to meet the
necessary engineering structural performance requirements for the underlying body structure.


QIMR Case Study: Altair and Dell Improve HPC Capabilities for Leading Research Institute
Queensland Institute of Medical Research (QIMR) is using PBS Professional on a Dell cluster to improve HPC computing. According to the CIO, “Everyone has benefited from this installation. Researchers can do things they couldn’t do before, like running jobs multiple times or utilizing larger data sets, to achieve outcomes they couldn’t otherwise get. It’s pretty easy to see the value."

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

Danish Team Uses HyperWorks to Prove the Value of Topology Optimization for Concrete Architectural Structures
Denmark’s Aarhus School of Architecture
was interested in exploring the potential
of applying the kind of simulation-based
topology optimization used in the automotive,
aeronautical and naval industries to
architectural concrete structures and coupling
it with robotic fabrication of polystyrene
formwork for concrete casting. Led by
Per Dombernowsky, who served as project
manager and engineer, and Asbjørn
Søndergaard, who headed the project’s
design and optimization aspects, the
combined academic and industrial team
created the Unikabeton Prototype project.

Intel AcuSolve Case Study: Analyzing Complex Designs Faster
Working in collaboration with Intel’s technical support team and utilizing key Intel® software development tools, Altair was able to improve performance, scalability, and time-to-results for AcuSolve, Altair’s leading CFD flow solver.

PBS Professional at The Scripps Research Institute
The campus of The Scripps Research Institute (TSRI) overlooks the Pacific near San Diego. Its proximity to the famed (but unrelated) Scripps Oceanographic Institute occasionally causes confusion of identities. But TSRI is prestigious in a totally different way. TSRI uses Altair’s PBS Professional software to provide a consistent workload management infrastructure for its users across all three computing environments.

Aircraft Seating Design, Analysis, and Optimization


QinetiQ Keeps the Army’s Kiowa Copter Flying Lighter and Longer Through HyperWorks Optimization
A large proportion of Army aircraft are legacy platforms. Program managers of these aircraft are challenged to integrate new technology into these older platforms to enable them to meet the constantly expanding demands of today’s missions. These new devices and systems, however, often add weight to the vehicle or otherwise impact mission profiles. To sustain aircraft performance, weight reduction methods need to be adopted for aircraft components if technology insertions are going to continue.

Extending Extrusion Die Life Using HyperXtrude
Altair HyperXtrude is used to predict die
performance and run virtual die tryouts.
Using these capabilities, die designs can be
modified and tested to improve the die life
and reduce the number of die trials.

The Art of Packaging to Protect Cultural Assets
Simulation tools isolate the cause of
undesirable shipping loads on museum’s
cultural treasures.

CFD Advances Racing Bike Performance
Highly automated computational fluid dynamics (CFD) workflows enable the discovery of flow behaviors, improving wheel aerodynamics.



Mathew N. Godo, Ph.D. and David Corson, Ph.D.

Concept To Reality Summer / Fall 2012 Subscribe to C2R Magazine

Right-Sizing PLM Software Investments
An Indian motorcycle manufacturer leverages business analytics to optimize software usage and procurement decisions.



By Beverly A. Beckert

Concept To Reality Summer / Fall 2012 Subscribe to C2R Magazine

Simulation: The Connection between Speed and Safety in Racing
Chassis manufacturer relies on simulation
and optimization to develop the fastest
– and safest – race cars on today’s circuits.


By Luca Pignacca

Concept To Reality Summer / Fall 2012 Subscribe to C2R Magazine

[AB]structures Relies on HyperWorks in Developing Three Record Breaking Round the World Racing Yachts
[AB]structures, an Italian structural design and engineering company, used the CAE suite HyperWorks first for the Volvo Ocean Race in 2006 to design the yacht for the ABN AMRO White team and has used it since then successfully for several other Volvo Ocean Race and America’s Cup yachts.


This year [AB]structures used HyperWorks to structurally design and optimize three VO70 Round The World Racing Yachts for the 2011 – 2012 edition of the Volvo Ocean Race. This included the yacht Groupama 4, skippered by Franck Cammas, which claimed victory on July 9, 2012 in Galway, Ireland, after 9 months and more than 37,000 nautical miles sailed around the world under the harshest conditions.

Nippon Sharyo Uses AcuSolve Simulation to Make Japan’s Bullet Trains Safer, More Comfortable


Alex Thomson Racing
Composite Optimization of a Racing Yacht Coach Roof



Alex Thomson Racing required a team of composite material design and manufacture specialists to bring their expertise to a number of areas of the IMOCA Open 60 yacht. A key component that required attention was the development and production of the yacht’s sliding coach roof. The coach roof is designed to offer Skipper, Alex Thomson protection from waves crashing over the deck while still allowing him to sail the boat to its full potential while remaining highly robust and lightweight.

U of M Solar Car- Composites Optimization for a Solar-Powered Race Car: Minimizing Body and Chassis Weight With Altair OptiStruct
The University of Michigan Solar Car Team, through the application of Altair’s OptiStruct optimization technology, was able to reduce the weight of its solar car by 90 kg from the 2009 Infinium car design to the 2012 Quantum car design. The Michigan team finished third in the 2011 World Solar Challenge, the first American team to finish. The team also has placed first in seven other American Solar Car Challenge competitions.

Altair Enables BorgWarner to Automate Process for Determining Combined Impact of Temperature and Mechanical Stress on Turbochargers
Inherently, turbochargers are adversely impacted by hot exhaust gases. This heat impacts the material strength of the turbocharger housings, resulting in degraded performance and the potential creeping or rubbing of turbine wheels. When extreme fluctuations occur, the turbocharger can suffer from premature thermal-fatigue resulting in cracking.

Topology Optimization Used to Make Lighter Plastic Parts
Kanto Auto Works, Ltd. is a core member of the Toyota Group, developing and producing Toyota vehicle bodies. The company’s organic-material engineering department evaluates and develops plastic parts to be used in vehicle bodies. In the initial stage of development for large plastic parts, such as instrument panels, rigidity and heat resistance are verified using computer aided engineering (CAE). While plastic is significantly lighter than metal and can be molded into complex shapes, deformation, such as warping from external force or thermal expansion in high temperatures, also occurs easily. In order to make parts lighter while still ensuring sufficient rigidity and heat resistance, there is a need to identify which areas require reinforcement.

Mabe - Improved Protection of White Goods through Packaging Optimization
For white goods manufacturer Mabe, the quality of the design and engineering of their home appliances is paramount. The products need to be highly robust as well as visually appealing but must also arrive with the customer in perfect condition. The appliances’ packaging must be equally well designed to protect from drops, impacts and other disruption events, but over-protecting the goods can result in significantly higher costs. The objectives of this project were to use the HyperWorks suite to simulate the effect of the distribution environment events to a washer and dryer product and perform optimization to improve product protection while reducing material costs and weight.

HyperWorks improves development processes at PSA Peugeot Citroën
Challenge: Define new process that includes accurate component data

Altair Solution: Use HyperForm and RADIOSS in development process

Benefits:
  • Reduce Development Time
  • Accelerate Innovation
  • Improve Quality and Robustness


AcuSolve Validation - NACA0012 Airfoil
This benchmark validates AcuSolve for external aerodynamic applications. NACA0012 has been studied in depth both numerically and experimentally. AcuSolve results are compared with other CFD software results and with available test data


AcuSolve & Radioss Solution on FSI Model
This benchmark demonstrates the ability of AcuSolve to capture the effect of impulse load on a profile submerged in channel flow. A P-FSI simulations is performed using the structural output from Radioss.


Gordon Murray Design
Overcoming the Challenges of Composite Design



Automotive manufacturers are utilizing lightweight materials as a method of minimizing mass and maximizing fuel economy. Automotive design company, Gordon Murray Design (GMD) believes that composite materials can play a much larger role in the manufacture of vehicles. To prove its case, the company has developed ‘iStream’, an efficient process for manufacturing low and high volume cars from lightweight material. To validate the iStream structure, GMD required an experienced simulation partner.

Formidable Challenges in Formula Student Racing
Industry: University

Challenge: Remove weight and improve performance from vehicles

Altair Solution: Optimization with HyperWorks tools


Benefits:
  • Reduce weight of vehicle while
    keeping or increasing the component
    stiffness
  • Speed up time of development process
  • Save material and real-world testing
  • Reach top rankings during competitions


Automotive Weight Management Article
The automotive development process is still focused on objectives such as durability and crash safety, while weight is often limited to the very end of the design process. Through the establishment of the “Optimization Center” (OC) concept, Altair ProductDesign has developed an innovative design model combining performance features with weight reduction goals. This article describes the OC concept dealing with everything from the optimization of single components to an entire optimization process known as “CAE Weight Management”.

World-Leading Crane Manufacturer TADANO FAUN Accelerates Its Design Processes with HyperWorks
Industry: Heavy Industry

Challenge: Generate accurate finite element method (FEM) calculations.

Altair Solution: FEM structural analysis utilizing the suite of HyperWorks tools

Benefits

•Faster time to results

•Flexible unit-based licensing model

•Cost reduction

Gordon Murray Design Discuss the Future of Automotive Manufacturing & iStream
Dr Ralph Clague, Powertrain Systems Manager at Gordon Murray Design (GMD) speaks to Altair ProductDesign about the current challenges in the automotive industry and how their iStream process can deliver lighter, low cost electric vehicles. Altair ProductDesign has worked with GMD to analyse and test the safety performance of its iStream, composite material based vehicles.

Altair BUSolutions
Developing the World’s First Series Hydraulic Hybrid Bus



The Federal Transit Administration (FTA) requires modern transit bus systems to provide more efficient services across America. Currently, U.S. public bus transit authorities are subsidized to meet operating budgets with State and local subsidies exceeding $19 billion per year and Federal subsidies exceed $7 billion per year. The goal of the BUSolutions project is to design and manufacturer a new bus with improved fuel economy, lower emissions and a lower life cycle cost than today’s buses.

Global Appliance Manufacturer Mabe Analyzes Spin Cycle with HyperWorks to Improve Washing Machines and Bring Them to Market Faster
Typically when engineers consider the most complex problems involving multi-body dynamics, hydrodynamics, and noise-vibration-harshness, they are focusing on the complexities of automobiles or aircraft. Design issues that can be just as challenging, however, impact every household’s laundry room. For companies like consumer goods manufacturer Mabe, simulation has helped them better solve product issues such as balance ring distortion, move products to market faster and reduce cost.

Airbus
A380 Weight Reduction through Optimization



Through collaborative partnerships with Altair in the UK, the software was developed to produce an innovative rib design, which resulted in an optimized weight saving over 500kg per aircraft. Exceptional team working has been an essential component in ensuring the total integration of design, manufacturing and supply chain capabilities.

Tallent Automotive
Customized Solutions to Reduce Chassis Mass by 25%



To meet the growing demands for lightweight, fuel efficient vehicles, Tallent Automotive required a more automated method to produce minimum mass sheet metal chassis components which took performance targets and manufacturing constraints into account.

OPEL
Improving Design Productivity through Automation



OPEL identified the design process of engine mount systems as a candidate for a process automation solution. As an objective, NVH engineers had to be able to generate input decks even without detailed load case information. Knowledge had to be captured and re-used in a standardized workflow. Automatic optimization and robustness analysis of the mount parameters had to be integrated into the process to quickly improve final product quality.

Medtronic
Reducing Medical Stent Stress by 71%



Medtronic designs and manufacturers medical devices used the world over. Traditionally, computer aided engineering (CAE) and virtual simulation were not fully utilized within the industry as the verification process for often microscopic components was too slow. When designing a new medical stent (an expandable mesh inserted into a patient's artery to keep it open) Medtronic wanted to improve the design and speed up the validation process. Altair ProductDesign worked closely with Medtronic’s own engineers to optimize the performance of the new stent.

Unilever Optimizes Packaging Designs & Reduces Prototype Costs
To remain at the forefront of innovation within the male grooming market, Unilever, constantly looks for ways to differentiate their products from competitor offerings. For the Lynx (Axe) brand, Unilever needed to adopt a simulation and analysis approach when designing a new deodorant packaging concept and required a development partner to assist with the design and testing of the new can.

NASA
A Safer Landing with Water Impact Analysis



Using Altair’s own HyperWorks virtual simulation suite, Altair ProductDesign built an accurate finite element model of the module from CAD data supplied by NASA, as well as a section of water and air which matched the conditions from the lake used during the physical tests. The effect on the module’s structure during impact was simulated to gauge how well the results correlated with the physical tests. The results showed excellent correlation between the simulation and physical tests, identifying areas where the model, input parameters and meshing methods could be improved to give a more accurate prediction of the event.

Heart Valve Analysis
Predicting Aortic Stenosis through Simulation

Aortic valve Stenosis is a heart value disorder that narrows the aortic valve opening due to calcium build up in the leaflets. This prevents the valve from opening properly and obstructs the flow of blood causing the heart to work harder. Finite Element Analysis (FEA) has the potential to allow researchers to study the condition without the need for traditional physical testing. An efficient process was required to make this possible since modeling tissue behavior, back pressure, and the interaction between tissue and blood are highly complex challenges. Altair ProductDesign led this self funded project to improve the simulation and analysis of heart condition research.

Unilever Customizes Solutions to Reduce Packaging Waste
With increasing pressures on all manufacturers to reduce the environmental impact of their products, consumer goods giant, Unilever, needed a way to minimize the material used in its packaging while ensuring that it remained strong enough to withstand transportation loads and a variety of use conditions.

Using HyperWorks to Generate Electrically Large Surface Meshes for Radar Cross Section or Antenna Placement Simulation
Radar Cross Section (RCS) and installed antenna placement are important parameters for aircraft designs. RCS is a measure of how detectable an object, such as an aircraft, is with radar. A large RCS indicates that an object, such as a jet aircraft, is easily detected.


SELEX Galileo used HyperWorks to generate arbitrarily large surface meshes, with defined electrical properties at the element level, for use with electromagnetic (EM) solvers to calculate either RCS of an aircraft or to determine where to place an antenna for optimum performance.


For this case study a fast-jet aircraft with approximately 100 million mesh elements was assessed for radar tracking and avoidance capabilities.

Simulation Streamlines Aircraft Door Development
The Eurocopter Group leverages analysis to cut design time and automate the process of developing safe aircraft closures.



By Michele Macchioni

Concept To Reality Summer/Fall 2011

Bird Strike Simulation Takes Flight
The increasing number of bird-plane impacts gives rise to new CAE methods to address aircraft safety.



By Robert Yancey

Concept To Reality Summer/Fall 2011

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