ATCx- Hyperviscoelastic Coefficient Determination of a Spherical Impacter using HyperStudy Optimization William Giannetti, Sr. Research and Development Engineer, Swift Engineering

1. FEA Explicit Dynamic for Drop Impact Simulation Using Altair Radioss　 2. Multi parameter Sensitivity Analysis & Deterministic Design Optimization on A/C Outdoor Unit. 3. Uncertainty Quantification & Reliability Based Design Optimization 2D CFD Case Study

AAM has been providing mechanical drivelines to automotive customers for more than 25 years. As the automobile transitions to electrification, so too must the driveline. AAM has developed a suite of innovative, lightweight, compact and cost-optimized electric drive units and electric beam axles to meet the growing global technology demand as electric vehicles continue to expand over the next decade. Engineering simulation, optimization and validation tools were significant enablers to increase the validation confidence and reduce the time to market for these new products.

Gaining insights into a product’s performances has never been easier. With the HyperWorks Design Explorer, users can easily set up and execute the design of experiments (DOE) and optimization studies, learning which attributes contribute the most to the different performances, review, plot, and compare results from multiple runs, and ultimately identify optimal designs. The quick and easy setup process is solver independent, yet fully integrated with Altair’s structural analysis solutions. On the other hand, many design specifications are quantifiable and can be confirmed by physics but optimizing a design for subjective design requirements such as the look and feel of a product requires a different approach. This is when expertAI can help. It uses machine learning to enable you to include criteria that have traditionally been considered purely subjective or expert-driven in design optimization. The AI algorithms cluster your designs with respect to their subjective behaviors allowing them to be labeled to train a model aligned with your preferences.

Altair products are quickly evolving into AI-driven products. Starting from the modeling and visualization products, the latest release of Altair HyperWorks includes features like shapeAI, which quickly finds and classifies parts “by shape” inside geometry files or finite element meshes - when you want to locate all of the bolts, shafts, and gears in a complex assembly - by applying machine learning.

What makes artificial intelligence a game changer is not what movies depict with the loud destructive powers of artificially intelligent robots. It’s the opposite, it is the silent creative destruction that it brings as apps in our phones or features in the tools that we use such as spam filters, fraud detectors, and recommendation engines. When combined, these tools make our lives more enjoyable, safe, and productive. In a similar spirit, at Altair, we have been working on powering product design and development with AI to make your work lives more enjoyable, and productive. Our focus has been improving processes and outcomes by reducing repetitive, labor-intensive, non-value-added tasks as well as emulating experts and enriching performance predictions with real-time field predictions. What makes these offerings unique is their no-code integration to the tools that you are already familiar with and hence not requiring you to have to leave your own working environment. In this presentation, examples of such AI-Powered product design processes will be demonstrated. The presentation by Dr. Fatma Kocer, VP of Engineering Data Science at Altair, aired at Future.AI in June 2021, and is almost 30 minutes long. Ready to see how your company can drive innovation with AI-powered design? Contact our solutions experts today. View all Future.AI 2021 Presentations

Dr. Fatma Kocer VP, Engineering Data Science at Altair showcases the impact of AI in development environments. In particular on how CAE tools will evolve and Design Exploration is taken to the next level.

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.

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.

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.

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.

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.

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.

Matt Kedgley from Engenuity introduces us to FiRMA, an analysis method that tackles the difficult task of predicting the structural performance of randomly oriented fibre composite components. This method has been developed and made possible using a customisation of Hypermesh. The Finite Element (FE) models are pre-processed into the FiRMA format before being submitted for analysis solve through HyperStudy.

Steven Ford, Principal Engineer at Edwards Lifesciences does a high-level walk through on how simulation has evolved in the cardiovascular device space over the last two decades. An example of how Altair HyperStudy has been an exceptional tool for deeper learning with respect to device performance will also be highlighted as a step along this journey. The recording is about 15 minutes long and was originally presented at the Altair Technology Conference 2020.

Full evaluation of a design concept requires the definition of many complex details. However, complex geometric details constrain design flexibility.

Simulation-driven design powered by topology optimization was created by OptiStruct over two decades ago. Its success has changed the CAE/CAD industry as today all vendors have embraced this trend.

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

The Altair Multiphysics platform provides a broad portfolio of solvers and tools to help engineers develop e-motor design requirements by using simulation and optimization methods. This presentation provides examples, using Altair Machine Learning and optimization solutions, of the e-motor requirements by leveraging in data available, which is key for e-motor designers to reduce time-to-market.

In optimization it is sometimes desirable, but not possible to define constraints that fully reflects an expert’s requirements. This may lead to a design that does not function as intended. Machine Learning enables the user to set up subjective constraints, ensuring a design that has been trained to replicate the expert’s opinion. In this presentation machine learning is used to ensure axial crush for an automotive front crash event.

Presentation by Koby Ingram, Gevasol BV. Conceptual Design and optimization of an Electric Motor using Altair Flux and HyperStudy. The customized electric machine with high level demands and efficiency is a challenging topic requiring top level of expertise and best in class simulation tools. This work focuses on the usage of Flux and Hyperstudy as tools for bettering the design and design process of e-motors. Presentation at the ATCx in Israel, Netanya on October 30, 2019.

Presentation by Konstantin Arhiptsov & by Eitan Maler, Simulation Dept. IWI Israel Weapon Industries (IWI) at the ATCx in Israel, Netanya on October 30, 2019. These days, in IWI, complete multi physics simulation is an integrated tool in the development of any new product. The motivation is to completely simulate one or two firing cycles as close to reality. First step is the Multi Body Dynamics simulation to check all mechanism are synchronized and work properly. Second is the explicit simulations - calibrating the mechanical properties of the pistol, in that the springs, contacts, materials and gun powder properties based on one firing cycle. The following is to calibrate the Non Rigid Boundary conditions (NRBC’s). This calibration of boundary conditions which are not completely fixed is crucial to understanding the actual strains and stresses on the parts. One of the approaches was to use known data of the stiffness of arm and wrist, implementing this data into a HyperStudy model to compare and calibrate the results based on a slow motion capturing of a real firing. The results are promising, with high accuracy of the behavior compared to a real capturing of the shooting, up to the point of slider getting to the end of its move – where most of the kinetic energy transform into loads on the frame. The following steps will be to calibrate, using the same method, the return of the slider to it’s original position and perform more than one firing cycle.

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

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

This presentation was given at the 2019 ATCx Multibody & System Simulation conference at the Altair Headquarters in Troy, MI.

Presentation by Markus Schemat, BMW Group

Gestamp Chassis design and manufacture 25% of European passenger car chassis components and have been using optimisation to drive their design process for over 10 years. This presentation will highlight some of the innovative and market leading optimisation based approaches used by Gestamp to deliver class leading lightweight chassis frames for their customers.

The automotive industry, in its constant quest for weight reduction, is increasingly considering composite materials as a substitute for sheet metal components to meet future fuel consumption standards. However, composite forming processes are expensive and difficult to control because of the complexity of the material behavior with fiber and matrix layers or plies and its dependency on many parameters, such as non-linearity of tensile stiffness, effect of shear rate, temperature and friction. Hence, numerical simulation could be a viable approach to predict material behavior during composite forming. The objective of this study is to highlight capabilities of RADIOSS™ to simulate forming simulation of composite plies made from woven fibers, each ply modeled as a layer of woven fibers along two directions of anisotropy, warp and weft. For validation the well-known double dome model published in NUMISHEET’05 proceedings is used. The compared result is the shear angle after stamping that is, the final angle between warp and weft fibers, at several prescribed points on the ply. The variation of this angle has a strong impact on material characteristics which severely deteriorates when a critical value is reached. Hence, a study on crash simulations is performed, after mapping fibers angles from stamping simulation.

This Workshop Presentation on Multi-Body Dynamics was conducted by Keshav Sundaresh at the Americas ATC on May 5, 2015.

In this workshop, learn how MotionSolve is used to design and evaluate new suspension systems, optimize the ride and handling characteristics of vehicles, assess system durability, simulate for low frequency vibration avoidance, design and optimize steering systems, and validate Mechatronics components

Top researcher Tzuo-Liang Luo from the Industrial Technology Research Institute, Taiwan presents how the industry moves Towards self-learning CNC Tooling Machines and how integrated mechatronics simulation teaches automatic path error adjustment and allows predictive maintenance.