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

Together with cloud providers and our other HPC partners, Intel is driving the performance and flexibility that are critical to running advanced HPC workloads in the cloud. We collaborate across our HPC ecosystem to help cloud providers offer accelerated, secure, and agile environments using our latest technologies, such as Intel® Xeon® processors. As cloud customers continue exploring new possibilities and applications for HPC, Intel is dedicated to facilitating their success. Intel works with HPC partners from various industries to enable forward-thinking cloud use cases such as bursting, AI, and advanced analytics. Learn how Intel collaborates with Public and Private Cloud Service Providers to optimize HPC workloads for fast, cost-effective execution on Intel-based Cloud Instances.

This presentation discusses the rise of intelligent design technologies used throughout industry to rapidly assess and optimize product performance before physical prototypes. The session includes a brief hands-on demonstration of some of the latest, easy-to-use simulation technologies that are empowering designers and design engineers around the world to capitalize on the digital design revolution. Speakers: Dr. Royston Jones, CTO, Altair Ken Welch, Senior VP Inspire Design and Manufacturing Products, Altair Duration: 20 minutes

Dactem (a DAM group company), developer of specialist test, measurement and assembly solutions for the aerospace industries, presents an overview of the optimization of a thrust balance used for accurate measurements in electrical thruster qualification endurance testing. The presentation will provide details on how a Multiphysics simulation approach was used to find the optimum design taking mechanical, thermal and electromagnetic performance into account. Speakers: Emmanuel Pouleau, CEO, Dactem (a DAM Group company) Pierre Moutet, Engineer, Dactem (a DAM Group company) Duration: 15 minutes

This workshop demonstrates how a simulation-driven design approach to product development can have a drastic impact on the performance, design time, and profitability of a new product. Using a belt sander tool as a demonstration model, our presenters show how Altair’s design and simulation technologies can conduct a concept design analysis and optimization of the sander external housing to improve stiffness and reduce weight. They go on to show how we can simulate the manufacturing process itself by looking at filling, packing, cooling and warpage of the plastic housing; before concluding with a series of stress analysis and validation studies such as a virtual drop test, 3-point bending simulation and even a study of the effect of the heat transfer of the electric motor. This is a valuable session to see how simulation technologies can be used throughout the design process, adding value and reducing development time at each stage. Speakers: Ujwal Patnaik, Global Business Development Manager, Altair Chris Sambell, Application Engineer, Altair Duration: 60 minutes

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.

Inspire’s new parametric modeling allows you to capture the evolution of your model’s shape by showing the linear sequence in which the geometry was created. You can roll the model backward or forward, as well as group, delete, insert, suppress, or edit entities in the History Browser. Inspire also features a new and improved sketching interface and several new sketching tools. See how you can use these new tools to seamlessly add, remove, and parameterize features in your model and then use the Variables table to quickly make design updates and see how they affect performance is in seconds to minutes.

Product engineers are under constant pressure to reduce costs, improve quality and increase the throughput of manufacturing processes. Applying a simulation-driven design for manufacturing (SDfM) approach to product development can help understanding the product manufacturability early in the design cycle, while considering various design alternatives and choosing the best performing, manufacturable design up front. After a brief introduction of the metal forming process, the presentation will explore a typical use case of a sheet metal part - subject to static and dynamic loading – showing how simulation can be very effective in reducing cost for parts redesign and dies modifications, while providing engineers with valuable insights on the manufacturing process and product performance.

The goal for any design, structural and manufacturing simulation is to predict and fix defects early in the product development. This panel will discuss how design and simulation tools are helping engineers to be efficient. Experts will share their thoughts on current and future trends in manufacturing, focusing on how designs evolve using manufacturing simulations.  

At Altair, we see a future where seemingly disparate systems work seamlessly together to help businesses succeed. Where pin-point accuracy and speed mean the difference between winning and losing. The world of data science is intersecting with high-performance cloud computing, artificial intelligence, and IoT, unlocking limitless potential and enabling enterprises of all sizes to compete on a global scale while creating a more sustainable future.

Formula Student is an international motorsport engineering competition where teams from around the world design, build and then compete a formula style racing car. In this presentation, Team Bath Racing discusses how they make use of Altair Inspire for topology optimization and how it enables rapid design iterations.

Presented at the 2nd Altair Academic Outreach Event in June 2021

Speaker: Conor Smith, Outboard Suspension Designer, Team Bath Racing
Duration: 18 minutes

In order to ensure the safety of passengers and on-board personnel, finite element calculation is used at SNCF as part of the acquisition, renovation / modernization projects of trains as a decision aid and preparation for testing approval of trains. This is the main case of the mechanical strength of bolted and screwed assemblies, and more and more of the integration of composite materials into rolling stock structures in order to make them more capacious and less energy intensive. To do this, SNCF is developing methodologies to make the modeling of bolted assemblies and composite parts more reliable, as well as topology optimization. The tools of the HyperWorks suite, and in particular, the OptiStruct solver, allow SNCF to represent its types of materials, as well as these phenomena (bolted assemblies + topology optimization).

Presented at the ATCx Heavy Equipment in May 2021.

Speakers: Patrick Jumin, Derik Joël Kengne Tapchom & Karim Slimani, SNCF

Duration: 20 minutes

TransAnt GmbH is an Austrian joint venture by ÖBB Rail Cargo Group and voestalpine Stahl GmbH with the aim to bring more efficient and effective transport alternatives on to the market and thus making rail freight transport more attractive and sustainable.

In this presentation the company talks about the development of their freight wagon “TransANT” - a revolutionary platform concept that reacts to the changing needs of their customers. Its 20% lighter underframe creates a payload advantage of up to 4 tonnes per wagon. Industry-specific wagon bodies and straightforward swapping make for ideal logistics solutions - adaptable to every type of logistical requirements. Using Altair software, the company is currently making TransANT assemblies ready for serial production.

Presented at the ATCx Heavy Equipment in May 2021.

Speakers: Anja Schmid, Key Account Manager & Andreas Tomschi, Development Engineer, TransAnt

Duration: 20 minutes

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.

Brett Chouinard, President and COO of Altair discusses Development challenges in Industrial machinery and illustrates how Altair's scalable simulation solutions provide the environment for simulation-driven innovation and how machine learning expands the capabilities furter.

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.

Daniel Jauss, Application Engineer CAE, gives a Demo Sessions on Altair Simulation Solutions for faster evaluation of real-world machines, explaining how to improve system understanding with dynamic motion analysis to Identify real behavior of the machine assembly and Identify peak loads.

Felix Koerfer, Technical Consultant at Altair, gives a Demo Sessions on Altair Simulation Solutions for faster evaluation of real-world machines, explaining how accurate structural assessment with real loading conditions allows assessment of global stress and deformations, evaluation of bolt forces, and how accuracy & deformation of linear bearings cna be achieved.

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.

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.

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.

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.

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.

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.

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.

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.

In his presentation, Sebastian Wachter of Porsche takes us through an exciting project where topology optimisation technologies were combined with 3D printing to create a highly innovative engine-gearbox housing that is 10% lighter than the existing component and twice as stiff.

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.

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.

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

Altair CTO James Dagg presents an overview of the journey Altair took to develop the leading modeling and visualization technologies we have today, and provides a look at what’s coming next to help you reduce your product delivery time. James Dagg has been at Altair for more than 30 years and is a visionary behind Altair’s software strategy and development activities. He has also led the development of Altair’s concept design technologies and oversaw the development of Altair’s CAE software suite for more than a decade.

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.

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.

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.

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.

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.

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.

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.

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.

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.