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HyperWorks Improves Development Processes at Automotive Consultancy
csi entwicklungstechnik GmbH, a leading engineering service provider for the automotive industry has enhanced its simulation power with Altair‘s HyperWorks Suite. The company consolidated its CAE tools and now uses the large scale of HyperWorks, which offers a solution for almost every application needed in modern product development. csi will apply OptiStruct for optimization tasks, MotionView and MotionSolve for multi-body applications, and HyperMesh for pre-processing tasks. Additionally HyperShape/CATIA will be used for CAD integrated optimization and weight reduction.

Improving Efficiency and Accuracy at Eaton Aerospace with HyperWorks
The Hydraulic Systems Division of
Eaton’s Aerospace Group designs hydraulic
components and systems on many of the
world’s military and commercial aircraft
in the skies today. Eaton uses Altair HyperWorks within it's simulation processes to improve solution efficiency and accuracy.

WJH Engineering Uses Altair HyperMesh™ to Cut Physical Testing Costs of Medical Devices by 95%
WJH Engineering Consultants provides finite-element analysis and design for many of America’s largest developers of medical devices. Company President, Jim Harrison, works directly with engineers at companies producing medical devices and with doctors to understand the clinical application of these products, including any anatomical loads or displacements that should be incorporated into their design.

HyperWorks Accelerates Design Process and Development of Diesel Export Locomotive at RDSO
Altair HyperWorks helped RDSO reduce development time and optimize structural characteristics of the diesel export locomotive. Physical testing on these large, complex structures had to be limited. Using HyperMesh/HyperView pre/post processing capabilities, RDSO were able to simulate design and verify that engineering specifications are being met and help validate the final design.

Airline Seat Testing Soars to New Heights
French manufacturer Sicma Aero Seat SA
relies on virtual dynamic testing in the
evaluation of its custom aircraft seats.

Simulation and Analysis Investments Help Drive PLM Market Growth
The need to improve designs and reduce the cost of prototyping is fueling increased investments in simulation and analysis tools.

HyperWorks helps to improve development processes at F.S. Fehrer Automotive GmbH
F.S. Fehrer Automotive GmbH in Kitzingen is using the HyperWorks Suite to develop seat parts, form cushions and complete vehicle interior systems. The engineers use HyperWorks and especially RADIOSS for static and modal analysis. The seat of a vehicle is the direct and closest connection of the passenger with the automobile. Design and seating comfort play an important role in personalizing the vehicle model and convey the feeling of quality to the passenger. In addition, safety and variability are vital aspects for the development of interior parts of a vehicle.

HyperWorks Helps to Develop Race-Winning Yacht for Volvo Ocean Race 2009
The CAE suite HyperWorks has been used by ABstructures to structurally design and optimize the winning yacht in the Volvo Ocean Race, Ericsson 4. The yacht, skippered by Torben Grael, claimed victory in the Volvo Ocean Race on June 27, 2009 in St. Petersburg, Russia, after 8 months and more than 37,000 nautical miles sailed around the world
under the harshest conditions.

A Comprehensive Process for Composite Design Optimisation
Composite structures offer unmatched design potential as laminate material properties can be tailored almost continuously throughout the structure. Moreover, composite laminate can be manufactured to fit the ideal shape of a structure for aerodynamic and other performances. However, this increased design freedom also brings new challenges for the design process and software. It is shown in this paper that optimization technology is well suited to exploit the potentials that composite materials offer.

Innovative Design Analysis Solutions to Handle the Complexity of Modern Structures
This is a press article published by CAD User Magazine in June 2009.

"The signature buildings that architects love to put up these days might be designed to enhance the architect’s reputation along with the skyline of the client city, but their increasing complexities of shape pose significant challenges for the builders. In the first instance such large projects are never single sourced. They rely on close integration between a number of partners, each addressing significant issues. Secondly,
they come with demands for shorter development times with increased pressure to reduce engineering costs (engineering, because of the complexity of the projects, being a major cost element)."

Rapid Airbag Folding Technique for Side Curtain Airbag
TECOSIM has developed techniques which can shorten the folding & packaging process time to a few hours and still achieve the essential airbag deployment performance. We will present methods which rapidly fold a free mesh and allow for rapid shape changes for a detailed folded model. These methods can significantly reduce the turnaround time to incorporate design changes into the working CAE model for side impact and OOP [Out Of Position] studies. This technology can integrate airbag development further into the virtual world to allow ‘CAE led’ design of airbag profiles, chambers and seam lines to be established early in the design phase and establish a fully folded deployable airbag for all virtual phases.

The Use of MBD Modelling Techniques in the Design and Development of a Suspension System
This paper describes the use of Multi-body Dynamics (MBD) modelling techniques in the design and development of a suspension system for a novel autonomous vehicle. The general approach and philosophy is described, whereby MBD techniques are used in conjunction with an independent (parametric) whole vehicle handling simulation. This is supplemented with examples, showing how MotionSolve was used (in tandem with CarSim) to develop the suspension elasto-kinematic geometric properties to meet specific cascaded targets, to optimise a weighing strategy, to predict forces under a variety of quasi-static and dynamic loads, and to estimate response to track inputs.

Hawk T Mk2 - Arrestor Barrier (BAN MK2) Engagement Analysis
As the UK Ministry of Defence (MoD) Design Authority for Aircraft Arrestor Barrier Nets, AmSafe products are used to stop aircraft from over-running the end of the runway. The British Arrestor Net (BAN) Mk2 is suspended across the runway over-run area by two electrically driven stanchions and raised or lowered by remote control from the Air Traffic Control tower.

This paper describes the process and results of a FE analysis of the engagement of the Hawk T Mk2 aircraft into a Type A Barrier (BAN Mk2). The analysis was performed using RADIOSS, an advanced non-linear explicit Finite Element solver.

HUMOS - An FE Model for Advanced Safety and Comfort Assessments
Biomechanics modelling is becoming increasingly accepted as a tool for enhance assessment of vehicle safety, in particular in the field of injury assessment and virtual testing. Firstly, a generic RADIOSS model for safety applications (HUMOS2) is presented and applications are demonstrated. Important tools associated with the scaling, and positioning of the model is also described. Secondly, an innovative model for scaling of human organs (individualization) is presented. The method which employs optimization techniques, identifies critical (optimal) anatomical control points which allow for a best scaled model of the HUMOS2 representing an individual. Finally, some remaining challenges for future human models are discussed and solution paths are described.

Automotive Modal Testing Support and CAE Correlation Using Altair HyperWorks
To derive the natural frequencies and mode shapes of a given structure, the test Engineer has to decide on excitation positions that will efficiently excite all the modes of the structure in the frequency range of interest. Excitation positions are usually decided upon from experience or trial and error methods which can be time consuming and still not capture all of the modes in the selected frequency range. Using Altair HyperStudy and Radioss (bulk), Pre-test CAE analysis has been carried out to identify effective excitation positions before the commencement of modal testing, thereby significantly reducing pre-test lab time.

The Application of Process Automation and Optimisation in the Rapid Development of New Passenger Vehicles at SAIC Motor
As a relatively young automotive company, SAIC Motor has drawn on the expertise of its UK Technical Centre to help in its objective to bring a new range of vehicles to market in an aggressive time frame. CAE has formed an integral part in doing this and the UK technical centre has worked closely with Altair Product Design amongst others to utilise its Engineers’ skills as well as the Hyperworks suite of software.

The paper aims to showcase what has been achieved to date, on the Roewe 550 medium car programme - currently on sale in China - and on another current vehicle programme, where processes have been developed further. Several interesting optimisation examples are highlighted in the development of the body structure as well as some key process improvement methodologies which have been jointly developed between SAIC and Altair to streamline the design process.

Delivering Innovation and Intelligence in Product Design
Packaging designers must constantly inject innovations to attract consumers in a constantly evolving and highly competitive market. Keeping ahead of the competition by bringing new and exciting products to market faster whilst maintaining quality, presents a major engineering challenge. A new packaging development process is described, which introduces advanced automated simulation and optimization technology right from the concept development phase. Detailed predictions of primary, secondary and tertiary packaging performance are made possible through use of advanced simulation technology. Design optimization is then employed using the modelling as a virtual testing ground for design variants. The approach provides clear design direction, an opportunity for wider experimentation, helps to improve performance and reduces uncertainty in the development process.

Evolutionary Design in Chassis Technology
This paper details the use of the Thyssenkrupp eDICT process for the design of sheet metal chassis components. eDICT (evolutionary design in chassis technology) is an innovative structured process flow for the design of optimal structures. eDICT uses the optimisation capability of Optistruct with a set of custom tools to guide and translate a design into a production feasible sheet metal solution. Fundamentally it reverses the usual design loop of CAD first then CAE assessment. The function is used to determine the design and the form follows. On recent projects eDICT has produced 25% mass reductions compared to the current series design. eDICT is also able to reduce development times and resource with an efficient solution production right from the outset.

Fast Tracking Rail Vehicle Design
Bombardier Transportation UK offers one of the most comprehensive and diverse rail vehicle portfolios in the world. The strategy is one of continuous development that provides the most effective and cost-efficient rail solutions for today and the future. A key ingredient is the use of Altair HyperWorks enterprise computer aided engineering (CAE) solution. Altair's technology is now present at every stage of the design process and has increased the efficiency of the product development process. The paper details how Altair tools have been used to generate Finite Element (FE) models of carbodies, bogies and secondary structures in reduced time scales. Significant weight and cost savings are achieved through structural optimisation of components such as large steel castings, aluminium extrusions and steel fabricated structures which are subjected to linear static, fatigue and abuse loading. Automated post processing facilitates the interpretation of results and the writing of detailed official reports.

Targeting Composite Wing Performance – Optimising the Composite Lay-Up Design
This paper shows how Altair OptiStruct, part of the HyperWorks suite, is used to provide a complete solution when designing with laminated composites, taking the design through concept stages to producing the final ply lay-up sequence. The technology is applied to the design of a laminated wing cover to produce a mass optimised design which meets the requested structural targets.

Composite Optimisation of a Formula One Front Wing
This paper will show the application of a 3-stage approach to designing the optimum composite structure for a front wing on a Formula One car using Altair OptiStruct 9.0 Continual development of aerodynamic components is normal practice in the world of Formula One and the time taken to respond is paramount if a team is to be competitive.

Application of Optimisation Tools to the Design of Advanced Carbon Fibre Bicycle: FACTOR 001
FACTOR 001 is the result of a creative project by BERU f1systems to explore the transfer of design approaches, technology and materials from Formula One to a groundbreaking training bicycle. The design brief did not require the bicycle to comply with existing technical regulations, which resulted in great freedom during the design process. This paper details how OptiStruct Optimisation tools were used to help generate efficient lightweight solutions for the design of complex carbon fibre components. Free-size optimisation was used to generate laminate boundaries, ply thicknesses and fibre directions, which met stress and displacement requirements. Physical testing carried out on manufactured parts highlighted the accuracy of the FE models and demonstrated the advantages of incorporating OptiStruct Optimisation tools in the design process.

The CAE Driven Safety Development Process of the New Ford Fiesta
The new Fiesta is about premium feel of a larger car, delivers a new level of safety, driving quality and efficiency. The new Fiesta will be a great contribution towards sustainability and cost effective motoring. The first thing to notice is the design, but the vehicle performance and body structure attribute behaviour are the specific highlights to point out in this presentation. The attribute performance is not based on coincidences; the performance is a result of state of the art engineering work. Especially the safety performance in EuroNCAP.

Fighting Knee Pain with Finite Element Modeling
The Musculoskeletal Biomechanics Research Laboratory at USC, is using HyperWorks to investigate why so many people are incapacitated by knee pain when others are not. This is a tough, intractable issue for people with arthritic knees since there is no cure for arthritis today. Early detection can help and is the focus of USC’s work. (HyperMesh is used to create finite element models to analyze stress on the cartilage of the joint.)

Altair® HyperWorks® and Product Design Consultation at Force Protection
At Force Protection Inc. Altair HyperWorks and Product Design work together to increase CAE throughput and improve survivability prediction in a new class of military vehicles built for unconventional warfare.

Injecting Innovation in Performance Engine Design with Altair HyperWorks
MAHLE Powertrain outsourced model generation of large complex parts such as heads and
blocks to low cost countries to ensure sufficient mesh quality could be produced for their
automotive engine designs. The third party’s improved capabilities proved valuable but
ultimately MAHLE Powertrain wished to bring the process back in-house to maintain control
and reduce external expenditure. To achieve this a new pre and post-processing solution was
needed. HyperWorks was selected as the new platform as it afforded the required increase in
productivity through its automatic mesh creation and batch processes.

Application of HyperWorks in the Subsea Oil and Gas Industry
The volatile nature of deep sea installations presents a difficult challenge for engineers
to create products which can withstand extremely high pressures in a variety of weather
conditions. Duco selected HyperWorks to model subsea umbilicals, resulting in improvements
to their analysis productivity allowing models to be constructed faster than before.

Simultaneous Robust and Design Optimization of a Knee Bolster at Jaguar & Land Rover
Jaguar Cars needed a practical process to simultaneously optimize the robustness of a design
and its performance. Altair HyperStudy is applied to the design of an automotive knee bolster
system whereby the design is optimized to account for different sized occupants, impact
locations, material variation and manufacturing variation.

HyperWorks at B/E Aerospace: Lighter, Safer Seats for Airline Passengers
When you settle in for a flight on a major airline, you are probably in a seat and surrounded
by equipment designed and built by B/E Aerospace. With design and manufacturing facilities
across the globe, B/E Aerospace is the leading manufacturer of cabin interior products
for commercial and private passenger aircraft. One of B/E Aerospace’s leading products
is its line of commercial and business airline seats. These seats are engineered and tested
at its Commercial Airplane Products Group in Winston-Salem, North Carolina.

Multi-Disciplinary Design of an Aircraft Landing Gear with Altair HyperWorks
NAFEMS invited several software vendors to a roundtable in 2007 to demonstrate their best processes in the design of a
realistic aircraft landing gear system. (Figure 1). The emphasis was on simulation processes that can make problem solving innovative, accurate and efficient. This paper explains the
processes followed by engineers at Altair and should help increase awareness regarding the powerful tools available for solving realistic design problems.

PBS Professional at Chrysler: Managing 250,000 Simulations a Year
The people who design cars and trucks at Chrysler have been using computer simulation tools since the 1980s. Since those early beginnings, the use of computer-aided engineering and finite element analysis has expanded to become the powerhouse enabler for Chrysler designers that it is today.

Sheet Metal Transfer Dynamic Analysis Using Altair HyperWorks at Ford Motor Company
By applying Altair HyperWorks simulation technology, Ford Motor Company has been capable to simulate the dynamic behavior of their new generation of crossbar transfer presses.
Altair solutions have been adopted to optimize the automation tooling design and the
transfer motion operational parameters.

Managing 30 Teraflops of Compute Power: PBS Professional at Italy’s CILEA Consortium
With 30 teraflops of peak computing power, it has ranked as high as 135th among the Top 500 high performance computing centers. PBS Professional keeps CILEA’s processors humming.

OptiStruct Technology Application in Early Concept Design Stage Enables Weight Reduction of Cast and Forged Parts
Using Altair OptiStruct, India based Ashok Leyland was able to reduce cost and improve reliability of the components in their stride towards design an development of innovative, optimal and robust design solutions. Leveraging OptiStruct's technology was able to take quick and reliable design directions on the track rod lever.

OptiStruct Cuts Development Time to Design a Light Weight and More Durable Window Regulator Lift Plate at ArvinMeritor
Using Altair OptiStruct, ArvinMeritor was able to design a lighter weight window regulator lift plate which eased assembly. The new snap-fit design reduced the material compared to original design, without sacrificing performance and durability.

HyperForm Sheet Metal Forming Solution Provides Yield Improvement of Wheel Housing and Wheel Arch
Using Altair HyperForm, Mark Auto was able to significantly improve the material utilization for their existing production dies. Mark Auto re-designed two existing dies for wheel arch an wheel housing and was able to dramatically reduce material scrap with minimum rework in their tools while not compromising on component quality.

Biomedical Research at the Scripps Clinic: Modeling Orthopedic Implants with Altair HyperWorks
Every year, countless people — regardless of their age or level of physical activity — begin to experience the effects of osteoarthritis, a degenerative joint disease. As we age, the cartilage that cushions the joints begins to deteriorate. The head of the adjacent bones begin to break down from the friction, causing pain in the joint. When the condition worsens and non- surgical remedies are exhausted, surgeons may recommend joint replacement.

Typically, titanium alloy implants are lined with plastics that act as cartilage and are fixed in place with cement or screws by the surgeon. The implants can give patients a new lease on life, dramatically reducing pain and improving mobility. However, questions naturally arise in the patient’s mind: How much range of motion will I have in the new joint? How much strength will I recover? And how long will the new joint last?

From Incremental Change to Full Design/Validation Leap: A Multidisciplinary Approach to Optimize Safety and Crash Performance
Heavy-duty mining trucks at Hitachi are designed to meet ISO ROPS and FOPS safety requirements, while structures must be as lightweight as possible. The presentation will discuss Hitachi’s design and simulation approach, which consists of an integrated multidisciplinary analysis process. Dynamic analyses, multibody dynamics simulations, including flexible bodies and dynamic simulations are methods applied to optimize performance and vehicle safety.

The author will present examples such as the optimization of a trolley support structure, a kinematics model of a 100-ton truck and the analysis of a trailing arm. Finally, the author will share his thoughts on the important subject of how simulation can better impact the design.

Altair HyperWorks Helps Joe Gibbs Racing
Using OptiStruct from the Altair HyperWorks computer-aided engineering (CAE) suite of software tools, Joe Gibbs Racing was able to significantly redistribute vehicle mass and improve ride handling characteristics to design a more competitive race car.

Driving Million Dollar Savings at Ford using Structural Optimisation
The automotive business is a very competitive industry and in today’s markets, leading manufacturers are keen to find ways of reducing costs without compromising either quality or performance. This paper will cover the process of applying OptiStruct software to the re-development of a high volume and high cost plastic PAS (Power Assisted Steering) pump bracket into a much cheaper aluminium alternative. The outcome of this was a lighter, stiffer and cheaper replacement bracket that had the potential, based on the current production engine volumes, to save Ford Motor Company over $1.1 million a year.

Topology Optimization of Aircraft Wing Box Ribs
This paper considers the application of conventional energy based topology optimization methods for design of aircraft wing box ribs. Compared to standard topology optimization work undertaken at Airbus, the topology optimization of wing box ribs posed several additional challenges, mainly due to the wing box ribs being embedded in a redundant wing box structure. Several approaches to solving this problem have been investigated and are being reported as part of this paper, including a global analysis/optimization approach and two local analysis/optimization approaches.

Optimisation Techniques Leading the Development of a Steering Wheel
The early application of structural optimisation in the design of automotive components streamlines the design process and at the same time significantly increases the potential of the final design achieving maximum performance. This paper details the use of optimisation techniques during the development of a steering wheel, to generate an optimised design for cross attribute performance. This was completed in the Altair HyperWorks environment as Altair HyperMesh combined with Altair OptiStruct enables the creation of a parametric model with a multitude of design variables (i.e. size, shape, displacement, stress and frequency) in order to satisfy NVH, manufacturability, durability and crash targets.

Balancing Manufacturability and Optimal Structural Performance for Laminate Composites through a Genetic Algorithm
This paper details the application of a specialised genetic algorithm to reduce the mass of a laminated composite wing rib. The genetic algorithm has been customised specifically to optimise the performance of polymer-laminated composites. The technology allows the mass to be minimized by the removal or addition of plies of various discrete orientations whilst satisfying the structural intent of the component. For the rib structure assessed, the structural constraints consist of limits placed on the displacement, stress (i.e. ply failure index) and buckling behaviour.

Design Optimization Applied to the Development of an Oilfield Bistable Expandable Sand Screen
This paper will cover the design, development, and testing of an expandable sand screen using bistable cell technology. In addition, the design and development of the proprietary expandable connection will be presented. The testing presented covers a wide range of structural integrity, expansion, sand retention, mudflow, and geomechanical tests performed on the screen, base pipe, and connection.

The Automatic Calibration and Robustness Assessment of a Complex Engineering Component: Airbag Inflation
This paper describes the application of new technology to achieve automatic calibration and assess the robustness of an airbag inflation model. Calibration of the kinematic response of the airbag is achieved by defining the activity as an optimisation problem. The objective is to minimise the error between the experimental test and numerical simulation curves. Once calibration has been achieved, a unique robustness assessment is performed, which utilises the optimisation technology used in the calibration exercise.

Predicting the Dynamics of Mechanical Systems in the Automotive Industry
The application of CAE tools to help design and develop mechanical systems in the automotive industry is a widely accepted practice. This paper highlights various applications of these tools, in particular, the application of MotionView and MotionSolve from Altair Engineering. Each example demonstrates the advantages of using such tools to work rapidly and seamlessly within the general design process. This results in the development of innovative designs to face challenging problems in a short time frame.

The Complete Package: Applying Altair's Technology Process to Reusable Packaging Design
This paper demonstrates the flexibility that Altair technology provides throughout the design process with tools applicable to all stages. An overview of the LINPAC design process incorporating Altair's technology is given together with examples of how and which tools are being implemented. The limitations of the traditional LINPAC approach and the use of Altair's tools is demonstrated through the use of a detailed example; without the use of Altair technology, more iterations in expensive tool modifications would have been required to achieve a satisfactory design without introducing unacceptable costs.

A New Approach to Optimizing the Clean Side Air Duct Using CFD Techniques
An integrated approach to CFD design optimization is proposed. It consists of taking an initial CAD design, meshing it using HyperMesh, analysing it using Star-CD, parameterising its key features using HyperMorph, and then shape optimizing it using HyperStudy. This approach has been applied here to the shape optimization of the compressor inlet duct of a turbo system.

Delivering World Class Chassis Design
This paper details the extensive use of CAE optimisation technology at ThyssenKrupp Automotive Tallent Chassis Ltd (TKA). There are a number of trends in the automotive business that are presenting great challenges, these include severe cost pressures from OEM’s, platform commonisation and reduced vehicle development cycle time. The use of optimisation is critical for TKA to maintain its competitiveness, this paper deals with more advanced concepts of optimisation by extending into the severely non-linear region of analysis types.

A Holistic Virtual Design Process Applied to the Development of an Innovative Child Seat Concept
There is a need to minimise product development costs and provide efficient design solutions to maintain competitiveness, so increasingly companies in the Child Restraint System (CRS) industry are turning to Computer Aided Engineering (CAE) to enhance the design and development for their products. Graco has worked with Altair Engineering to develop a group 1 CRS using an advanced CAE driven design process. The design process introduces a number of key phases in the design cycle each of which are positioned to maximize the efficiency of the structure and reduce or remove the cost involved in a traditional, iterative ‘test it and see’ approach.

Simulating the Suspension Response of a High Performance Sports Car
The use of CAE software tools as part of the design process for mechanical systems in the automotive industry is now commonplace. This paper highlights the use of Altair HyperWorks to assess and then optimize the performance of a McLaren Automotive front suspension system. The tools MotionView and MotionSolve are used to build the model and then carry out initial assessments of kinematics and compliance characteristics. Altair HyperStudy is then used to optimize the position of the geometric hard points and compliant bush rates in order to meet desired suspension targets. The application of this technology to front suspension design enables McLaren Automotive to dramatically reduce development time.

Design Development of a New Consumer Personal Care Product Pack Driven by Optimization
Packaging designers must constantly inject innovations to attract consumers in a constantly evolving and highly competitive market. Keeping ahead of the competition by bringing new and exciting products to market fast, and at the necessary level of quality, presents a major engineering challenge. A new deodorant pack development process is described, which introduces advanced simulation and optimization technology into the concept development phase. Detailed predictions of interacting parts in a mechanism assembly are made possible through use of advanced simulation technology. Design optimization is then employed using the modelling as a virtual testing ground for design variants. The approach provides clear design direction and helps to improve performance and reduce uncertainty in the development process.

HyperForm Improves Accuracy and Robustness of Tool Design and Manufacturing Process at Summit Auto Body (SAB)

HyperForm Improves Accuracy and Robustness of Tool Design and Manufacturing Process at Summit Auto Body (SAB)

Leveraging HyperForm’s sheet metal forming solution, SAB designed the validation process and press tool design covering the vital areas of virtual prototyping/testing, which, in turn, reduced the time-consuming manual process drastically.

HyperWorks Process Manager Delivers Productivity and Quality Gains to Chassis Design Process
Using Altair HyperWorks Process Manager, M&M was able to implement best practices through standardization of CAE processes and minimize CAE analysis set-up time. Automated post-processing enabled through Process Manager facilitated a 40% reduction in time when compared with the manual practice of post-processing.

HyperWorks Cuts Design and Prototyping Costs for Truck Cabin Development and Testing
Using HyperWorks, Eicher Motors was able to significantly reduce the number of physical tests during the development process of their truck cabins. The numerical simulation helped in predicting the failure mode and estimating the stress level in the individual components in elastic as well as plastic zone prior to the first physical test.

The Altair HyperWorks Suite Speeds Development of Lightweight Alpine Trains
Stadler Rail is a dynamic company in a dynamic industry. With 2,000 employees at six European locations, Stadler produces light rapid-transit trains and streetcars for regional and local railroads, and is the leading supplier of cars to the cog railway market. The company uses modular, scalable concepts to design customer-oriented solutions, targeting specific needs. The Static/Dynamic/Certification Department, which creates CAE simulations of Stadler's CAD railcarmodels, used Altair's HyperWorks Engineering Framework to develop the Glacier Express, a lightweight train that carries passengers over a breathtaking route through the majestic Alps. HyperWorks tools enabled the department to move quickly and efficiently through the development process.


HyperWorks Tailors CAE Processes to Reduce Cell Phone Development Time at Motorola
Using HyperWorks, Motorola significantly reduced CAE cycle time by automating the process of input deck generation and results evaluation. By deploying HyperWorks’ process automation engine, analysts created a customized solution to simulate cell phone models more quickly.


Programmable, Open-Architecture HyperWorks Helps Toshiba Design Smaller Hard Disk Drives to Meet Market Demand
Toshiba Digital Network Company, faced with increasing global competition in the hard disk drive (HDD) marketplace, set out to create an advantage through the redesign of their existing HDD product(s). To support this effort, Toshiba partnered with Altair Engineering to automate its design process. This was accomplished by leveraging HyperWorks powerful modeling, visualization and optimization software applications with Toshiba’s proprietary solver for fluid dynamics. The specific goal was to optimize the air bearing surface (ABS) of the HDD’s magnetic head slider. This unique product development process resulted in minimizing the flying height as much as possible while considering its stability. This, in turn, reduced the overall size of the HDD and increased its recording density. In addition, the new design was brought to market in significantly less time than with Toshiba’s traditional design process.


Validation Ensures Trains Are on Track to Meet European Safety Standards
Numerical simulation aids in the design of passive safety systems to minimize passenger injury during railway
accidents.

Dialing into Simulation to Streamline Cellular Phone Development
Upstream model simulation reduces product development time and enables Motorola to meet critical market demands.

Quality Driven by CAE
Advanced CAE tools enable companies to design quality into their products.

Fine-Tuning 300-Ton Haulers: HyperWorks at Hitachi Truck Manufacturing
Hitachi Truck Manufacturing sought ways of reducing materials costs for its mammoth mining trucks, while remaining within standard specifications. The company's first project using HyperWorks CAE tools enabled Hitachi to do this with accuracy. HyperWorks is now an integral part of the design process at Hitachi.

HyperWorks CFD Optimization Helps MTU Improve Diesel Engine Compressor Blade Performance
To increase turbo charger efficiency, global diesel engine supplier MTU Friedrichshafen GmbH
combined Altair’s HyperWorks computer-aided engineering (CAE) software suite with a
computational fluid dynamics (CFD) solver. Combining the morphing capabilities of HyperMesh (the
pre-processor for finite-element [FE] analysis and CFD) with HyperStudy (the solver-neutral design
study and optimization tool), MTU redesigned the shape of the compressor blades to improve
pressure gain and efficiency. The redesign, in turn, increases the fuel efficiency of the engine.

Effective Product Convergence through Visual Brainstorming
When trying to reach consensus in new product development, a picture (or two) is worth a thousand words.

Technology Acquisition
Combination of HyperWorks and RADIOSS delivers broadest CAE product family in PLM.

Creating a Virtual Press to Optimize the Extrusion Process
Today's advanced computational tools increase productivity and quality, as well as lower energy consumption in the design and fabrication of extrusion dies.

Rotorcraft Design Takes Flight
Optimization tools enable Boeing to balance form and function in the development of advanced aircraft.

CAE in the Nanotech-enabling World
Zyvex engineers use finite-element analysis to build microscopically small devices.

Optimization Methods Land Results in ExoMars Project
Sophisticated simulation tools enable aerospace engineers to study the feasibility of airbag landing systems.

Optimizing Aircraft Structures
Optimization technology and methods for the innovative design of efficient civilian and military aircraft.

Where Is Your Performance Data?
A new data management system lets engineers easily manage, share and leverage simulation and test data.

Increasing the Velocity of Product Development
Applying simulation technology to industrial design accelerates the generation of design concepts that are exciting, feasible, desirable and profitable.

Simulation Links Welding Data to Structural Analysis Models
A robust modeling process greatly aids the design of lower cost and higher quality welded structures.

Smart Product Packaging Pays Off
Our experts examine the challenges, advancements and trends that are changing the product packaging industry.

Putting Simulation Muscle Behind a Sporty Concept Car
Optimization technology delivers innovative suspension design for Alfa Romeo's sleek concept car.

HyperWorks at Wagon Automotive: Speeding Development Time While Cutting Prototype Costs
Wagon Automotive, a system and module supplier of components to major car builders,
sought ways to accelerate product development and reduce prototyping costs while maintaining high quality.
Adopting the HyperWorks suite of advanced CAE tools enabled the company to achieve both those goals.
Wagon Automotive now uses HyperWorks during the entire development cycle, from concept design to optimization.

HyperWorks CAE Process Automation Accelerates Product Development at Scania
Scania chose HyperWorks – the Engineering Framework for Product Design – to automate the assembly process of virtual truck models for finite-element (FE) simulations. The new process significantly increased simulation efficiency and robustness, which are especially critical to
Scania’s truck-customization process.

HyperXtrude Technology Predicts Flow Behavior and Profile Deflection in Extrusion Dies
Using Altair HyperXtrude Sweden based AB Elektrokoppar was able to identify the flow problem in the extrusion die. Altair HyperXtrude is used to analyze material flow through the die and predict final profile shape as it exits the die. Profile deformation predictions form HyperXtrude were in good agreement with experimental measurements from the Elektrokoppar extrusions.

HyperWorks’ Simulation Technology Enables Godrej to Streamline Sheet Metal Tooling Processes
Using Altair HyperForm, HyperWorks’ stamping simulation technology, Godrej was able to design and
fine-tune a successful tool for a rear fender, while minimizing die testing time by reducing physical
trials. Leveraging numerical analysis, Godrej was also able to predict the size, shape and location of
the blank accurately. HyperForm’s ability to visualize failure in incremental simulation enabled them to
finalize the draw bead location and characteristics.

HyperWorks’ Stamping Simulation Technology Helps Reduce Front Housing Development Time at OMAX Auto
Using Altair HyperForm, India-based OMAX Autos was able to significantly reduce production
costs and maximize productivity by redesigning the manufacturing process for front housings.
Leveraging HyperForm’s simulation capabilities, OMAX Autos reduced the three-stage forming
process to a single-stage process.

HyperWorks’ Sheet Metal Forming Simulation Technology Enables Supreme Pressfab to Validate Fuel Tank Die
Using Altair HyperForm, India’s Supreme Pressfab was able to predict the high nonlinear
material flow for fuel tank dies accurately. In doing so, Supreme was able to optimize the
blank as well as minimize die tryouts.

HyperForm Sheet Metal Forming Simulation Solution Provides Product Design Optimization of Panel Front Dome
Using Altair HyperForm sheet metal forming simulation software solution, India based Mahindra & Mahindra was able to arrive at an optimum product (BIW Part) and tooling design. The Draw Shell was simulated using HyperForm to evaluate different tooling options.

HyperWorks Helps Create Accurate Finite-Element Models from CT Scans of Artificial Knee Joints
Using Altair HyperMesh, the HyperWorks finite-element (FE) pre-processor, researchers at the
University of Applied Sciences in Amberg-Weiden, Germany, created an efficient process to
create FE meshes of an artificial knee joint from supplied computed tomography (CT) scans. The
team, led by Professor Franz Magerl, deployed HyperMesh’s re-meshing capabilities to convert
STL data to a high fidelity tetrahedral-based FE model and investigated the effect of imperfections
induced by the manufacturing process on part strength.

HyperWorks Structural Optimization Reduces Suspension Design Time at Alfa Romeo
Using Altair HyperWorks, Italy-based Alfa Romeo was able to significantly reduce design time by
integrating multibody dynamics (MBD) with structural optimization. The resultant suspension
design showed superior performance characteristics.

HyperWorks Cuts CAE Modeling Time by Up to 50 Percent at Dunlop Aerospace
Using HyperWorks for the creation and modification of complex finite-element meshes, Dunlop Aerospace was able to dramatically cut modeling time. The software’s stability, ease-of-use and superior technical capabilities for HEX meshing contributed to the successful deployment.

OptiStruct Drives Weight Reduction in Commercial Aircraft: Door Support Arm Design Optimization
Using OptiStruct topology and shape optimization tools, Eurocopter created an innovative new design of a door support arm for the Fairchild Dornier 728 aircraft. The company achieved a weight reduction of approximately 20 percent, using structural optimization techniques as an integral part of the design process.

PBS Professional at Toulouse Genopole
The Toulouse Midi-Pyrénées Genopole, a research program set up in 1999 in southern France by the French Minister of Research, is part of the massive French research initiative known as the National Genopole Network. The genopole name is metaphoric. It brings to mind a magnetic pole that attracts researchers and entrepreneurs to the potential of genomic research. And it is working: the initiative has drawn together, at seven locations across France, a symbiotic mix of public laboratories, biotech companies, and educational institutions. The genopoles stimulate genomics research and may provide an incubator for biotech enterprises.

HyperWorks at Changchun Railway Vehicle Co., Ltd.: Accelerating Design and Analysis of High-Speed Railcars
Asia's largest railway vehicle manufacturer, Changchun Railway Vehicle Co., Ltd. (CRC), was looking for ways to increase development efficiency through streamlined CAE processes. By implementing HyperWorks, Altair's engineering framework for product design, CRC was able to reduce modeling cycle time by up to 50 percent. In addition, simulations were more accurate as a result of better model quality.

Accelerating Product Development at the Nanotech Level with Altair HyperWorks
In addition to looking for a way in which to reduce product development time through simulated modeling and analysis, Zyvex Corporation wanted to be able to communicate the features and value of its MEMS product more effectively to internal and external audiences. Using the Altair HyperWorks computer-aided engineering (CAE) framework for product design, Zyvex not only accomplished its goal to significantly speed time to market, but also used HyperView’s visualization technology to prepare informative compact slide and PowerPoint presentations on the nanotechnology to various stakeholders, including Zyvex management and potential investors.

HyperWorks at Sea Ray: Engineering High-Performance Pleasure Boats
For Sea Ray Boats, the leading, U.S.-based manufacturer of high-end pleasure boats, CAE simulations
are an integral part of the design process to achieve shorter time to market. HyperWorks is deployed
for the entire analysis process of the vessel, from modeling and simulation, to visualization and reporting.
By using HyperWorks, Sea Ray’s engineers can quickly model their advanced composite structures, as well as run complex inertia relief and durability load cases.

PBS Professional at TRW Automotive: A Standard Solution for European Design Centers
As a global technology company, TRW Automotive touches most of us in ways we're unaware of. And when we drive, it is practically a certainty that a TRW system with brakes, airbags, seat belts, or steering is part of the experience. A Tier One automotive industry supplier with a focus on safety products, TRW Automotive works with almost any car and truckmaker you can name, worldwide.

OptiStruct Technology Cuts Production and Maintenance Costs of Crop Harvester Reel Assembly
Leveraging OptiStruct's topography optimization capabilities, CLAAS designed an optimal reel hub reinforcement bead pattern for a crop harvester.

PBS Professional at GE's Oil & Gas Business: Putting an Engineering Cluster to Work
Next time you stop to fill your fuel tank, reflect on the fact that a company on the sunny slopes of Tuscany may have helped to make it possible. Nuovo Pignone, now a key technological component of GE's Oil & Gas business, began life 100 years ago as a foundry. Today more than 20,000 machines – turbomachinery, compressors, pumps, valves, and metering and fuel distribution equipment – manufactured by this GE business are operated worldwide by major companies to keep petroleum products moving from oil rigs to storage facilities to refineries to distribution points.

PBS Professional at Boeing: Workflow Management for R & D
The Boeing Information Technology group provides a wide range of computing services to the entire corporation from its Bellevue, Washington computing campus. For the engineers who design Boeing commercial aircraft, the heartbeat of this campus is the Data Center, which houses the high performance computing (HPC) systems that they access to run engineering simulations and analyses.

Parametric Optimization of Fluid Dynamic Simulations using StarCD
HyperStudy's design optimization was combined with CFD simulation in order to optimize fluid flow.

PBS Professional at Trelleborg: An Automotive Design Group Maximizes Productivity
When you look for a new car, you probably think about style, comfort, performance, economy, or innovative electronics. You won't be thinking about the kinds of parts that Trelleborg Automotive makes. But they're there, all right, mostly unsung and out of sight, and you wouldn't want to be without them. Trelleborg, a Swedish corporation with a 100-year pedigree in engineering innovation, makes molded rubber components that damp down vibration and smooth out your ride. They cushion your engine where it meets the chassis. They buffer the mechanics of your steering column and your suspension. Almost all of them do their jobs without ever seeing the light of day – but if your floor gearshift lever has a rubber housing, that housing may have come from Trelleborg.

F-35 Joint Strike Fighter Structural Component Optimization
Lockeed Martin uses OptiStruct to meet the aggressive weight targets on the Joint Strike fighter project. High potential parts for mass savings include compact fittings and planar webs.

Designing All-Terrain Vehicle Frames Using Topological Optimization
Upfront concept design optimization on a all terrain vehicle frame resulted in a 9% mass reduction. Using Design of Experiment (DOE) methods, peak accelerations during crash decreased by 22%.

Significant Weight Reduction by Using Topology Optimization in Volkswagen Design Development
Using Altair’s topology and topography optimization as an integrated part of their design process, Volkswagen is able to reduce mass of engine components by 20% and more

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