A Walk Through the Simulations Gallery

It’s always interesting to see how our simulation platform enables engineers to solve real engineering problems. Numerous examples are presented by customers at the Altair Technology Conferences (ATC) throughout the world this past year. Just to give you an idea there were close to 800 presentations at all the events in 2017. Now obviously that’s a ton of content, but we also share appreciation of our customers for attending these events and presenting interesting applications of the technologies. Sampled below are a few presentations that cover the breadth of problems addressed by our customers in different industries.

Most of the customers are solving multi-physics problems that require in-built capabilities or coupling multiple solutions. Clearly under the HyperWorks suite we provide a broad portfolio of multi-physics solvers covering mechanical, electromagnetic, fluid/thermal, and model-based development systems, all wrapped around optimization technologies. We just finished a multi-physics webinar series showing different applications that require coupled solutions. Watch these on-demand webinars or read a nice supplemental blog to learn more.

 

First we start off with a presentation by ABB at the European ATC designing industrial manufacturing robots. The topic focuses on studying the dynamic behavior and fatigue evaluation of industrial robots using multi-body dynamics analysis in MotionSolve. The Automatic Tool Change (ATC) interface was studied to minimize the vibrations and optimize the speed and accelerations. MBD analysis was done to extract the sequence of forces and deformations of the cross bar leaving and approaching the position.

Mr. Fujikawa of Tokyo Denki University presented a butterfly flight simulation at the Japan ATC! The tiny butterfly robot with motor and wing mechanism was modeled with AcuSolve and MotionSolve. A must see video!

Refrigerated display cases are used to store food products in retail markets. Overloading affects the efficiency of the refrigerator and in turn reduces the shelf life of food products. Study of overloading effects in a refrigerated display case using AcuSolve was presented by HUSSMANN at the India ATC. HUSSMANN has done a market research on overloading and captured all variations of overloading in CFD, to study and analyze its effects on airflow and thermal behavior inside the display case.

Composite materials are playing an increasing role in various industry segments like aerospace, automotive, defense and space, marine, consumer products due to desirable characteristics of lightweight, corrosion resistance, high strength, and design flexibility among many others.


Adrian Sawyer from Reichel-Pugh that makes racing superyachts with high-end amenities presented at the Americas ATC event about designing composite hull shapes and the internal structure for optimum performance. High sailing rig loads are analyzed that dictate the load paths and optimizing structures to improve global stiffness (a stiffer and lighter boat translates to a faster boat). An interesting observation is presented which many engineers encounter in accommodating competing demands from customers and designers that sometimes clashes with what could be an ideal engineering solution.

Continuing with composites, Altair colleague Ravi Kodwani presented at the Americas ATC the results of a blind prediction involving composite bumper and crush cans. The work was done as part of U.S. Automotive Materials Partnership (USAMP) LLC initiative. USAMP is an industry partnership of Chrysler Group LLC, Ford Motor Company and General Motors Company focused on developing materials and processes. The work progressed with increasing levels of complexity to do a blind prediction on the system level tests of design geometry from the available coupon tests and simple component geometries. RADIOSS was used to do the crash simulations and developing the material models. HyperStudy was also used to determine material parameters describing damage and rupture behavior from the test data. Draping estimator in HyperMesh was used to define the local orthotropy of material direction. In the end, simulation results showed good predictive correlation to tests with some room for improvement on modeling how the crush cans are attached to the bumpers.


Mahindra and Mahindra presented numerous case studies performing nonlinear analysis of automobile components using OptiStruct at the India ATC. As automotive companies are trying to reduce tests based on simulation, it is necessary to consider all aspects of a real world behavior namely to model contact, material and geometric nonlinearity to predict the accurate results. It further helps to have optimization wrapped around the analysis to meet design goals. Efficient use of CAE resources and robust simulation processes will help in reducing product development timelines.



Philipp Frank from Volkswagen presented a different perspective on Multi Model Optimization (MMO) at the European ATC designing reinforcement of an A-pillar for roof crush considering a non-static loadcase. What is interesting is that the MMO concept was applied on different deformation stages of the event on the same model. Since the event is transient in nature with large deformation, the A-pillar reinforcement needs to withstand loads during the entire event to demonstrate maximum energy absorption rather than buckle after initial stiff behavior. The design space is also affected due to deformations, so it’s no longer the initial volume but transformed to the new location and linked together.

Electric motors are versatile in many applications. Luigi Rizzi of SPIN Applicazioni Magnetiche presented vibro-acoustic analysis of a brushless IPM electric motor for automotive applications using Flux and OptiStruct at the European ATC. The mechanical and electromagnetic sources of vibration within the motor cause structural integrity and noise issues that need to be handled during design stage in order to prevent overheads, reduce the time to market and improve the quality. The EM forces from Flux are transferred to OptiStruct to perform a radiated sound analysis.

The electromagnetic solutions in HyperWorks is comprehensive with the presence of Flux, FEKO, WinProp, and a collection of APA products. Main electromagnetic simulation applications across industries are shown in the image. This was presented by Altair colleague Jordi Soler at the Japan ATC talking about the role of electromagnetic simulations in wireless charging systems. Key topics on inductive charging like efficiency of inductive charging systems, influence of offset between coils, radio interference, thermal effects, and radiation hazard analysis were covered.

And finally, another must see video is the two wheeled self-balancing scooter presented by Altair colleagues Kosuke Ikeda and Woohee Kim at the Japan ATC. The generic 2 wheeled self-balancing scooter with a rider demonstrates a multi-disciplinary design approach applying control systems, electromagnetics, and multi-body analysis at a system level evaluation. The scooter design focuses on closed loop control system development for stabilizing the rider and powering the wheels while accelerating, turning, and braking during different maneuvers. The complete demonstration was developed in HyperWorks and solidThinking suite of products. Scooter, road profile, tires, and the rider (robot) were modeled and analyzed with MotionView and MotionSolve, the multi-body solution. The motors were designed in Flux, the general purpose electromagnetic tool. Control system for motors and stabilizing the system are all done in Activate, an intuitive block diagram environment to support model based development. Finally a photorealistic rendering of the animation as shown in the video below is done with Evolve:

 

Sridhar Ravikoti

Sridhar Ravikoti

Technical Director - Global Partner Programs at Altair
Sridhar Ravikoti is the Technical Director of Global Partner Programs at Altair. He has been with Altair since 2000, gaining experience in engineering product development and software program management. In his current role as a technical lead for the Altair Partner Alliance, Sridhar drives a synergetic relationship between Altair offering and its Partners. He holds a Bachelor’s degree from Osmania University in India, and a Master’s degree from the University of Nebraska-Lincoln, with a major in Mechanical Engineering and a minor degree in Applied Mechanics.
Sridhar Ravikoti
Sridhar Ravikoti

About Sridhar Ravikoti

Sridhar Ravikoti is the Technical Director of Global Partner Programs at Altair. He has been with Altair since 2000, gaining experience in engineering product development and software program management. In his current role as a technical lead for the Altair Partner Alliance, Sridhar drives a synergetic relationship between Altair offering and its Partners. He holds a Bachelor’s degree from Osmania University in India, and a Master’s degree from the University of Nebraska-Lincoln, with a major in Mechanical Engineering and a minor degree in Applied Mechanics.