Simulate at the Speed of Design 2023

Moderator: Ujwal Patnaik – Director, Product Strategy – Altair

A session designed for those who do not currently use simulation technologies, are outsourcing most/all of their analysis, or still use limited CAD embedded simulation tools. Here you can understand the benefits of the technologies from companies that have recently implemented simulation using Altair SimSolid; and through interactive sessions, experience how easy it is to get started, even with limited resources or on the Cloud.

Moderator: Warren Dias – Director of Global OptiStruct Business Development – Altair

Suspension components are connected to the body to support weight and reduce road shock. Various tests and analytical evaluations are being conducted to evaluate these suspension parts, but the time to evaluate these parts is limited compared to the period required for vehicle development.

In this presentation, compared to the existing FEA software, by using the Mesh-Free Method SimSolid, we increased work efficiency by significantly reducing the time spent on analysis while maintaining the consistency of the analysis results.

This study presents a comparative analysis of traditional Finite Element Analysis (FEA) and SimSolid, a new structural analysis software, for simulating the von Mises stress of a mechanical rack system used to support heavy equipment. The accuracy and efficiency of SimSolid are evaluated under different loading conditions, including stress and displacement, using a Keysight mechanical rack system. The rack has a complex geometry, composed of a complex design plates with multiple attachment points, and is modeled as a single assembly using SimSolid. The results demonstrate that SimSolid can provide accurate stress analysis in a fraction of the time required by traditional FEA, with the simulation for the entire rack solution completed in just one day. SimSolid’s rapid structural analysis capability is particularly beneficial for large and complex geometries, such as the rack analyzed in this study, making it a promising tool for stress simulation of large assemblies in engineering design. These findings suggest that SimSolid can improve the efficiency and accuracy of stress analysis, which is crucial in the design and development of various engineering structures. Overall, this study highlights the potential of SimSolid as a more efficient and accurate alternative to traditional FEA for von Mises stress simulation of complex mechanical components, including large assemblies like the mechanical rack system analyzed in this study.​

Lakshmi Machine Works Limited (LMW), a leading Textile Machinery Manufacturer in India and one among the three in the world to produce the entire range of Spinning Machinery.

Fastener pretension is a common technique in mechanical engineering that is used to assemble parts in preload. The preload should neither be higher nor lower than required. Optimizing preload is always a challenge in parts assembly since it requires ample of iterations. Solving fastener physical 3D modelling approach in classical FEA software is always challenging because it consumes a lot of computational time to resolve. We need value engineering in the particular coupling assembly, which is required multiple numbers in a single machine. We proposed a coupling material conversion from aluminum to polymer to lower part costs. We have considered a single coupling with equivalent loads and resolved it using 1D element approximation in the classical FEA software. We would like to solve the coupling with the structure as a whole unit assembly. Due to the higher number of coupling assemblies corresponding higher number fasteners, the classical FEA software takes much longer time also could not debug the solving error.

Based on the simulations that we ran in simsolid we were able to perform multiple design exploration quickly on textile machinery components. Complex assemblies that would take days to solve in traditional FEA is reduced to 40 Minutes with Simsolid.

Simon Zwingert – Technical Consultant – Altair

Learn from other small and medium design and engineering teams how simulation can be applied early in the product development lifecycle, to rapidly accelerate the creation and optimization of structurally efficient parts, systems, and assemblies. Attend this session to see how a simulation-driven design approach, using Altair Inspire, can reduce your development time while saving development and manufacturing costs.

Moderator: Simone Bonino – VP of Business Development Manufacturing Solutions – Altair

In the new energy vehicle and new materials fields, we face not only the challenge from the manufacturing process, but also the problem of multiple iterative designs due to manufacturing.If we consider the manufacturing issue in 3D printing process in the early stage of structure design, we can greatly reduce the structure repairs later and shorten the product production cycle. In addition, with the rise of generative design, customers are more sensitive with the mass of components. How to achieve greater value and more benefits with less material, that is, structure light-weighting, is also a major challenge we face.

When designing mass production to improve quality problems and reduce weight of window regulator parts that are difficult to standardize, Altair Inspire was applied to optimize design. The window regulator is a device that is housed in the door of a vehicle and raises and lowers the glass. Among them, the carrier plate is a part that fixes the glass, moves along the rail, and lifts and lowers the glass, and is responsible for many functions.
The carrier plate has a problem in that it is difficult to standardize due to the small size of parts and various customer requirements. In addition, although it is a plastic material, it is exposed to a relatively harsh environment and accounts for a large proportion of quality problems. To improve this, harsh test conditions were selected through DFSS at the beginning of design, and the load applied to the product was calculated. Afterwards, the optimal design was derived using Inspire, and the optimal design was presented as 3D data to the design team. Through this, it was possible to reduce the weight by about 8%, and it was possible to shorten the development period by eliminating product modification cost and modification period by satisfying all of our tests at once.

This research aims to investigate the accuracy of thermomechanical simulation in predicting aileron bracket distortion made of austenitic stainless steel SS316L additively manufactured using selective laser melting (SLM). SLM-based components often induce significant distortion as result of high temperature gradient induced by rapid cooling of the melt during fabrication process. This study begins with utilization of topology optimization to obtain optimal material layout based on defined loads and constraints as well as design objective to minimize mass with desired safety factor. Prior to actual 3D metal printing, a process simulation was conducted to predict distortion by optimizing process parameters such as build orientation, laser power and speed. Support structures are defined which can give significant impact on heat dissipation while preventing possible distortion at the cost of higher printing time and material usage. For validation purpose, a number of experiments were carried out using SLM machine, followed with manual postprocessing of support removal and sand blasting. Further, an optical 3D scanner was used to measure the fabricated component and the result were compared with simulation result. As conclusion, Altair Inspire software is capable to produce lightweight design, predict the distortion accurately and fully digitalize 3D metal printing process from design to fabrication.

The design of rocker arm and swingarm of the rear suspension system for a heavy scooter was conducted in this project, in which both components were expected to be manufactured by gravity casting with the cast aluminium alloy JIS ADC 12. The rear suspension system was comprised of engine block, exhaust system, transmission system, brake system, shock absorber(s), swingarm, wheel, and tire. Besides, this rear suspension system was a common design of two alternative versions, including middle mono shock and rear double-sided shocks. Altair Inspire was used to conduct the motion analysis of this rear suspension system by simulating the loadcase of the scooter running over the treadmill mounted with a bump on the test bench in the fatigue laboratory. In the motion analysis, the grounded joint(s) were set at the supports between the main frame and rear suspension system, including the engine block and shock absorber(s). The actual tension/compression force-displacement curve of the shock spring provided by the supplier was input as well. The load was given by using an actuator mounted at the rear axle to apply a sinusoidal vertical displacement. After the motion analysis, the time history data of the joint forces at the rocker arm and swingarm were used to conduct stress analysis of the two parts, and the safety performance was then assessed. After several design iterations by manually tuning the highly stressed geometric feature in the CAD model, the stress concentration on both components was effectively reduced, and the design of rocker arm and swingarm met the requirement of the manufacturer.

Unleash the full power of simulation by exploring the behavior of your products in any possible working condition to maximize performance and improve robustness. Through examples and best practices, find out how Altair SimLab based easy-to-use Multiphysics solutions can inject innovation, and how our unique token-based licensing model makes it highly cost-effective.

Moderator: Ujwal Patnaik – Director, Product Strategy – Altair

To do the transient analysis on a complex system, it is challenging from research, design, CAE analysis to test verification. By integrating solutions with Simlab, HWs, Radioss and Hyperlife, we are able to ensure the accuracy the Simlab’s powerful mesh capabilities, so as to know how to improve the system design.

Nowadays, many countries are shifting from IC engine vehicle to electric vehicles because of its environment pollution. Battery charging is a main part of electric vehicle. On-Board charger is generally used in vehicle for the charging as well as monitoring charge rate of battery. The electric components of OBC board are diodes, MOSFETs, inductors and transformer. Among these components, the transformer is a higher heat generating component which can leads to overheating and breakdown of OBC board. For correct design of transformer, an optimized simulation is required at initial level. This paper presents the simulation study for the sensitivity analysis of transformer using Altair HyperWorks CFD software. In this study the sensitivity analysis has been done for the parameters such as Air gap between coil, bobbin, and core, change of bobbin and potting material, and potting thickness. This sensitivity study helps in understanding of critical thermal design parameter for transformer. Furthermore, the study is useful for the further improvement in thermal management of transformer.

Keywords: Critical Thermal Design, Optimized simulation, Sensitivity analysis, thermal management

With a SDfM approach, product designers can be confident in their chosen manufacturing method because design flaws can be detected much earlier and corrected before any physical prototyping has to be done.In this session find out how to plan for the manufacturing process & understanding critical parameters, Defects and issues, and challenges. Also, ideas of enhancing your manufacturing process, targeting, improved Yield, optimal energy, lowering wastage, improve tool life and enhance production quality for Forming/Stamping and Casting

Moderator: Simone Bonino – VP of Business Development Manufacturing Solutions – Altair

Reinforcement Cross Member Front is a vital structural component used in a Cross Member Front Assembly of a car, which is a sheet metal component.

To develop the tooling method plan for Reinforcement Cross Member Front component, customer provide us component 3D cad data, Part drawing etc. from the part CAD model we generate the surface model of the tools for each forming stage in Catia V5. We setup the multistage operation considering the real time process condition in Altair Inspire Form to predict forming defects and to validate the die design, Inspire Form is User Friendly environment for setting up multistage operation, where in we can exclude intermediate stages on the fly in order to optimize number of stages.

The purpose of this study is to predict % of Thinning, Wrinkles/failures zones by Forming Limit Diagram (FLD), Material crowding, spring back effect and die compensation.

OEM’s are now insisting to use high strength steel material for BIW components. The challenges for this HSS material will have high spring back effect after forming. Inspire Form helps to predict accurate spring back results and also to perform Die compensation.

During sheet metal stamping process lot of parts fails due to die design fault, where manufacturing aspects or actual process parameters are not taken into account, which in turn hinders product development time & eventually increases number of tryouts. Hence, it is important to validate the die and process through simulation during design stage in order to reduce the number of physical tryout, product development lead time and improve the efficiency and cost of the product.

McWane India Private Limited is a manufacturer & Supplier of Gate Valves, spigot valve, Butterfly Valves, Check Valve, Air Relief Valve, etc. These products are manufactured from high quality metals and alloys.

Running simulations for casting have gained popularity in industries since it helps study mould filling, solidifying metal, and cooling part in the cast. Moreover, it is of great use to understand the probable locations where internal defects such as shrinkage porosity might occur without prototypes, thereby saving time and money. The paper showcases the process and inferences drawn by creating casting simulations for a Spigot Gate Valve to provide a high degree of process certainty, prevent technical problems and ensure that a project does not encounter delays.

With the challenge of performing more prototypes, Mcwane recognizes that Inspire cast helps to check the shrinkage and optimize the metal flow condition to achieve a better product with reduced time in trial and error in creating numerous gating systems for numerous tests. Cost savings in eliminating the process of having to create new gating system samples and molds to test. To perform the casting simulation to determine the casting defect at the earlier stage of product development cycle.

This research deals with the application of the numerical simulation for analyzing the defects in investment casting process. Upon visual inspection of the preliminary casting design of component as vehicle barrier support, it has been discovered that shrinkage porosity is often present. The component is made of austenitic stainless steel SS304 with gravity pouring process. The simulation starts with creation of the CAD model of the product using CATIA. The actual location of shrinkage porosity is compared with the numerical model of the preliminary casting designs and process using the simulation software Altair Inspire Cast 2021. In order to eliminate defects and achieve optimal casting yield, a series of simulation casting designs had been proposed considering the behaviour of liquid metal during the filling and solidification stage. It was revealed that the position of the casting part attached to the runner influences the solidification of metal which leads to shrinkage porosity. The smaller runner volume can lead to higher casting yield as it reduces the amount of molten metal used in the shell mold. However, if the filling time is not optimized during the pouring process, molten metal filling can effect on the occurrence of cold shuts and air entrapment. For validation purposes, the optimized casting design is manufactured and compared with the simulation which shows good agreement. Based on the results, it can be concluded that the location of defects can be accurately forecasted using this software with actual process parameter and the procedure can be used for optimizing the process and product.

Main objectives of this technical study are to reduce the lead time in production of leak proof and defect free investment castings, and at the same time saving significant cost by avoiding multiple real life casting trials.

This paper describes the effectiveness of Altair Inspire Cast simulation software in prediction of the critical investment casting defects.

The key focus of this paper is on estimating and correlating casting soundness and defects seen in software simulation and those observed on real life castings, essentially enabling good confidence level in simulation model with parameters available within Altair Inspire Cast simulation software. The casting models evaluated are typically thin walled and are prone to fail in pressure leak test, though no defects are seen in radiography analysis.

The key defects evaluated are, shrinkage, microporosity, cold shuts, warpage and others, by conducting Filling and Solidification analysis, capacitated by software in-built calculations, and are largely based on theories of Solidification Modulus, Solid Fractions, Niyama Criterion and others.

Inspire Form: Hariharasudhan Palaniswamy – Senior Program Manager – Altair

Inspire Cast: Martin Solina – Vice President, Inspire Manufacturing Solutions – Altair

Moderator: Ujwal Patnaik – Director, Product Strategy – Altair

A session designed for those who do not currently use simulation technologies, are outsourcing most/all of their analysis, or still use limited CAD embedded simulation tools. Here you can understand the benefits of the technologies from companies that have recently implemented simulation using Altair SimSolid; and through interactive sessions, experience how easy it is to get started, even with limited resources or on the Cloud

Moderator: Warren Dias – Director of Global OptiStruct Business Development – Altair

• SimSolid has enabled us to work on production models.
• SimSolid has enabled us to design to strict VCA guidelines.
• SimSolid has enabled us to increase our technical competence across a wider team

Exhaust system suppliers are continuously improving and adopting advanced simulation techniques and quick testing proceduresfor exhaust system optimization to address time to market, faster vehicle launch and first time and all time right strategy to comply performance and durability. This paper deals with the methodology development of Exhaust system Cold end hanger rod and Muffler Shell stiffness analysis using Mesh less simulation tool SimSolid. During concept stage, design team will develop the CAD model of whole Cold end system based on isolator position provided by customer.

There may be 4 to 7 No of hanger rods present in the system. Muffler shell with internals such as baffle plate and perforated tubes are developed based on Vehicle level tail pipe noise and back pressure target.

To conclude the cold end layout, CAE team will perform multiple Modal analysis iterations on hanger rod and Muffler shell to achieve the natural frequency target.

As the traditional approach, FE modeling of hanger rod with shell elements for hollow hanger rod and Solid meshing for solid hanger rod for every design improvement proposal CAD shared by design team. Multiple iterations of CAE Modal analysis has been performed for each hanger rod to achieve the natural frequency target of F > 500 Hz. This is time consuming, as we have to develop the FE model for every design change of hanger rod and proposed to add reinforcement rod until to meet the natural frequency target. Here weld locations on hanger rod considered as boundary condition to apply displacement constraints. Also Muffler shell configuration such as Single layer shell of thickness 1.0mm, 0.8mm, Double layer of 0.5mm with insulation 1.0 mm present in the cold end system. Multiple simulation iteration performed for the given muffler shell layout with confirmed internals like baffle plate and perforated pipes to achieve the natural frequency target of F > 450 Hz. In this scenario, SimSolid helps to perform multiple iterations in the given CAD model itself until the hanger rod meets the natural frequency target. Here seam weld locations considered as surface constraints on each hanger rod to verify the natural frequency and mode shapes. Similarly muffler shell with internals CAD considered for Modal analysis as free – free boundary condition and its natural frequencies are verified. Simsolid helped us to reduce simulation timeline and providing quicker hanger rod and muffler shell analysis results when compared to traditional approach of FE modeling of each hanger rod and muffler shell CAD design improvement proposals to reach the solution. SimSolid’s rapid calculation enable the team to model subassemblies within minutes, providing us with the ability to fully assess many variants to get the best possible design.

Learn from other small and medium design and engineering teams how simulation can be applied early in the product development lifecycle, to rapidly accelerate the creation and optimization of structurally efficient parts, systems, and assemblies. Attend this session to see how a simulation-driven design approach, using Altair Inspire, can reduce your development time while saving development and manufacturing costs.

Moderator: Simone Bonino – VP of Business Development Manufacturing Solutions – Altair

The healthcare industry is rapidly evolving, and historically, standard-sized prostheses made from various materials such as titanium, steel, and PEEK were the primary implant options for patients. These implants undergo rigorous testing according to the standards of each country to ensure safety and effectiveness in daily activities, such as chewing and walking. However, research suggests that conventional implants may not adapt optimally to different anatomical shapes, which can significantly affect surgical success and patient health.

E-Shifter includes a knob and lever arrangement similar to a conventional gear shifter.While conducting structural analysis, the lever component showed high stress concentration on ribs as compare to the allowable stress. The rib structure needed to be improved and was hence chosen as the optimisation target. With the help of Altair Inspire, we have optimised the design of ribs in a lever of EShifter. The main purpose of this topology optimisation is to achieve a design which satisfies the supplier request for lower allowable stress than that of previous models. To optimize the lever ribs,a structural simulation model was created in Inspire and base results were obtained. For optimisation, a design space was created on the lever, while respecting the operation clearances. This desgin space defined the volume to be optimised and shape control parameters were used do define the flow direction of material.Multiple optimisation simulations were run using different parameters.After obtaining favourable rib shape the geometry was extracted using polynurbs feature. The optimised shape we got from Inspire used as a reference while re-designing the ribs.The stress results we got from re-designing the ribs were lower than the requested results.

Unleash the full power of simulation by exploring the behavior of your products in any possible working condition to maximize performance and improve robustness. Through examples and best practices, find out how Altair SimLab based easy-to-use Multiphysics solutions can inject innovation, and how our unique token-based licensing model makes it highly cost-effective.

Moderator: Ujwal Patnaik – Director, Product Strategy – Altair

Altair SimLab enables the meshing of complex parts and assemblies fast and with high quality. The possibility to automatically generate FEM models from CAD geometry speeds up the simulation of design iterations, enables parametric optimization, and minimizes manual work

DESTEC operates within the oil and gas industry where the design and production of all products is heavily controlled by the standards we work to, they govern everything from the formulae used in our calculations to the allowable shape profiles of certain components. Because of this, we must stay in line with the most recent versions of the ASME code and the API Specification so that we may retain a competitive edge.

We are looking to begin designing some of our products to API 6X, this uses design by analysis, and require multiple simulations with various loading conditions. Because of the nature of this analysis and the relative complexity of the simulations, with multiple sliding joints and contact seals with high surface pressures, our previous software, Simulation Mechanical, was not sufficient.

Upgrading to Simlab allowed us to accurately analyse the connections against the various failure modes presented in the API 6X, these included:

• Protection against Plastic Collapse, this involves pressurising the connection under an elastic, plastic, analysis and ensuring that the simulation stays converged up to 1.11 x the connection test pressure.

• Protection against local failure, this involves pressuring the connection to 1.7 x the connection design pressure under an elastic, plastic, analysis and ensuring that the strain in peak areas does not exceed expected limits.

• Protection against ratcheting, this analysis involves pressurising the connection to the design pressure in separate loading cycles, measuring the deformation between the second and third cycle to ensure that nothing changes.

• The other checks and criteria are visual checks done during the previous simulations to ensure that the sealing faces remain in contact and that the connection remains in place.

SimLab has allowed DESTEC to satisfy the conditions of the API 6X and so qualify our connections to this standard in the future.

With an SDFM approach, product designers can be confident in their chosen manufacturing method because design flaws can be detected much earlier and corrected before any physical prototyping has to be done. In this session find out how to plan for the manufacturing process & understanding critical parameters, Defects and issues, and challenges. Also, ideas of enhancing your manufacturing process, targeting, improved Yield, optimal energy, lowering wastage, improving tool life, and enhancing production quality for Forming/Stamping and Casting.

Moderator: Simone Bonino – VP of Business Development Manufacturing Solutions – Altair

In our Presentation, we present a case study of how we integrated FEM simulation into our Workflow. In today’s competitive environment, Tool & Die Design Offices must continuously improve their design and manufacturing processes to stay ahead of the competition. FEM simulation can help design engineers optimize their workflow, reduce costs, and improve product quality.

Benchmark Die Casting Housing – Comparison Simulation – Reality

In our benchmark, together with the companies Sydow Druckguss GmbH and APS Wenden we show casting defects and expected problem areas and compare them with X-ray and sectional images. The results show how close we are to the actual results with our predictions from the FEM simulation.

Casting companies are under constant pressure to do things quicker at a reduced cost. Casting Simulation provides an ability to speed up method development, reduce physical try-outs and spot defects early in order to cut down on waste and improve yields. The session will feature case studies from Skaigh Engineering, demonstrating how they have implemented Inspire Cast to solve real-world production challenges, saving both time cost.

Inspire Form: Hariharasudhan Palaniswamy – Senior Program Manager – Altair
Inspire Cast: Martin Solina – Vice President, Inspire Manufacturing Solutions – Altair

Moderator: Ujwal Patnaik – Director, Product Strategy – Altair

A session designed for those who do not currently use simulation technologies, are outsourcing most/all of their analysis, or still use limited CAD embedded simulation tools. Here you can understand the benefits of the technologies from companies that have recently implemented simulation using Altair SimSolid; and through interactive sessions, experience how easy it is to get started, even with limited resources or on the Cloud

Moderator: Warren Dias – Director of Global OptiStruct Business Development – Altair

The work developed introduces a new product development cycle and applies this new concept to a pneumatic suspension bracket. The new workflow includes the use of meshless technology in the concept definition phase of the design and the use of the finite element method to validate the final version of the design. The workflow was expanded to include the usage of test data to define realistic load cases to correctly dimensioning of the component to accommodate the project criterions. In this study the commercial software Altair SimSolid and Altair OptiStruct were used to evaluate the proposed design structural performance in the design proposals and the test data used to define the model’s boundary conditions were obtained combining roads that represent the Suspensys accelerated durability procedure.

This proposed devlopment cycle also includes the virtual model construction, a comparison between the methods in terms of time and effort required to build the model in the pre-processing phase, computational time and cost to perform the calculation, as well as the answers found during post-processing to ensure that the benefits of implementing a new methodology will not compromise the accuracy of the final result. Concepts needed to define the test duration and roads used on the physical test and processing of the measured data will also be presented.

Learn from other small and medium design and engineering teams how simulation can be applied early in the product development lifecycle, to rapidly accelerate the creation and optimization of structurally efficient parts, systems, and assemblies. Attend this session to see how a simulation-driven design approach, using Altair Inspire, can reduce your development time while saving development and manufacturing costs.

Moderator: Simone Bonino – VP of Business Development Manufacturing Solutions – Altair

The healthcare industry is rapidly evolving, and historically, standard-sized prostheses made from various materials such as titanium, steel, and PEEK were the primary implant options for patients. These implants undergo rigorous testing according to the standards of each country to ensure safety and effectiveness in daily activities, such as chewing and walking. However, research suggests that conventional implants may not adapt optimally to different anatomical shapes, which can significantly affect surgical success and patient health.

Recent technological advancements and their convergence have revolutionized the healthcare industry, offering new treatment approaches for patients with trauma, tumors, or congenital malformations requiring implants. By integrating simulation technology, computer-aided design (CAD), additive manufacturing, and imaging examinations such as computed tomography (CT), patient-specific implants tailored to their unique anatomy and needs are now available. Custom implants offer enhanced precision during surgery with improved alignment and positioning, reducing the risk of complications and shortening surgical times. The use of custom implants has demonstrated improved implant longevity and patient satisfaction. These outcomes were previously unattainable with traditional implants, highlighting the potential of advanced of technologies to revolutionize patient care.

As each patient-specific implant (PSI) is manufactured only once, conducting physical tests on each individual implant is not feasible. Therefore, it is critical to ensure that PSIs possess the necessary strength and safety to withstand real-life mechanical loads that occur during a patient’s daily activities.

Altair’s simulation solution for virtual environment testing of implant mechanical loads is a crucial element in ensuring that patient-specific implants (PSIs) are reliable and safe for use. Using simulation, our team of engineers and designers can develop PSIs that meet regulatory requirements and safety standards while prioritizing patient rehabilitation and mechanical resilience to prevent implant damage. The safety of the final product is paramount in ensuring patient care, and Altair’s solutions plays a key role in this process.

Altair’s comprehensive portfolio of cutting-edge simulation solutions made it the ideal partner for ba-io to expand its healthcare offerings and provide superior experiences and outcomes for medical clients and patients.

E-Shifter includes a knob and lever arrangement similar to a conventional gear shifter.While conducting structural analysis, the lever component showed high stress concentration on ribs as compare to the allowable stress. The rib structure needed to be improved and was hence chosen as the optimisation target. With the help of Altair Inspire, we have optimised the design of ribs in a lever of EShifter. The main purpose of this topology optimisation is to achieve a design which satisfies the supplier request for lower allowable stress than that of previous models. To optimize the lever ribs,a structural simulation model was created in Inspire and base results were obtained. For optimisation, a design space was created on the lever, while respecting the operation clearances. This desgin space defined the volume to be optimised and shape control parameters were used do define the flow direction of material.Multiple optimisation simulations were run using different parameters.After obtaining favourable rib shape the geometry was extracted using polynurbs feature. The optimised shape we got from Inspire used as a reference while re-designing the ribs.The stress results we got from re-designing the ribs were lower than the requested results.

Unleash the full power of simulation by exploring the behavior of your products in any possible working condition to maximize performance and improve robustness. Through examples and best practices, find out how Altair Simlab-based easy-to-use Multiphysics solutions can inject innovation, and how our unique token-based licensing model makes it highly cost-effective.

Moderator: Ujwal Patnaik – Director, Product Strategy – Altair

TEN TECH AEROSPACE & DEFENSE, INC. provides multi-discipline engineering services including high-end mechanical engineering design, analysis, physical testing support and hardware prototyping services.
Because speed and accuracy are top priorities, we selected Altair® SimLab® for its intuitive interface that allows users to stay in the same tool for the entire process from meshing and setup to solving and visualization. Since we have historically have worked with large designs, where more than 200 million elements are common, we needed a better solution for every step of their CAE process from pre-processing, solving and postprocessing.
“Models that would take hours with competitive software tools, we were able to convert in roughly 10-20 minutes with Altair. With large models, analysis used to run for up to 24 hours, with SimLab, that is 3 hours.
We also needed a tool that could work with our existing legacy data, as we could not afford to lose many years’ worth of models the teams had created and stored and Simlab helped us achieve that.

With an SDFM approach, product designers can be confident in their chosen manufacturing method because design flaws can be detected much earlier and corrected before any physical prototyping has to be done. In this session find out how to plan for the manufacturing process & understanding critical parameters, Defects and issues, and challenges. Also, ideas of enhancing your manufacturing process, targeting, improved Yield, optimal energy, lowering wastage, improving tool life, and enhancing product quality for Forming/Stamping and Casting.

Moderator: Simone Bonino – VP of Business Development Manufacturing Solutions – Altair

Metal formed parts must meet rigorous quality, safety, and performance standards. To achieve this, companies typically conduct physical tests or try-outs, which can often be expensive and time-consuming. If the part has defects, it needs to be re-designed, resulting in lost tooling costs and wasted material.

With decades of experience in tool and die design and manufacturing, Jay Weiner, founder and forming specialist at BiggerBoat Solutions Ltd. in Ontario, Canada, will share some insights on how using Altair solutions has enabled him to provide his customers with the most accurate and precise results in the fastest, most efficient manner. Ultimately, this contributes to better parts, shorter cycle times, and reduced costs.

Casting companies are under constant pressure to do things quicker at a reduced cost. Casting Simulation provides an ability to speed up method development, reduce physical try-outs and spot defects early in order to cut down on waste and improve yields. The session will feature case studies from Skaigh Engineering, demonstrating how they have implemented Inspire Cast to solve real-world production challenges, saving both time cost.

Inspire Form: Hariharasudhan Palaniswamy – Senior Program Manager – Altair
Inspire Cast: Martin Solina – Vice President, Inspire Manufacturing Solutions – Altair