Design the Difference - EngineersOnline.nl Theo... · Design Exploration: a Simulation Driven Design Method Simulation Technology enables Design Exploration “Design exploration

Design the Difference

Introduction to Altair

Theo Verbruggen, Sales Director Benelux

How Simulation Driven Design Revolutionizes Product Development

Lutz Dobrowohl, application engineer

© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

“We are truly in the era of simulation-driven engineering —

an era where simulation can help synthesize and define the physical design, rather than simply evaluate and validate a completed

design.”

(CIMdata - 2016)


Our Vision

To radically change the way

organizations design products

and make decisions


Industry’s broadest integrated

Simulation Software Suite

(Model Builders, Solvers,

Optimisers Visualization)

HyperWorks

A global engineering and design

business delivering innovation to

our clients

ProductDesign

solidThinking Inspire enables

Product Designers to quickly

create and investigate structurally

efficient concepts

solidThinking

Our Solutions


30+ Years of Innovation

45+ Offices in 22 Countries

2600 Employees Worldwide

Altair Globally

150+ Technology &

Business partners

5000+ Customers


Who is Altair: History Milestones

1985

Altair Engineering Inc. founded

Engineering Services Supplier in Detroit,

MI

1989

HyperMesh 1.0 Breakthrough Mesh

Generation Technology

1993

OptiStruct 1.0 Revolutionary Optimization Technology

1999

HyperWorks Suite Release

Combines fifteen software titles under

one innovative, flexible Business

Modell

2008

Altair Partner Alliance Release Opens HW Platform to third-party applications

available to customers under HWU

2006

2003

2010

2014

2014

2016

2015

2008

2010

http://www.google.com/url?url=http://www.altair.com/History.aspx&rct=j&frm=1&q=&esrc=s&sa=U&ei=xJZaVMiuK4u5yQTVtILwBg&ved=0CBYQ9QEwAA&usg=AFQjCNE1w4pz-EL9PLyea3e6KkaH6IH94Q


We Work with Some of the Best

Automotive Aerospace Heavy Equipment Government

Life/Earth Sciences Energy Architecture Electronics/Consumer Goods


ALTAIR HYPERWORKS

comprehensive simulation platform

open-architecture technologies

design and optimize

high performance, efficient, innovative

Drive Innovation

Simulate Everything

Interoperate Freely

Access All Software


Who is Altair - solver technology view

Multiphysics Analysis and Optimization

Structural

Analysis

Manufacturing

Simulation

Systems

Simulation Fluid

Dynamics

Thermal

Analysis

Crash, Safety,

Impact & Blast

Electro-

Magnetics

Unique Hyperworks Licensing System


Revolutionary Business Model – Altair Partner Applications (APA)

1. Coustyx by ANSOL

2. DesignLife by nCode

3. DSHplus by FLUIDON

4. FEMFAT by ECS / Magna Powertrain

5. MADYMO by TASS

6. PTB Analytics by SandboxModel

7. SC/Tetra/STREAM by Cradle

8. VMAP by TechPassion

9. FTire by cosin scientific

10. StressCheck by ESRD

11. KEY to METALS

12. RadTherm by ThermoAnalytics

13. OntoNet by Ontonix

14. Amphyon 3D print simulation

15. …..


Why Simulation-Driven Design is a game changer

• Traditional CAD-CAE design too complex & does not lead to fast innovations

• Needs experts – hard to find

• Has too long development cycles

• New manufacturing methods, materials and product requirements need:

• Integration of MDO in an easy to use process

• Optimize: performance, weight, manufacturing, fatigue, costs, materials, …

• Our simulation driven design approach does:

• Integrates optimization from the early design stage

• Brings in intelligent tools also in the cloud

• Is scalable: no super experts required

• Brings efficient product design methods – fast results


Altair Benelux – what to expect ?

• Local presence – start in Hilversum, The Netherlands

• Increased attention to customers – interested to hear your opinion

• Benelux based calendar training in progress (English language)

• Technology seminars & webinars

• Bring our Product Design expertise

• Expansion of Benelux local team foreseen

• Invited to meet me at the booth!

• Contact information:

• [email protected]

• Mobile: +31 6520 73 825

mailto:[email protected]


How Simulation Driven Design Revolutionizes Product Development

Lutz Dobrowohl, application engineer


The Traditional CAD-driven Design Process Simulation too late and process too slow

Result:

CAE not impacting

design as it should

CAD

CAD

CAE CAE

CAD

CAD

Defeaturing

Modeling Results

Time

Design Performance

Maturity

Details


The CAE-driven Design Process Earlier, faster & includes mathematical optimization

Drivers:

Rapid CAE Modeling

Optimization methods

Concept simulation models

Design exploration

Benefits:

Innovation („Design the Difference“)

Shorter time-to-market

CAD

CAD CAE

CAE

CAD

CAE

Previous Design

CAE

Time

Design Performance

Maturity

Details

Optimization


The Evolving Role of CAE From Test Replacement to Design Driver

CAD Test

CAD CAE

CAD CAE

< 1990

< 2010

> 2017


Example: CAD to simulation model (strength/vibration analysis)

CAD CAE

Detailed CAD model Simplified CAE concept model

Traditional

CAE Driven


Example: CAD to simulation model (kinematics)

Highly detailed CAD model Simplified CAE model

Traditional

CAE Driven

CAD CAE


Design the Difference Simulation Driven Design of a Bionic Rocker Arm



© Landwirt Agrarmedien GmbH, Hofgasse 5, A-8011 Graz


Concept Phase: What Are the Loads? Multibody simulation of Rocker Kinematics


Concept Phase: What Are the Loads? Multibody simulation of Rocker Kinematics

Design Space

„Bionic“ design concept from topology optimization


Optimization with interface loads


Structural Redesign Process

Design Space

Design Interpretation Design Assessment

New Structural Concept


Structural Optmimization Theory „The Optimum Solution is Driven by the Constraints“

The more constraints a mathematical optimizer can „understand“ the more relevant the design.

Altair OptiStruct is the optimizer with the largest integrated set of possible design constraints!

Bionic Design 1: Sand cast, optimizer constraint on the

manufacturing process since die

needs to be seperable

Bionic Design 2: Also sand cast, but die was 3D printed,

allowing to create arbitary die shape


Bionic Rocker Arm: Results Lighter, better, cheaper

Previous design:

16 meters of welds!

Bionic design 1 (traditional casting): • Integral part

• 35% costs reduction

• 10% weight reduction

• 250% fatigue performance

Bionic design 2 (cast part with 3D printed mold): • 11% weight reduction

• 75% lead time reduction








Simulation Driven Design of a Injection Molding Tool Design Freedom through 3D Printing

CAE

CAE

CAD

CAE

Previous design:

Topology optimization:

Cooling simulation & optimization:

(Simulation driven) final design:


Komponenten im Analysemodell

• Nozzle side:

• Mold cavity

• Clamping plate

• Ejector side

• Mold cavity

• spacers

• Support pillars

• Clamping plate

Nozzle side

Ejector side


Results of existing tool

Relative displacement < 1/100 mm


Result of optimization


Displacement with optimized shape

• Displacement in optimized shape (iso 0.3)

Relative displacement < 1/100 mm


First interpretation of optimized shape

Nozzle side Ejector side


Original design space vs. Realized shape

• Drastic shortening of tool in z direction

• Some structures from the optimization could not be represented because they interfered with other spatial requirements of cables/water lines


Result of realized design

• displacements


Thermal optimization

• Material data

• Product (PA 6.6):

• Specific thermal capacity: 1675 J/(kg*K)

• Thermal conductivity: 0.3 W/(m*K)

• Tool (MS1-1.2709):

• Specific thermal capacity : 450 J/(kg*K) Thermal conductivity : 20 W/(m*K)

Heated nozzle

permanently induces

energy


Results of thermal analysis

• Temperature distribution after 9s

Original tool Optimized tool

Lower overall

temperature level with

optimized tool


Cooling within product

• Animation of first second after full injection

animated gif


Simulation Driven Design of a Injection Molding Tool Design Freedom through 3D Printing

Structural and Thermal optimized

3D printed injection moulding tools

Faster production cycles due to conformal temperature control (-

25%)

Reduced set-up time, easier handling

Reduced opportunity costs as tool

runs on smaller scale equipment

Weight reduction (75%: 60kg > 15kg)


Why are not More Organizations using Simulation Driven Design Methods?

Need more efficient modeling methods

Easy-to-use best in class optimization

End-to-end simulation processes

source: lifecycleinsights.com


Design Exploration: a Simulation Driven Design Method Simulation Technology enables Design Exploration

“Design exploration is the human-driven, often computer-

assisted, divergent/convergent process used to evolve

and investigate multidisciplinary design space with the

intent of design discovery and to inform decision making

throughout the design process.” Source: BYU, Mechanical Engineering

Varia

nts

Pro

toty

p


Design Exploration Enabler: Rapid Pre Processing Case Study European Aero Engines Manufacturer

Explore design space by simulating

300+ configurations per week and

select best design.

CAD

model Pre

process

Run

analysis

Post

process

Bottleneck Pre Processing:

from 40 min to 1 min per configuration


Summary

• Simulation Driven Design = Optimizing product before

committing to design decisions.

• Use of concept design optimization and design

exploration methods

• Efficient CAE modeling key to success.

• Simplified concept simulation and system models allowing

for easy concept changes.

• The role of CAD is to document the design.

Documents

Design the Difference - EngineersOnline.nl Theo... · Design Exploration: a Simulation Driven Design Method Simulation Technology enables Design Exploration “Design exploration