Optimization shines at NAFEMS World Congress

The breadth and depth of value that design space exploration and design optimization are delivering across manufacturing industry were on display at the NAFEMS World Congress 2015 last week in San Diego. Optimization-focused presentations filled three dedicated conference tracks:

A Novel Topology Optimization Approach for the Design of Hollow Turbine Blades
Kotur Raghavan, Cyient (India)

Composite Materials Multi-Objective Optimization of a Formula One Front Wing
Dimitrios Drougkas, BETA CAE Systems (Greece); George Korbetis, BETA CAE Systems

Composite Structures Optimization Including Non-Linear Analysis, Design, and Manufacturing Considerations
Michael Bruyneel, Siemens PLM Software (Belgium); Stéphane Grihon, Airbus; Leigh Hudson, Siemens; Patrick Morelle, Siemens PLM Software (Belgium)

Design, Analysis and Optimization of Five Bar Mechanism for Realization of Multitudinous Lemniscate Wing Trajectories for Entomopter Applications
Chitra C, Er. Perumal Manimekalai College of Engineering, Hosur; Mallar P, Er. Perumal Manimekalai College of Engineering, Hosur; T H Venkata Nagarjuna, Er. Perumal Manimekalai College of Engineering, Hosur (India); Rodriguez Arthurs S. A, Jawaharlal Nehru Technological University Anantapur (United Kingdom)

Design Exploration and Optimization
Fatma Kocer, Venkat Parameshwaran, Altair Engineering

Design of Advanced Gas Turbines Using Stochastic Methods and Robust Design Principles
Alexander Karl, Rolls-Royce (United States); Zach Grey, Girish Modgil

Enhancement of Multi-Disciplinary Optimization Capabilities through Integration of Materials/Manufacturing-Process Simulation Tools with Structural Analysis Codes
Krishnaswamy Ramachandra, R V College of Engineering (India); Krupashankara M S, R V College Of Engineering, Bangalore, India; Nataraj J R, R V College Of Engineering, Bangalore, India; Patnaik B V A, Ga S Turbine Research Establishment, Bangalore, India; Narendra Babu, Advanced Forming Technologies Centre, Bangalore

Flow Topology Optimization of a Turbo Charger’s Inflow Duct
Jens Iseler, Dassault Systèmes Simulia (Germany); Fabian Huck, Dassault Systemes; Björn Butz, Dassault Systemes

Making the Full Power of Simulation Available to Everyone – At the Confluence of Solution-Specific Web Apps, “Lights-Out” Automation, Design Optimization Tools, and “Infinite, Elastic Computing” on the Cloud
Malcolm Panthaki, Comet Solutions (United States); Glen Steyer, American Axle & Manufacturing; Michael Eckblad, Intel Corp.; Sreevidhya Anandavally, Cosma International (Magna); Raikanta Sahu, Comet Solutions, Inc.; Jean-Claude Mahuet, Comet Solutions, Inc.; Tim Keer, Comet Solutions, Inc.; Michael Tiller, Xogeny (United States)

Model-Based Systems Engineering: Successful Requirements Development, System Design, Process Integration and Design Optimization for Systems Engineering
Sven Kleiner, :em engineering methods (Germany); Marcus Krastel

Multi-Strategy Intelligent Optimization Algorithm for Computationally Expensive CAE Simulations
Zhendan Xue, ESTECO NORTH AMERICA INC (United States); Ching-Hung Chuang, Ford Motor Company; Stefano Costanzo, ESTECO (Italy); Maja Engel, ESTECO S.p.A.; Sumeet Parashar, ESTECO (United Kingdom)

Multidisciplinary Multimodel Design Optimization from an Enterprise perspective
Matteo Nicolich, ESTECO (Italy)

New Possibilities for Durability & NVH Optimizations of Engines by Combining Parameterization & Nonlinear Dynamic FE Analyses
Erich Payer, Evolution OSSP (Austria); Michael Pucher, evolution OSSP GmbH (Austria); Andreas Kainz, evolution OSSP GmbH (Austria); Katharina Payer, evolution OSSP GmbH (Austria)

Nonlinear Topology Optimization for Vehicle Rear Seat Backframe Design
Ohtae Kwon, Hyundai Dymos (Korea, Republic of)

Optimize Additive Manufacturing
Ming Zhou, Altair Engineering

Optimized Design of Heat Exchanger for Recuperative Aero Engine
Shrishail Gudda, CYIENT Limited (India); Ramesh Bandela, CYIENT Limited; Venugopal Dadi, CYIENT Limited; Nagaraju Kanike, CYIENT Ltd

Optimizing Thermomechanical Strength of High-Load Turbochargers
Ekkehard Rieder, Audi AG; Peter A. Klumpp, Audi AG; Michael Werner, Dassault Systèmes Simulia (Germany); Florian Jurecka, Dassault Systèmes Simulia (Germany)

pilOPT – An Efficient One-Click Hybrid Optimization Algorithm
Danilo Di Stefano, ESTECO SpA (Italy); Stefano Costanzo, ESTECO (Italy)

Robust Design Optimization and Operating Maps for Computational Fluid Dynamics
Roland Niemeier, Dynardo (Germany); Thomas Most, Johannes Will, Dynardo GmbH; Stephanie Kunath, Dynardo GmbH (Germany); Johannes Einzinger, ANSYS Germany GmbH

Seat Design for Crash in the Cloud
Fatma Kocer-Poyraz, Altair Engineering (United States); Eric Nelson, Altair Product Design

Shape Optimization for Thermoelastically Induced Warpage Problems
Michael Piniek, Karlsruhe Institute of Technology (Germany)

The Optimization of Semi Medium Bus FMC Ride and Handling Performance Using Analytical Target Cascading
Kwang Chan Ko, Hyundai Motor Company (Korea, Republic of)

Use of Swarm Intelligence for Topology Optimization of Truss Structures with Stochastic Loading Conditions
Marcel Röber, Fraunhofer Institut IWU (Germany); Eric Voigt, Fraunhofer IWU; Marcel Todtermuschke, Fraunhofer IWU

Weld Fatigue Considerations in Structural Optimization
Xiaoming Yu, MSC Software (United States)

Practitioners are invited to join the NAFEMS Optimization Working Group, responsible for promoting the adoption, further development and best practice of optimization theory and methods to engineering simulation for the benefit of the analysis community.

Structural optimization for automotive chassis weight reduction

Figure 1: Ferrari F458 Italia front hood: reference model and new layout from optimization results. The optimization was performed in three stages: topology, topometry and size. (a) Reference model, top view. (b) Reference model, bottom view. (c) Optimum layout. Source: MilleChili Lab

Executive summary—Improvements in design of vehicle structural components are often achieved through trial and error guided by the designer’s know-how. Although the designer’s experience must remain a fundamental element of design, this approach is likely to yield only marginal product enhancements. Design processes can be improved through structural optimization methods linked with finite element analysis. This study of weight reduction in automotive chassis design is based on approaches developed at MilleChili Lab, part of the MilleChili Project created by the University of Modena Engineering Faculty in collaboration with Ferrari to research and design a lightweight automotive chassis for high-performance cars. Continue reading

Weld and adhesive optimization in vehicle body structure development

Executive summary—Passenger-vehicle structural performance is extremely sensitive to welds and adhesive bonds. Traditionally, multidisciplinary optimization (MDO) has been performed largely using thickness, shape and material grade as variables. This project’s objective was to optimize the spot weld count and linear length of adhesives in the body while balancing vehicle structural performance and weight. Various optimization scenarios were carried out: maintain current structural performance but minimize weld count, adhesive length and body weight; maintain current weld count and adhesive length but maximize structural performance and minimize weight; and others. Including welds and adhesives as variables in the MDO process provided additional design space to improve structural performance and reduce cost through spot weld and adhesive minimization. Continue reading

Optimization at ANSYS Automotive Simulation World Congress

automotive-simulation-world-congressOptimization was a theme running throughout the 2015 Automotive Simulation World Congress organized by ANSYS last week in Detroit. We attended sessions on topology, structural, aerodynamic, adjoint, multi-objective and multidisciplinary optimization that ranged across all the conference tracks—Powertrain, Body & Interior, Chassis, Electrification & Electronics. Continue reading

RBF-based aerodynamic optimization of an industrial glider

Figure 1: Taurus glider

Executive summary—Improving the aerodynamic design of an industrial glider flying at Mach 0.08 was the goal of this project: RBF-based aerodynamic optimization of an industrial glider,” Emiliano Costa, D’Appolonia SpA, Rome, Italy; Marco E. Biancolini, Corrado Groth, University of Rome Tor Vergata, Rome, Italy; Ubaldo Cella, Design Methods (www.designmethods.aero), Messina, Italy; Gregor Veble, Matej Andrejasic, Pipistrel d.o.o., Ajdovščina, Slovenia.

The original design exhibited performance-degrading separation in the wing-fuselage junction region at high incidence angles. Using a numerical optimization approach designed to be affordable even with limited HPC resources, the separation was significantly reduced by updating the local geometry of fuselage and fairing while maintaining the wing airfoil unchanged. Shape variations were applied to the glider’s baseline configuration through a mesh morphing technique founded on the mathematical framework of radial basis functions (RBFs). Computational outputs were obtained using a combination of ANSYS DesignXplorer, ANSYS Fluent and RBF Morph software working in the ANSYS Workbench environment. Continue reading

Aerodynamic optimization of a high-speed train

Source: Optimal Solutions Software

The high-speed train market in recently industrialized countries is one of the most hotly contested engineered-product markets in the world, with even the smallest advantage important in gaining a competitive edge. In particular, fuel consumption is a critical factor in design, sales and maintenance of these vehicles. In this project, a manufacturer of high-speed rail vehicles needed to maximize efficiency, reduce emissions and decrease design time.

Seeking a more efficient engineering approach that would let it maximize the number of designs that could be tested within the project schedule, the manufacturer selected Sculptor from Optimal Solutions Software. By specifying key design parameters, the software allows hundreds of designs to be generated in a matter of minutes—a radical improvement over the company’s previous process, in which this phase of the project took months. Continue reading

Multi-objective optimization of a motorcycle composite swing-arm

Motorbike swing-arm. Source: iChrome

Composite materials are rapidly supplanting metals in racing and sport vehicles, providing comparable strength and stiffness at much lower weight. This project was a feasibility study to replace the single-sided swing-arm in MV Agusta’s high-performance F4 1000R and Brutale 990R/1090RR motorcycles, originally made of aluminum alloy, with a new design consisting of resin transfer molding (RTM) carbon composite. Injection-based technologies for long-fiber reinforcement such as RTM have proven particularly effective for motorsport cars and motorbikes. Continue reading

Hull form optimization of a mega-boxer

MSC Danit. Source: DSME

With a capacity of 14,000 TEUs, an overall length of 365.5 meters and a deadweight of 165,517 metric tons, the MSC Danit became the world’s largest container vessel when finished by Korean shipyard Daewoo Shipbuilding & Marine Engineering (DSME). A New Panamax design, the ship offers excellent performance despite its record size. DSME used FRIENDSHIP SYSTEMSCAESES / FRIENDSHIP-Framework (FFW) for variation and optimization of proven parent ships to arrive at a design with maximum performance and efficiency. The final hull displayed less than 50% of the wave resistance of the baseline design. In addition, the hydrodynamic optimization in CAESES/FFW had a favorable effect on propulsion performance. Continue reading

Aerodynamic and structural optimization of a turbofan

Geometry of existing fan. Source: FEA-Opt

Optimizing turbofan designs is challenging because of the need to deal with both aerodynamic and structural performance. While designing a fan with high performance and efficiency is important, strength and reliability of the structure are also critical. Further, integrating parametric CAD, CFD and stress analysis is not a trivial task and usually takes extensive effort.

In this project SmartDO and ANSYS were utilized together to optimize a turbofan. The technical services team at SmartDO’s developer, FEA-Opt Technology, helped the customer build a parametric model with ANSYS DesignModeler, construct the CFX and mechanical analysis block, and integrate SmartDO with ANSYS Workbench. SmartDO was able to increase the mass flow of the fan by almost 14% while slightly reducing the maximum stress under aerodynamic and structural loading. These results showed promising possibilities for further design development. Continue reading

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