Optimization 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.
Internal Combustion Engine Design and Optimization with Integrated Multiphysics, Multidisciplinary Simulations, a presentation by Laz Foley of ANSYS, highlighted various engineering workflows used in design and optimization of combustion engine components, subsystems and systems. A series of use cases explored how these workflows and associated processes reflect the diversity in physics disciplines, user personas, user expertise and simulation tools that need to work together in an integrated engineering CAE platform.
In Multi-Objective Optimization for Cross Flow Heat Exchanger Design, Apurva Gokhale of ESTECO demonstrated formal, multi-objective engineering optimization for heat exchanger design using ANSYS Fluent and other commercial optimization software including modeFRONTIER. The session showed how problem setup involving both geometry and process parameters is tricky and requires effective formulation and strategy selection.
External Aerodynamic Optimization Using ANSYS Mesh Morphing, a session by Marco Evangelos Biancolini of the University of Rome Tor Vergata, looked at how aerodynamics development requires the exploration of many shape variations, and thus a highly reliable and fully automated workflow using HPC is needed. The presentation showed how mesh morphing can be used to make the ANSYS CFD model parametric, and how the ANSYS DesignXplorer optimizer can be used to automate the calculation.
In GTAM—GENESIS Topology for ANSYS Mechanical, Hong Dong of Vanderplaats R&D presented GTAM, an integrated extension that adds topology optimization to the ANSYS environment. The extension lets users set up the topology problem, optimize it, post-process and export the optimized geometry, all within the ANSYS environment. The presentation demonstrated how GTAM topology optimization can be applied to multiple analysis systems including static, modal, linear buckling, harmonic and random vibrations.
Structural Optimization Using the New RBF Morph ANSYS ACT Extension, by Marco Evangelos Biancolini—author and owner of the RBF Morph software, in addition to his university position—showed how mesh morphing allows quick exploration of many shape variations in a short time, and demonstrated shape modifications using mesh morphing with full automation using ANSYS ACT technology in the ANSYS Workbench environment.
In CAD and CAE Needs for Optimized 3D Printed Designs, Andreas Vlahinos of Advanced Engineering Solutions provided an overview of Additive Layer Manufacturing (ALM) techniques, and showed how today’s topology optimization tools do not provide the necessary solutions for ALM design. A list of topology optimization enhancements required to reach the full potential of ALM was discussed, with a focus on ANSYS SpaceClaim 3D printing capabilities.
Design Optimization of Vehicle Exhaust Mufflers Using ANSYS, by John Cherng of the University of Michigan, discussed development of an efficient method to optimize the transmission loss of a vehicle exhaust muffler. The sensitivity study included perforated hole variations, partition variations and absorption material insertion.
In Advances in Adjoint Methods, Zheming Zhang and Chris Hill of ANSYS explored the Adjoint Solver as a tool for optimization of aerodynamics and design of thermal management systems. The talk reviewed the tool’s improved usability and greater ability to handle large calculations; new tools to aid in multi-objective design in the presence of constraints, and for the exploration of what-if scenarios; and the systematic improvement of designs through mesh morphing.
Finite Element-Based Computationally Efficient Scalable Electric Machine Model Suitable for Electrified Powertrain Simulation and Optimization, by Kan Zhou of the University of Michigan, explored how computationally efficient models for electric machines are essential for design, simulation and optimization of electric/hybrid electric vehicle (EV/HEV) powertrains. The presentation demonstrated an ANSYS finite-element-based method for quickly generating torque-speed curves and efficiency maps for electric machines.