Research Report: Simulation-Driven Design for Manufacturing (SDfM) Experiences

Product engineers are under consistent pressure to reduce the costs, improve the quality and increase the throughput of manufacturing processes. This fast-paced environment is not well suited for trial-and-error manufacturing engineering. How are engineers responding to these challenges? Is simulation and simulation-driven design for manufacturing (SDfM) well established across the industry? When simulation is deployed, does it deliver on the promises of reducing costs while improving throughput and quality? And what are the barriers to the adoption of simulation during the early stages of product development? In this 2021 survey report conducted by Engineering.com, we discuss those questions and discover: • Top design priorities • Top benefits of SDfM • Top barriers to expanding and adopting SDfM • Risks to staying competitive in the market

From Product Feasibility to Process Optimization for Metal Forming: Inspire Form

Product engineers are under constant pressure to reduce costs, improve quality and increase the throughput of manufacturing processes. Applying a simulation-driven design for manufacturing (SDfM) approach to product development can help understanding the product manufacturability early in the design cycle, while considering various design alternatives and choosing the best performing, manufacturable design up front. After a brief introduction of the metal forming process, the presentation will explore a typical use case of a sheet metal part - subject to static and dynamic loading – showing how simulation can be very effective in reducing cost for parts redesign and dies modifications, while providing engineers with valuable insights on the manufacturing process and product performance.

Using Altair Software for Manufacturing

Altair offers a unique set of simulation tools to evaluate product feasibility, optimize the manufacturing process, and run virtual try-outs for many traditional, subtractive, and additive manufacturing processes. Users can validate designs early in the manufacturing process with the simplicity and affordability of the simulation software, as well as use optimization technology with specific manufacturing constraints to design better, more efficient products.

Learn more at altair.com/manufacturing-applications.

Optimization-enabled Structural and Multiphysics Analysis

Simulation-driven design powered by topology optimization was created by OptiStruct over two decades ago. Its success has changed the CAE/CAD industry as today all vendors have embraced this trend.

Altair Inspire Form - Sheet Metal Forming Feasibility

Altair Inspire Form is is a complete stamping simulation environment used by product designers and process engineers to optimize designs, simulate robust manufacturing and reduce material costs. With the fast and easy feasibility module, users can analyze parts in seconds to predict formability early in the product development cycle.

Altair Inspire Form - Virtual Stamping Tryout

Altair Inspire Form is is a complete stamping simulation environment used by product designers and process engineers to optimize designs, simulate robust manufacturing and reduce material costs. The tryout module includes a highly scalable incremental solver, helping users to iterate and simulate multi-stage forming, trimming and springback in a modern and intuitive user interface.

Driving Design from Concept to Manufacturing with Inspire

Altair Inspire has rapidly advanced from a topology optimization tool for designers to a design environment spanning industrial design, structural simulation and optimization, motion analysis and manufacturing simulation.

Altair for Manufacturing Applications

Altair offers a unique set of simulation tools to evaluate product feasibility, optimize the manufacturing process, and run virtual try-outs for many traditional, subtractive, and additive manufacturing processes.e

Training - Simulation Driven Design & Manufacturing For Sheetmetal Components Using Altair Inspire Form & Structure

Simulation Driven Design & Manufacturing For Sheetmetal Components Using Altair Inspire Form & Structure

Design for Forming Webinar

Simulation of multi-stage stamping process fully automated and highly scalable without sacrificing accuracy.

Inspire Form 2019 Introduction

In this course, you will have the opportunity to learn about the Inspire Form 2019 interface along with tools and workflows contained within Inspire Form. Modules contained within the course provide detailed descriptions of the tools and workflows within Inspire Form. You will also have the opportunity to watch and perform hands-on exercises within each module.

Altair Inspire Form Helps Pragati Engineering Address Sheet Metal Formability and Inconsistent Thinning Issues While Reducing Physical Try-out Time by 50%

Pragati Engineering, established in 2004, is one of the leading press tool design and manufacturing companies in India. The company has a national reach and successfully carries out projects riding on the robust shoulders of qualified and dynamic engineers from their Design department and Tool Room division. The company’s competency lies in manufacture of Press Tools Fixtures and Panel Checkers for various critical sheet-metal components and assemblies. With new technologies, facilities, and experience in Press Tooling, the company is confident of seamlessly catering to any requirement in the sheet-metal forming segment.

Altair Inspire Form Datasheet

Altair Inspire Form enables users to better design products while reducing lead time by enabling early consideration of formability, process parameters, material utilization, and cost.

Altair Aerospace: Bird Strike and Other Nonlinear Transient Analyses

This webinar covers bird strike analysis on a wing, starting out with model setup, going over the impactor management and ending in the analysis of the results. Another topic to be discussed is the forming simulation of a composite rib and result mapping.

HyperForm 2017 Brochure

Altair HyperForm is an industry proven comprehensive finite-element-based sheet metal forming simulation framework. Its unique process-oriented environment captures the forming process with a suite of highly tailored and configurable analysis and simulation tools to optimize all aspects of stamped products development. HyperForm delivers a cost-effective solution to meet the demands of customers varying from individual analysts, and tool shops, and to large OEMS.

Harita Seating Standardizes on Altair Suite of HyperWorks for all CAE Applications

HyperWorks used by leading Indian manufacturer of seating systems Harita, for homologation testing, regulations and crash analysis for all commercial vehicle seats, bus passenger seats and tractor & off-road seats

Application of HyperWorks to Develop Human Body Models to Assess Injury Potential for Vulnerable Populations in Vehicle Crashes

The effects of obesity on occupant responses in frontal collisions were investigated using the UMTRI whole-body human finite element models. A modeling approach was developed and applied that allowed for rapid change of a baseline human body model into geometries representing adults with different BMIs without the need for re-meshing the models.

Forming Simulation of Woven Composite Fibers and Its Influence on Crash Performance

The automotive industry, in its constant quest for weight reduction, is increasingly considering composite materials as a substitute for sheet metal components to meet future fuel consumption standards. However, composite forming processes are expensive and difficult to control because of the complexity of the material behavior with fiber and matrix layers or plies and its dependency on many parameters, such as non-linearity of tensile stiffness, effect of shear rate, temperature and friction. Hence, numerical simulation could be a viable approach to predict material behavior during composite forming. The objective of this study is to highlight capabilities of RADIOSS™ to simulate forming simulation of composite plies made from woven fibers, each ply modeled as a layer of woven fibers along two directions of anisotropy, warp and weft. For validation the well-known double dome model published in NUMISHEET’05 proceedings is used. The compared result is the shear angle after stamping that is, the final angle between warp and weft fibers, at several prescribed points on the ply. The variation of this angle has a strong impact on material characteristics which severely deteriorates when a critical value is reached. Hence, a study on crash simulations is performed, after mapping fibers angles from stamping simulation.

Failure Criteria for Stamping Analysis in Radioss

In this paper, several failure criteria are compared in their ability to predict necking point and failure propagation during a forming process. The paper has been presented at the 2014 IDDRG Conference in Paris, France.

HBPO GmbH Achieves Flexibility and Cost Efficiency in Automotive Development By Leveraging the APA

HBPO GmbH optimizes their design process by utilizing multiple products, such Total Materia and MADYMO, alongside HyperWorks products for the development of their front end modules.

BiggerBoat Solutions Makes Waves in Auto Industry Using HyperForm to Cut Die Development Costs and Time

When the auto industry crashed in 2008 and the tool shop where Jay Weiner worked closed its operations, he started his own company, called BiggerBoat Solutions Ltd. He carries out metal-forming simulations for major tooling suppliers and originalequipment manufacturers. With 15 years of experience in tooling design, Weiner and his Toronto-based practice offered a service that no one else had perfected but that was crucial to a key process in automotive manufacturing: the simulation-based die design for stamped sheet-metal parts.

HyperWorks improves development processes at PSA Peugeot Citroën

Challenge: Define new process that includes accurate component data
Altair Solution: Use HyperForm and RADIOSS in development process
Benefits:

• Reduce Development Time
• Accelerate Innovation
• Improve Quality and Robustness

HyperWorks Improves Development Processes in Automotive Industry

In 2008 PWO Germany (Progress-Werk Oberkirch AG) had to develop and produce a new steel made automotive cross car beam (CCB) for the dash board of a new car. PWO received the CAD model, the design space definition and other pre-defined standards of the component from the customer and developed and produced the fitting cross beam based on this information. PWO used the HyperWorks Suite to develop the component. HyperMesh was used to transfer the CAD model into a FEA model, which was then used to run dedicated analysis and simulation tasks. To fulfill the requirements for crash and modal analysis, the company used OptiStruct to optimize the component, RADIOSS and other external solver to run the calculations and HyperView for the post processing. HyperForm was used to check the production feasibility of the individual components and for metal forming simulation tasks. It was important for PWO to have a software suite available that could cover all simulation tasks within one graphical user interface and licensing system.

HyperWorks at Wagon Automotive: Speeding Development Time While Cutting Prototype Costs

Wagon Automotive, a system and module supplier of components to major car builders, sought ways to accelerate product development and reduce prototyping costs while maintaining high quality. Adopting the HyperWorks suite of advanced CAE tools enabled the company to achieve both those goals. Wagon Automotive now uses HyperWorks during the entire development cycle, from concept design to optimization.