Reducing Performance Variability & Improve Design Robustness through Simulation and Optimization
On-Demand Recordings
Virtual Product Development via Physics-Based Simulation
Presenter: KK Choi - Managing Member, RAMDO Solutions
Duration: 13 minutes
As manufacturers face demands for faster time-to-market, higher quality, and cost-effective design, they started adopting Virtual Product Development (VPD) using physics-based simulation tools and avoid the build–test–redesign–retest cycle. The benefits of VPD are palpable, with reduced development costs, significantly fewer physical prototypes, and drastically shortened development schedules. Highly powerful CAE (FEA, CFD, MBD, Durability, Acoustics, etc.), CAD, CAM and Optimization Software make realization of VPD possible. However, to develop an effective VPD, the physics-based simulation model needs to be statistically validated (V&V) so they can represent the physical system well.
Delivering Off-Road Mobility for the U.S. Soldier
Presenter: Dr. David J. Gorsich - Chief Scientist, U.S. Army Ground Vehicle Systems
Duration: 16 minutes
The ability of a ground force to maneuver has always been critical to determining success or defeat on the battlefield. On the future battlefield, mobility will remain essential with predictive intelligence central to mission completion. At present, mobility models are not terribly precise, as mobility depends on a large number of interdependent variables, like soil characteristics, moisture, temperature, vehicle characteristics, and with large amounts of uncertainty. The convergence of better ways to measure the key parameters either directly or remotely coupled with the increase in computational power and advanced vehicle design is bringing the promise of more accurate terrain and mobility models. Imagine a battlespace where we could accurately advise our forces where it is possible and not possible to maneuver, while the adversary does not have such an advantage. Dr. Gorsich describes the GVSC’s current programs to deliver an operational model and insights into future terrain mobility models.
Robustness Optimization of Welded Structure for Minimized Mass and Target Fatigue Life
Presenter: Petteri Kokkonen - Senior Scientist, VTT Technical Research Centre of Finland Ltd.
Duration: 14 minutes
There is increasing need to reduce CO2 emissions and energy consumption, rising motivation for light weight design of load carrying structures of vehicles. However, as the structures are designed lighter, the stresses and risk of fatigue at welds tend to increase. Fatigue of welds is sensitive to variation of manufacturing quality. In this presentation, the effect of misalignment of welds on the fatigue life of an example steel structure is studied together with minimization of the structural mass. This is done using robustness optimization by RAMDO software. The robustness optimization enables minimizing the mass of the structure and still achieving the target reliability for the fatigue life. Local detailed weld FE-model is coupled with coarse shell element model of the structure, and the coupled FE-models are used in the optimization. Two ten piece series of welded structures were manufactured, from which the distributions of misalignments were estimated after dimensional measurements by a coordinate measuring machine (CMM).
Design Optimization & Lightweighting: Considering Uncertainties for Marine Applications
Presenter: Hyun-Seok Kim - Senior Researcher, Korea Research Institute of Ships & Ocean Engineering (KRISO)
Duration: 12 minutes
Reducing weight through design optimization can be another way to deal with global warming since it could reduce greenhouse gas emission. However, uncertainty can have a decisive effect on reliability and safety of a structure when the design is near-optimal or optimal. In this presentation, we will introduce how to consider uncertainties from environmental (wave, wind, current) loads, material properties, and manufacturing process in marine applications using RAMDO to obtain a reliable and light weighted design.
Achieving better Vehicle NVH performance using MSA and RBDO methods
Presenter: Peter Benzie - Senior Technical Specialist NVH, Altair
Duration: 15 minutes
In the context of NVH vehicle development, a common source of costly design change is where issues are discovered late in a program during vehicle testing or even post launch. Often this occurs where the simulation has met the targets including vehicle level analysis. By considering a population of results rather than the nominal CAE result, a process is demonstrated to develop a more reliable design that will deliver high levels of customer satisfaction and lower levels of late change and warranty costs. In this presentation we will introduce how this can be achieved through the use of MSA and RBDO methods within the framework of Altair’s NVH Director environment.
Design for Variability: Possibilities and Challenges
Presenter: Jianmin Guan - Sr. Director, Vibration and Acoustics Solutions, Altair
Duration: 12 minutes
A brief overview of successful applications of variability simulation techniques in achieving better product designs, and discuss challenges in taking design for variability to the next level.