The Challenge: Remove Weight and Improve Performance
Reducing weight while improving performance is an essential approach in the design and construction of Formula Student vehicles. Both Stuttgart teams, therefore, employed OptiStruct, the finite-element based technology for structural optimization found within the HyperWorks software suite, to optimize their entries and gain equal benefits for two very different cars with similar optimization requirements.
The Rennteam designs, develops and builds a completely new internal-combustion vehicle each year. Some parts are based on former models and optimized each year, while other parts require entirely new designs. The weight of the Rennteam’s 2012 race car was targeted to between 175 and 185 kg.
OptiStruct proved to be the perfect tool for these requirements.
In 2011 the KA-RaceIng team’s major goal was to improve the maintainability of its racing car. To get a better access to the engine and the suspensions, the concept of a hybrid vehicle frame was chosen. The team aimed to combine a tubular steel frame in the rear of the car with a CFK monocoque, thus replacing a pure CFK monocoque solution, which was used in the previous racing season. Since the steel of the tubular frame brings in additional weight, the challenge was to keep the overall weight on the same level while taking advantage of the combined solution in terms of maintainability during the race and low production costs.
• Need to create high fidelity finite element models
from computed tomography (CT) scans
• Geometry input only available in STL format
• Mesh requires cleanup and quality improvements
are necessary in order to achieve accurate results
Challenge: A change in mindset
The use of computerized optimization tools is largely foreign to the field of architecture. Søndergaard observed that the principal reason for this was “conservatism in the architectural industry toward embracing CAE as constitutive design tools,” a reluctance to lose design control to the optimization software.
The Unikabeton project would be one
of the first academic research projects
to address the use of topology optimization in architectural design. The payoff of the team’s experiments could be significant, since CO2 emissions from the production
of concrete produce 5 percent of total
Since their first Australian SAE Student Racing competition in 2000, the Monash Motorsport team has steadily improved the performance of their race car. The results speak for themselves: six consecutive victories in the Australasian competition, a strong performance in the European Formula Student competitions plus a current number 7 world ranking.
This success is based on a strong fundamental engineering understanding, innovative concepts and a passion to perform at the highest level. Recently the students discovered the benefits of combining Altair‘s OptiStruct optimization technology and 3D printing. Based on an initial prototype rear hub design from the 2013 car, the team proceeded to pursue titanium front hubs and uprights to decrease the car’s unsprung mass. This was a tough challenge, since the former design was already made of lightweight aluminum. To tackle this, Monash Motorsport employed Altair’s optimization technology OptiStruct to design and optimize a titanium upright, which was then produced using additive manufacturing technology from CSIRO. As a result, the students were able to reduce the component’s weight by a further 30 percent whilst maintaining the component stiffness and reducing the development time and costs.
Formula SAE is a competition between university student teams, organized by the Society of
Automotive Engineers. Each student team has to design, build, test, and promote a prototype,
which is then evaluated in eight types of tests, ranging from pure performance and design
to advertising and presenting the vehicle. The worldwide competition takes place during
nine official events in four continents. All official events are subject to a single technical and
sporting regulation. The basic idea of the Formula SAE is that a fictional company engages
the team to realize a prototype with characteristics in accordance with the regulation, which
occupies the market segment dedicated to the non-professional races autocross.
One of the competing teams is SquadraCorse, the student team from the Politecnico di Torino,
Italy. In the development of their cars the team applies Altair‘s HyperWorks suite, in particular
HyperMesh for model creation as well as OptiStruct, the finite element solver and optimization
tool of the suite, which helps them to create better and lighter components.
This session will highlight composite modeling in HyperMesh and optimization using OptiStruct. We will focus on ply-based modeling and explore Altair’s three step optimization process. The key aspects that will be covered are ply and laminate creation, freeshape optimization setup to minimize compliance include some manufacturing constraints, size optimization as it applies to ply composite optimization and finally the ply shuffling optimization.
This session will highlight the capabilities of Altair’s award winning solver technology found in OptiStruct. Live demonstrations will feature the Linear Analysis capabilities as well as the multi-disciplinary Optimization capabilities found in this industry leading software. Linear static, modal and buckling analysis as well as topology, topography, size, shape, free size and free shape optimization techniques will be shown.
This session will highlight the Pre and Post processing capabilities of Altair’s flagship products, HyperMesh and HyperView. Attendees will see live demonstrations of the advanced geometry handling, meshing, and universal analysis setup capabilities of HyperMesh and the power and ease of use of the unique post-processing capabilities of HyperView.
The session will be about composite modelling in HyperMesh and optimization using OptiStruct. We will focus on ply-based modelling and explore Altair’s three step optimization process. The key aspects that will be covered are ply and laminate creation, freeshape optimization setup to minimize compliance include some manufacturing constraints, size optimization as it applies to ply composite optimization and finally the ply shuffling optimization.
This session Altair’s senior training specialist, Erik Larson, will highlighting the capabilities of Altair’s award winning solver technology found in OptiStruct. Live demonstrations will show off the Linear Analysis capabilities as well as the multi-disciplinary Optimization capabilities found in this industry leading software. Linear static, modal and buckling analysis as well as topology, topography, size, shape, free size and free shape optimization techniques will be shown.