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Company:

Simusolve Australia

Products:

MSC Apex

Industries:

Automotive

Overview:

Simusolve Australia was tasked with the structural evaluation of the preliminary design of a fabricated “road registered” supercar. The structural system involved various vehicle sub-assemblies, comprised of over 100 individual components made from metallic, carbon composite and elastomeric materials. The data was supplied as a single structured Parasolid assembly file – generated from SolidWorks. Simusolve was required to do internal load and stress surveys, torsion and beaming stiffness assessment, as well as modal response and confirmation of internal load paths.

The assignment was quite challenging due to several factors. First, the sheer scale of the mesh creation activity would have been sufficiently challenging on its own. However, when combined with the need to manage and organise such a large number of components and subassemblies, their structural interfaces and properties, and the problem became even more difficult. Traditional pre-processors struggle to handle problems of this magnitude. In addition, the team needed to make rapid changes to the geometry in order to assess design changes arising from analysis insights.


 
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Company:

Royal Enfield

Products:

Actran
Adams
MSC Nastran

Industries:

Automotive
Noise Pollution

Overview:

Indian motorcycle manufacturer Royal Enfield holds the distinction of being the oldest global motorcycle brand in continuous production. In production since 1901, the company is well known for its iconic Royal Enfield Bullet and other single-cylinder motorcycles.

As part of its growth drive, the company was in the midst of expanding its portfolio across the overseas markets. To achieve this, the company was keen to launch multiple variants of their bikes to cater to newer markets. The company was not only exploring bikes in newer styles, it was also keen to launch bikes across different capacities and price points. At the same time, it was looking to launch bikes in niche categories such as electric bikes.

One of the standout characteristics of Royal Enfield bikes is the distinctive engine noise that its ardent fans swear by. However, newer noise regulations such as Euro 4 R41 and ISO 9028 on pass by noise require that each bike manufacturer needs to meet the standard in order to launch their products into the market.

The iconic engine noise of Royal Enfield is one of its Unique Selling Points (USPs). The challenge therefore was to ensure that the signature sound would remain while meeting the required noise standards. The company needed to find a way to record noise levels for each part of the engine even before the manufacturing process started.


 
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Company:

D. Y. Patil College of Engineering, Pune

Products:

Adams

Industries:

Automotive

Overview:

Team Predators is a student team of D.Y. Patil College of Engineering, Akurdi, that has participated in several national automotive competitions and events since 2009. The team participates regularly in BAJA SAE India and BAJA SAE International competitions and has won several accolades in the past.

The team specializes in single seater All-Terrain Vehicles (ATV) and has been on a quest to manufacture the lightest and most durable All-Terrain Vehicle (ATV).

While preparing for its entry for 2019, the team was facing some challenges with respect to the design of dynamics of the vehicle. The vehicle that the team had showcased in the previous year (2018) was facing an understeering issue, which affected its manoeuvrability. In the year before that, the vehicle that was showcased had a tendency towards excessive rolling, which compromised the stability of the vehicle. This resulted in the driver of the vehicle being underconfident during the 4-hour endurance race of the competition. The team was keen to address all these issues in its 2019 entry.


 
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Company:

Products:

Actran
Actran AeroAcoustics
Actran DGM
Actran SEA
Actran SNGR
Actran VI
Actran VibroAcoustics

Industries:

Aerospace

 
 
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Company:

Products:

Actran
Actran AeroAcoustics
Actran for Trimmed Body
Actran SEA
Actran VI
Actran VibroAcoustics

Industries:

Rail

 
 
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Company:

Products:

Actran
Actran DGM
Actran VI
Actran VibroAcoustics

Industries:

Automotive

 
 
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Company:

Products:

Actran
Actran VI

Industries:

Automotive
Electronics
Rail

 
 
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Company:

HofSpannung Motorsport e.V.

Products:

Adams
Adams Car

Industries:

Automotive
Motorsports

Overview:

More than 380 teams from 36 countries compete in the Formula Student with racecars they developed themselves. The students combine business and technical achievements, theory and practice with the sporting challenge. MSC Software support the Team HofSpannung Motorsport with free licenses for Adams, the standard product for vehicle motion design at all big automotive OEMs.

Team HofSpannung Motorsport e.V. from Hochschule Hof launched their development “Bonnie” in Varano de´ Melegari in the Italian province of Parma. The 40 members team took on company-specific roles and shared tasks like marketing, fundraising and sponsor search, and finance, as well as the actual vehicle development. “By working in this small “company” we were able to directly apply what we learned and gain a significant advantage for our transition into into professional life,” said Frank Meyer, head of suspension and braking system. The 25-year-old mechanical engineering student has been an active member of Hofspannung since 2016. “I particularly enjoy taking on responsibility and making significant contributions to the racecar design.”


 
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Company:

HorsePower Hannover e.V.

Products:

Adams
Adams Car

Industries:

Automotive
Motorsports

Overview:
  • Adjust suspension design of an electric racecar
  • Model validation with the help of test curves
  • Simulate the Formula Student competition test situation

 
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Company:

McMaster University

Products:

Actran

Industries:

Automotive

Overview:

The transportation industry is facing various new technological changes. Among them, the replacement of traditional internal combustion engines by electric powertrains makes new vehicles quieter. Still, new challenges in noise and vibration are rising, in particular during the design of electric motors. In order to develop efficient architectures meeting the expectations both in terms of performance and acoustic comfort, engineers need to access new methods and tools.

Motor design generally starts with the torque as the main purpose of an electric motor is to deliver the required torque at a given speed range. Then, the dimensions of the motor start becoming apparent and efficiency analysis, radial force analysis, structural analysis, and acoustic analysis enter the loop.

“Acoustics analysis should be part of the process and not applied at the end of it” explains Dr. Berker Bilgin, Research Program Manager and Chief Engineer of Canada Excellence Research Chair in Hybrid Powertrain program at McMaster University. If not, it will become difficult to reduce acoustic noise from the motor once the motor design is finalized. Electric motor noise is mainly due to the impact of electromagnetic radial forces (see Figure 1) that excite the stator structure.

Results Validation:

By including Actran in their design process, McMaster researchers developed current control techniques to limit acoustic noise: “Without making any changes in the motor we can actually reduce the acoustic noise just by optimizing the current, because the radial forces are also related to stator excitation, and we experimentally verified drastic noise reduction in switch reluctance motors”, said Dr. Berker Bilgin.

The use of simulation tools has reduced significantly the cost of prototyping and allowed a more advanced analysis of the designed product. Another added value of simulation is of course the attention paid to details thanks to 3D acoustic modelling capabilities. In addition, Actran’s visualization capabilities offer a great possibility for students to train and dig deeper in their research.

In the future, CERC in Hybrid Powertrain team plan on working on how to modify the structural modes without affecting the torque performance of the motor, focusing on current controls of the motors, or modelling the damping ratio of the motor for accurate estimation and reduction of acoustic noise in electric motors.


 
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Company:

Hyundai Motor Company

Products:

Actran

Industries:

Automotive

Overview:

At moderate to high speeds, the only external noises typically generated by electric vehicles are caused by wind resistance or tire noise. As a consequence, electric vehicles present a risk to pedestrians and cyclists, especially those who are visually or hearing impaired or listening to headphones.

Hyundai active pedestrian alerting system Regulations have been issued in both the United States and the European Union requiring that newly manufactured electric vehicles make an audible noise when traveling at low speeds. These regulations have differing requirements for the amplitude and frequency content of the warning sound.

Results Validation:

The simulation results were validated by conducting a 1-volt sine sweep test for both the actual speaker and the simulations. As shown in the figure above, the spectral behavior of sound at 1 meter from the speaker predicted by simulation matches the physical measurements nearly perfectly.

By using Actran to optimize cavity and duct resonances, Hyundai engineers were able to design the speaker to handle low, mid and high frequencies as needed to meet both US and EU regulations while at the same time minimizing speaker size and power consumption. “The simulation results provided by Actran were much more comprehensive than information generated by physical testing, which helped Hyundai engineers quickly iterate to an optimized design in about half the time that would have been required using traditional build and test methods,” Lee said.


 
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Company:

Major automotive OEM

Products:

Digimat

Industries:

Automotive

Overview:

While Sheet Molded Compound (SMC) materials have been widely used in the automotive industry for some time, recently there has been a move to apply SMCs on more structurally demanding components. Though the material has long been considered quasi-isotropic with relative success, it has become apparent in industry that due to the complex manufacturing process, optimal structural design is not possible without considering the real anisotropic nature of the material.. With growing demand from the market, now is the time to leverage advanced SMC modeling capabilities targeting crash performance.

Results Validation:

Static and crash FEA simulations can now attain an excellent level of accuracy in stiffness and can capture peak load and displacement trends for typical part load cases.

The inner seat part illustrates the proposed workflow from process simulation to structural application. The Digimat simulation achieves a much better fit with respect to test data for most load cases, including head impact (puncture) and provide a good indication of hot spot localizations.


 
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Company:

Products:

Simufact Forming

Industries:

 
 
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Company:

Products:

Simufact Forming

Industries:

 
 
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Company:

Products:

Simufact Additive

Industries:

 
 
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