1. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Definition of available package space Mesh generation, definition of loads and boundary conditions Setup of optimization problem, definition of design constraints Computation Interpretation of results CAD Design Topology Optimization – Conceptual Design The CAE Driven Design Process

2. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Engine Mount Bracket - Material saving Initial Design Mass: 950g Design Space Design Proposal (1997) Design Mass: -20% 7 Loadcases Objective: Minimize the Mass Stiffness should be the same Annual Cost Savings Weight reduction per part = 0,22 kg Annual Prodution Volume = 200,000 pcs Total Mass Reduction = 44,000 kg Nominal Material Cost = $0.80/kg (1997) Total cost Savings in Material = $35,200/yr Case study – Bracket Redesign

3. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Old Design Altair OptiStruct Proposal New Design Multivan V6 3,2l 173 KW Mass Reduction: 23% Case Study – Bracket Redesign

4. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Design Development Bracket VW Multivan Test Topology Optimization Stress Anal. Des. Adj. CAD Design space Topology Result CADStress check Entwicklung Aggregate, Volkswagen Case Study – Bracket Redesign

5. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Base Design 2.000g Entwicklung Aggregate, Volkswagen New Design 1.550g Mass Reduction 23% << Case Study – Bracket Redesign

6. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Dramatic Increase of Product Performance Reduction of Development Time Case Study - Bracket

7. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Case Study - Topology Optimization Process Design Problem Connector element between door and fuselage Three static load cases Door blocking Emergency opening Hit of damper mechanism on door Optimization Statement Minimize Mass Stress Constrains Methodology Topology Optimization followed by Size&Shape Optimization Fairchild Dornier 728 – door support arm

8. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Analysis of Original Design Meshing of Design Space Export of Geometry with OSSmooth Topology Optimization Determination of Design Space Case Study - Topology Optimization Process Fairchild Dornier 728 – door support arm

9. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Drafting of Design Proposal Analysis of Design Proposal Size&Shape Optimization Export of final Geometry from HyperMesh DVDV Case Study - Topology Optimization Process Fairchild Dornier 728 – door support arm

10. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. -14% Original DesignAfter Topology Optimization After Shape Optimization -19% m = 7.5 kgm = 7.90 kgm = 9.15 kg Case Study - Topology Optimization Process Fairchild Dornier 728 – door support arm

11. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Optimization In The Design Process

12. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. OptiStruct proposal of optimized bead pattern Definition of desired bead dimensions and optimization targets Interpretation of proposed bead pattern Topography Optimization – Conceptual Design

13. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. -10 dB sound emission << Case Study – Topography Optimization Muffler

14. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. “Thanks to OptiStruct, the stiffness of the boiler was significantly improved leading to a accoustically superior heating boiler.” Andreas Schubert CAE Manager VIESMANN GmbH, Germany  Challenge Reduce noise emission of heating boiler Increase stiffness of cover through innovative bead pattern  Solution OptiStruct topography optimization for initial bead pattern layout Shape optimization for further optimization of bead width  Results 20% stiffness improvement 30% reduction of parts (needed to stiffen the old design) Case Study - Reducing Heating Boiler Sound Emission