1. Innovation Intelligence®
Multi-body Simulation Workshop
Cinco de Mayo, 2015
Keshav Sundaresh

2. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
2
Agenda
11:00 – 11:10 Introduction
11:10 – 11:30 Altair Multi-body Solution for the Automotive Industry:
Vision & Roadmap
11:30 – 11:50 3D contacts For Automotive Applications
11:50 – 12:10 Technical Overview – MotionSolve For Auto Chassis,
Body & Components
12:10 – 12:30 Automotive Bushing Solution
12:30 – 01:15 Hands-on Session (Room 106) | Live Demo
01:15 – 01:30 Interactive Session, Summary & Conclusion

3. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
3
MotionSolve In the Automotive Industry
• Chassis Solutions
• Body Solutions
• Components
• Conclusion

4. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
4
Chassis: Suspension Design
Model:
Built-in vehicle library supporting many vehicle
components and front & rear suspensions
Solve:
Full set of K&C events
User-defined events
Evaluate:
Automated Suspension Design Factors report
Automated plotting and animation
Improve:
HyperStudy for system DOE & Optimization
ESLM for component optimization (OptiStruct)
GM, Chrysler, US Army (TARDEC), Volvo, Tesla, Mahindra, Chery, Geely

5. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
5
Chassis: Vehicle Dynamics
Model:
Easily assemble full vehicles using
wizard. Full support for many driver,
road &tire models
Solve:
Full set of industry standard open- &
closed-loop handling events
Evaluate:
Automated calculation of metrics
Easy plotting and animation
Improve:
HyperStudy for DOE & Optimization
GM, Chrysler, Volvo, Tesla, Mahindra, Chery, Geely, Metalsa
Image credit: Bremar Auto

6. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
6
Chassis: Vehicle Components
GUI for easy creation & modification
Property files for component data
A/Car property file compatibility
(Tiem Orbit)
Unit conversion of property file data
to model units
Entity Function
Bushing Elastically mount suspension arms, links,
sub-frames, engines, gearboxes, etc. to
vehicle chassis
Bump-stop Limit suspension bump or jounce travel
Damper Dissipate energy stored in springs and
damp chassis motions.
Rebound-stop Limit suspension rebound travel
Spring Limit forces in suspension components
and isolate chassis by absorbing energy
from vertical road inputs
Tire Generate forces for steering,
accelerating, and braking. Isolate the
vehicle from small road irregularities

7. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
7
Chassis: Tire Models Supported In MotionSolve
MotionSolve also supports user defined tire models via TYDEX STI
Author Model Application
MF-Tyre Handling
FTIRE Ride/Durability
CD-TIRE Handling/Ride/Durability
MF-SWIFT Ride

8. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
8
Chassis: Durability
Model:
Enhance chassis models with flex bodies, rough
roads, hi-fidelity tires, “realistic” bushings and
dampers (co-simulation with Simulink)
Solve:
Complete set of road loads for all components
Automated utility to map MBD loads to FE
Evaluate:
Examine stress history, identify hot spots
Compute fatigue life
Improve:
HyperStudy for system DOE & Optimization
ESLM for component optimization
Toyota, Honda, Hyundai, MAN, FDTE, DANA, TATA Daewoo, Ducati,
Piaggio, Mahindra, Bajaj

9. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
9
Chassis: Road Models Supported In MotionSolve
Road Type Supplier Works with:
2D
Flat,
Sinusoidal,
etc.,
COSIN HTire & FTire
3D - RGR
Rectangular
Grid
COSIN FTire
3D-RSM
Road Surface
Model
Fraunhofer CDTire
3D - CRG
Curved
Regular Grid
Opencrg.org
MF-Tyre,
MF-Swift,
CDTire, FTire
User Written
Road
(Subroutine)
User Defined User All Tires
Point Contact Line Contact Brush Contact
WIP: Road Builder

10. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
10
Chassis: Driver Models – Precise & Repeatable
• Steer a vehicle to follow a path
• Accelerate/Brake to match speed
• Shift gears
• Switch controller action mid-
simulation
• Follow script like an actual driver

11. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
11
Comprehensive Bushing Solution – Altair Bushing
The Universal Bushing Model. Co-developed with BMW & Honda
F
Rubber Damping
Hydromount Damping
Spline
Stiffness
Cubic
Stiffness
Constant
Stiffness
Constant
Damping

12. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
12
Powertrain For Full Vehicle Simulation
Vehicle Model
SteeringBrake
Throttle
Gear
Clutch
Driver Gear BoxPower Train
Clutch
Torque
Trans
Speed
Torque at
Differential
Differential
Rotation speed

13. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
13
MotionSolve In the Automotive Industry
• Chassis Solutions
• Body Solutions
• Components
• Conclusion

14. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
14
Body: Closures
Model:
Build model in MotionView
Transfer components from HyperMesh
Solve:
Full non-linear time domain solution
30X faster compared to competition (FE Explicit)
Evaluate:
Examine stress history, identify hot spots
Compute fatigue life
Improve:
Unique Multi-body system level optimization using
Equivalent Static Load Method in OptiStruct.
HyperStudy for system DOE & Optimization
Toyota, GM, Ford India, JLR, Volvo India, Mahindra, EMBD Italy, Daewoo
Bus Corp, Amsted Maxion, etc…
Simulations on your laptop!
No HPC required.

15. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
15
Body: Seating Systems
Model:
Build model in MotionView. Include Higher pair
constraints such as Point-to-Deformable Curve,
Point-to-Curve,…
Solve:
Full non-linear time domain solution
Kinematic or dynamic
Evaluate:
Automated repositioning of seats
Improve:
Unique Multi-body system level optimization using
Equivalent Static Load Method in OptiStruct.
HyperStudy for system level DOE & Optimization
Jamco, B/E Aerospace, JCI, CRH

16. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
16
MotionSolve In the Automotive Industry
• Chassis Solutions
• Body Solutions
• Components
• Conclusion

17. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
17
Components: Brake Noise
Model:
All components deformable
Friction and stiction at contacts
Solve:
Full non-linear time domain solution
Evaluate:
Examine brake moan, groan and low frequency squeal effects
10 100 500 1k 3-4k 10k
forcedself-excited
Frequency [Hz]
Low frequency Effects
High
frequency
Effects
Squeal
Squeal
Judder
Moan
Groan
…
…

18. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
18
Agenda
• Currently available Altair tools
• Case Studies
• Conclusion

19. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
19
Conclusion
• MotionSolve has a well developed automotive solution
• Many large automotive OEMs successfully use MotionSolve today
• AltairPD will help you with customizing and deploying solutions
• Altair has an aggressive plan for continuing to improve its MBD
capabilities
The Best Technology
+
The Best User Experience
MotionSolve =