IVECO relies on ESTECO technology to innovate its simulation-driven product development process. IVECO engineers combine the use of CAD and CAE solvers within modeFRONTIER workflow to automatically execute parametric simulations across a wide spectrum of disciplines: structural calculation (crash, durability, strength), fluid dynamics, NVH (Noise, Vibration, Harshness) and vehicle dynamics. On top of the automated simulation process, they apply optimization algorithms to achieve better vehicle designs with increased performance at reduced production costs. ## Challenge The IVECO S-WAY is a complete transport solution which provides excellent life on board conditions to drivers. With a brand-new cab designed to enhance aerodynamic performance and increase fuel efficiency, engineers at IVECO had to completely rethink the suspension system to improve the comfort standard level. In fact, one of the main challenges of the project was to evaluate the cab comfort before the construction of any prototype. Consequently, they made use of multi-body simulation and optimization techniques to verify the overall behavior of the cab by defining the correct set of stiffness and damping parameters for the suspension elastic components. Solution A 3D truck model was generated in MSC Adams/Car to simulate the behavior of mechanical components (cab body, suspension, actuator, tractor and trailer frame) on different proving grounds as pave, patched asphalt and speed bump. The simulation model was directly integrated in modeFRONTIER workflow to automatically tune the suspension properties, with the aim of optimizing output parameters related to vibration, cab movements and comfort. An initial Design of Experiments (DOE) analysis allowed to identify the correlation between design variables and system responses, with the aim of simplifying the multi-body simulation model to be further validated in the optimization process. Finally, the MOGA-II algorithm, available in modeFRONTIER, enabled engineers to pick the right designs with minimized cab vibration on different paths. Benefits “We took advantage of modeFRONTIER software solution to automatically execute a huge number of simulations and evaluate thousands suspension system designs within few weeks. The Parallel Coordinate Chart enabled us to easily plot several variables and visualize the distribution of the designs in an effective manner. The optimization process led us to achieve up to 10% reduction in cab vibration compared to the baseline. Moreover, the results achieved with modeFRONTIER allowed us to identify specific properties of dampers, springs and bushes that have been considered during the prototype phase of the IVECO S-WAY truck development” said Andrea Morello, Performance Engineer and CAE Senior Analyst, IVECO - CNH Industrial.

In today’s Industry 4.0-driven market, companies strive to offer the most competitive and valuable solutions while being efficient and reducing costs. Unlocking the advantages of digital transformation is key to face these challenges. Through production process optimization, manufacturers can improve their decision making process to enhance efficiency and quality, while reducing costs and uncertainty. As a case study, this white paper illustrates how out ESTECO technology helped optimize a computer assembly line by: increasing profitability, total throughput and same-day shipment, minimizing work-in-progress, subject to a maximum allowed limit on staff utilization.

This webinar explains how modeFRONTIER was used to drive CONVERGE in the optimization of a Urea/SCR flapper-type mixer. Meeting NOx (NO + NO2) emissions regulations with aftertreatment system designs that are both effective and economical is critical to successful product performance. The favored approach to satisfying NOx emissions regulations in heavy- and light-duty diesel vehicles is to use a Selective Catalytic Reduction (SCR) device where ammonia catalyzes to reduce NOx. Current industry trends are moving to more compact integrated Urea/SCR systems, which increases the need for an optimum mixer design that may be difficult to achieve with traditional design approaches. ESTECO and Convergent Science during the webinar demonstrate how combining fast and accurate CFD simulation with effective multi-objective optimization of the geometry has the potential to substantially improve the mixer designs and produce high levels of NOx reduction without a substantial backpressure penalty.

This webinar presents the latest features of VOLTA and modeFRONTIER coming with 2019R1. This includes Autonomous Optimization mode, advanced collaborative data intelligence capabilities, new RSM tool and machine learning algorithms. VOLTA platform simplifies the simulation process, enabling teams to concurrently compare, validate and collaboratively decide on design solutions with advanced data intelligence tools. Also, its process automation and optimization driven design technology allows to automate every sort of simulation process, integrate with any solvers, run intelligent algorithms, as well in autonomous mode, and pick the right design. Watch it now to learn more how VOLTA and modeFRONTIER 2019R1 capabilities make the work of engineering design smooth as never before.

Evangelia Despoina Giouri, MSc graduated from the Faculty of Architecture and the Built Environment of Delft University of Technology, used modeFRONTIER to assess the energy performance and thermal comfort towards zero energy high-rise buildings. ## Challenge Currently, 40% of the European Union’s final energy consumption and 36% of greenhouse gas emissions are attributed to buildings. New strategies to design nearly Zero Energy Buildings (nZEBs) are essential to meet climate targets set by the European Energy Performance of Building directive. This research applies process automation and optimization technologies to develop a new integrated simulation methodology to design nZEBs in a Mediterranean climate. This concept has been applied to a high-rise office building featuring photovoltaic panels integrated into the facade walls, located in the hot-dry climate of Athens, Greece. ## Solution The goal is to define which construction parameters have the highest impact on annual energy demand and thermal comfort in the building. The simulation process was created in modeFRONTIER workflow coupling Rhino/Grasshopper modeling environment and EnergyPlus software to simulate energy consumption and daylight illuminance levels. Two optimization runs have been executed to investigate the influence of building parameters that can have a contradictory impact on cooling, lighting, heating energy loads, and four different facade orientations. ## Benefits The genetic algorithm NSGA-II allowed performing 1000 evaluations in order to find the trade-off solutions for several design issues affecting energy performance and thermal comfort levels. “We were able to achieve 33% reduction on annual building’s energy consumption (from 109.12 kWh/m2 to 73.13 kWh/m2) compared to standard data provided by the current Greek legislation. Moreover, modeFRONTIER engineering and data intelligence capabilities enable us to visualize optimization trends and perform sensitivity analysis to assess the impact of the various facade parameters on the energy use and adaptive thermal comfort performance of the building” said Evangelia Despoina Giouri, MSc graduated from the Faculty of Architecture and the Built Environment of Delft University of Technology.

Takenaka Corporation offers comprehensive services worldwide across the entire spectrum of space creation from site location and planning to design and construction as well as building maintenance. Recently, structural engineers and computational architects at Takenaka Corporation Technical Research Institute have started to apply an optimization-driven design approach in their architectural and engineering projects with the aim of exploring and obtaining innovative design solutions in a shorter time. They chose modeFRONTIER software to optimize the 3D model of a new complex-shaped office building in Osaka, Japan. ## Challenge Responding to a request of a client - a steel manufacturer - asking for a new office building featuring their fabrication technologies, Takenaka Corporation designed a steel pavilion-like office building which also facilitates and accelerates the communication between employees. Several requirements were considered to perform parametric studies on 3D building models: from maximizing the connections between rooms and expanding office space to designing a stunning atrium. Facing these challenges by manually conducting simulations is quite time-consuming, leading to delays in project schedules. Architects at Takenaka Corporation look at multi-objective optimization as an effective methodology to quickly generate creative and innovative designs while meeting client’s expectations ## Solution The shape of the building was generated through the 3D Voronoi component available in Rhino3D/Grasshopper. The 3D geometry was integrated in modeFRONTIER workflow to automatically adjust the Voronoi parameters and slab levels, with the aim of optimizing conflicting outputs of the model (area of rooms, floor heights, connection between rooms, angle of surfaces) while also considering required room area and floor height as constraints. After performing an initial Design of Experiments (DOE) to assess the correlation between slab levels and other parameters, the optimization process was guided by the pilOPT algorithm available in modeFRONTIER to maximize the connection between rooms, minimize the sharp angle surfaces of office area and maximize the sharp angle surface of the hall. ## Benefits “With modeFRONTIER, we run and evaluate 3000 designs in just one day instead of losing weeks doing it manually. Moreover, the easy to use interface and data analysis & visualization tools enabled our designers to process the results faster and select their favorite designs for further studies. Finally, we look forward to demonstrating the potential of combining modeFRONTIER workflow with BRAIN, our in-house structural design software that we use in most of our projects” said Takuma Kawakami, Structural Engineer and Computational Architect at Takenaka Corporation.

This webinar presents the successful integration of aPriori cost data technology in the modeFRONTIER workflow in order to investigate a wide selection of manufacturing options quickly. Manufacturing cost is a critical component to finding the best possible design when completing engineering optimization. This webinar demonstrates how to leverage modeFRONTIER capabilities to coordinate a parametric optimization that includes all the performance requirements plus manufacturing cost with aPriori. Watch it now to learn how: Automate your costing activities in engineering workflows Find multiple design alternatives meeting performance and cost targets Select the best alternative from the set for moving forward Compare the old and new design to understand the overall savings Find the best cost decision throughout the design process

Guaranteeing effective signalt ransmission with modeFRONTIER Antenna design relies on understanding of directivity, impedance matching, radiation efficiency, wave polarization, frequency range and orientation specifications. These imply complex electromagnetic simulation analysis which can be executed by employing computer-aided optimization techniques instead of opting for time-consuming trial and error approach. ## Challenge The present study focuses on optimizing the shape parameters of a GSM dual band mobile phone antenna to guarantee effective transmission and reception while reducing the loss of power in the signal returned at specific frequencies. The optimization case requires the satisfaction of multiple criteria at the same time. It is necessary both to minimize the return loss amplitude of the signal and the difference of the tuning frequencies at 920 and 1860Mhz. ## Solution The geometrical structure of the antenna was modeled in Catia V5 by setting four parameters (cut position, cut width, scale ratio and antenna thickness). Then, the model was imported in CST Microwave Studio to perform accurate analysis of high frequency range. modeFRONTIER has been used to automate the entire process by integrating the CAD model in the workflow and running electromagnetic simulations. The optimization task was driven by the pilOPT algorithm which evaluated different antenna design configurations with the purpose of minimizing signal return loss and tuning the frequencies. ## Benefits pilOPT algorithm reached optimum solutions after few design simulations. The execution of the algorithm in autonomous mode allowed to obtain the best signals of the perfectly tuned antenna just with 100 simulations performed in few hours. This methodology may be extended to any component of an electronic system (including geometrical, material and operating parameters ).

This webinar presents an overview of the EXPEDITE Program and the role ESTECO technology will play in order to advance Multi-disciplinary Analysis and Design Optimization (MADO). In 2017 Lockheed Martin Aeronautics Advanced Development Programs (ADP - The Skunk Works) was the winner of the US Air Force Research Laboratories (AFRL) Multi-Disciplinary Science and Technology Center EXPEDITE program. EXPEDITE (EXPanded MDO for Effectiveness Based DesIgn TEchnologies) is a successful program by AFRL seeking to advance the state-of-the-art of Multi-disciplinary Analysis and Design Optimization (MADO) as applied to US Air Force programs. For EXPEDITE the primary thrusts for the program include path and state-dependent design to capture discipline transients, HPC and higher fidelity physics to support Uncertainty Quantification (UQ), and expanding conceptual design down through Operational Analysis to support Effectiveness Based Design. Watch the webinar to learn more about EXPEDITE program, ESTECO’s role in achieving the AFRL objectives, and progress to date (July 2018).

Aerodynamic performance enhanced by 2.5% and wing weight reduced by 4% In an ambitious collaborative venture, Leonardo is heading the Green Regional Aircraft (GRA) design team of the The Clean Sky Joint Technology Initiative, committed to developing environmentally-friendly aircraft. The future of domestic air travel lies in: weight reduction, aerodynamic efficiency, high level operational performance, compliance with emission standards and respect of noise limits. ## Challenge Targeting multiple objectives such as lowering aircraft drag, wing weight and environmental impact of lower speed conditions (i.e. take-off and landing), enhances overall environmental performance, measured by fuel consumption and noise generation. Seeking the most promising solution for this new generation aircraft, two wing shapes were studied using modeFRONTIER optimization. A “thin” configuration was selected to analyze aerodynamic performance, without any structural restrictions to airfoil thickness; a “thick” configuration was chosen reduce the weight of the wing. ## Solution modeFRONTIER integrated complex objectives, achieving remarkable enhancement for both wing configurations, while still complying with Top Level Aircraft Requirements (TLAR). The design automation process piloted by the modeFRONTIER workflow generated 20,000 design profiles of the 2D wing shape, while incorporating aerodynamic and structural analysis using Leonardo in-house codes. Once the optimal 2D profile was selected, CFD computations were validated by employing a suitable parametric Catia 3D wing-body. Good aerodynamic results were maintained in the 3D analysis. ## Benefits “modeFRONTIER has proven to be an effective tool for the design team, identifying feasible solutions and achieving a 2.5% enhancement of aerodynamic performance and a 4% wing weight reduction”, says Enrica Marentino, CFD Specialist at Leonardo. modeFRONTIER successfully streamlined the two-step optimization process for wing shape configuration and its multi-objective genetic algorithm (MOGA-II) was profitably used to solve the optimization problem. Correlations among the aerodynamic parameters were explored thanks to modeFRONTIER statistical tools, providing deep insights which helped set up the optimization strategy effectively. The MCDM tool provided a useful framework towards attaining a ranking for the Pareto front solutions, supporting the design team in determining the best outcome. “The optimized configurations, while still matching TLAR requirements, determined substantial advantages compared to the initial wing profiles”, says Enrica Marentino.