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ESTECO VOLTA: the game-changer for SPDM & collaborative Design Optimization

Listen to a 30-minute deep dive into our software solution VOLTA SPDM and explore how to enhance your product performance.

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White paper
Numerical optimization of polymer die design for multiple objective
Research engineers at Dow Chemical were interested in exploring the application of recent advances in engineering optimization using commercial Computer Aided Engineering (CAE) tools for their simulation based design phase. The design of a polymer die, also known as a “coat hanger” die, was chosen as a test case for such an optimization study to improve more than one objective. Polyflow, a commercial Computation Fluid Dynamics (CFD) code, and modeFRONTIER were used to optimize the design of one such coat hanger die. This white paper highlights: how CFD-based optimization can be used to improve the flow uniformity of a coat hanger die while minimizing the pressure drop, how optimal solutions can be identified by increasing the number of geometric parameters that are allowed to change, which are the best algorithms and optimization strategies according with the number of parameters considered.
White paper
Changing tack: moving to collaborative, simulation-led engineering
Imagine if you could examine dozens, hundreds, thousands of design alternatives before committing to a single component. If you could understand the tradeoffs you’re making between weight, shape and capacity? This white paper explores how leading companies are balancing the tradeoffs between components, materials, manufacturing processes and costs to create the optimal product for a particular market niche. Even though physics simulation is still the most frequently used type of optimization, innovators are moving towards agile product development routines. This helps companies make simulation relevant across the enterprise to shape a reliable and effective product innovation framework. Read about how companies like Bombardier, Cummins and Land Rover BAR have been successful in managing the complexity of modeling across multiple domains.
Shroud Design Exploration using PowerFLOW integrated with modeFRONTIER
This webinar, cohosted by ESTECO and EXA Corporation in 2017, presents the successful integration of PowerFLOW simulation technology in the modeFRONTIER workflow to provide Ditch Witch® with valuable insight to guide the shroud design on one of its Vacuum Excavators. Watch it to find out how Ditch Witch® have performed multiple analyses, by integrating EXA's PowerFLOW simulation technology into modeFRONTIER workflow, on their equipment to gain a deep understanding of how key design parameters impact performance and manufacturing costs – critical inputs for next-generation machine designs. AGENDA Overview of EXA and ESTECO Focus on Simulation Driven Design Exploration > how to exploit PowerFLOW simulation software into modeFRONTIER workflow Case study > Explore shroud design options to improve machine performance of a FX65 Vacuum Excavator
Integrating GT-Suite, ANSA, TaiTherm and modeFRONTIER to optimize a muffler heat shield
This webinar hosted by ESTECO, Gamma Technologies, BETA CAE Systems and ThermoAnalytics, presents the successful integration of their technologies in the modeFRONTIER workflow to reduce bumper temperature through coupled simulations for a compact car. Expert engineers from GT-Suite, BETA CAE Systems, ThermoAnalytics and ESTECO will demonstrate the advantages of the integration of their software to reduce bumper temperature in order to prevent car paint peeling. Watch it to find out more about an integrated approach to modify the muffler heat shield properties to reduce bumper temperature by implementing various solvers.
Success story
Lucid Motors boosts electric vehicle performance with modeFRONTIER
Performing multi-objective inverter cooling system optimization with modeFRONTIER California-based electric car company, Lucid Motors, applies innovative engineering, design and technology to define a new class of premium electric vehicle. Their first Lucid Air all-electric sedan, with up to 400 mile range battery options and 1,000 horsepower twin-motor configuration with all-wheel drive, is to be delivered in 2019. In preparation for production, Lucid Air prototypes are undergoing a rigorous development program. modeFRONTIER has been used - together with other applications - to optimize the design of an inverter with the aim of enhancing efficiency and minimize failure rates. ## Challenge An inverter is an electronic device that converts the direct current (DC) stored in the battery into alternating current (AC) and send electricity to the three phases of the AC induction motors. Overheating is the most critical issue beside vibration, humidity and dust when designing a drive inverter for hybrid and pure electric vehicles. Its efficiency is instead driven by low chipto-coolant thermal conductivity together with temperature balance and low pumping pressure. The Lucid Motors team focused on designing an inverter cooling system that keeps the temperature under control. ## Solution Starting from the conceptual design of a cooling channel with different configurations, engineers at Lucid Motors performed different Design of Experiments (DOE) evaluations and sensitivity analysis using a fully-parametric CFD model with modeFRONTIER, which enabled them to find optimal design candidates for temperature reduction, lowering pressure and minimizing channel size. “After deciding on an optimum channel solution, we went further and optimized the manifold design by including a mesh-morphing step in the modeFRONTIER process integration workflow. The objectives there were to keep pressure variations low and reduce velocity variation”, said David Moseley, Director, Powertrain, Lucid Motors. ## Benefits modeFRONTIER provided an environment to identify inverter optimal designs while enhancing efficiency and minimizing failure rates. The use of modeFRONTIER enabled Lucid engineers to make more power available to the inverter and increase alternative current from 1200 to 1500A. The ESTECO Technology also supported the Lucid Air development in optimizing suspension components and enhancing the thermal performance for the motor cooling.
Exploiting Design of Experiments (DOE) techniques for multibody and structural vehicle analysis with modeFRONTIER, Adams and MSC Nastran
In this webinar ESTECO and MSC Software present the successful integration of their technologies to explore and improve design solutions for multibody and structural vehicle analysis. Dynamic behavior of a car in terms of handling, steering and ride is influenced by many vehicle body parameters, which also affects the structural behavior of the system. ADAMS and MSC NASTRAN software can be coupled together with modeFRONTIER multi-disciplinary optimization environment in order to efficiently explore the combination of the design parameters and improve the system design.
Reliability based robust design optimization of a free-fall-life-boat
This webinar, hosted by ESTECO and BETA CAE Systems, focuses on a reliability-based optimization method that statistically increases the safety of free fall lifeboats, which are typically used to evacuate passengers in oil platforms and large transport vessels. Dimitris Drougkas from BETA CAE Systems and Alberto Clarich from ESTECO demonstrate the advantages of the integration of their software in the modeFRONTIER multi-objective design environment for a reliability based optimization of a free fall lifeboat. ANSA software is used to morph the free fall lifeboats mesh by editing its shape and its initial position, and modeFRONTIER is used to automate the simulations performing an optimization under the uncertainties of the operational parameters.
Success story
modeFRONTIER helps Azimut Benetti optimize yacht propeller performance
Using modeFRONTIER to perform multi-objective cavitating propeller optimization Azimut Benetti Group is the world’s largest network producing megayachts and leading private group in the luxury yacht industry. Azimut-Benetti’s R&D Centre develops unique technologies, for an effortless and safe navigating experience. The Naval Architecture and Marine Engineering Unit (DITEN Department) of Genoa University work jointly with DETRA Custom Propellers and Azimut Benetti’s R&D Centre, using modeFRONTIER to optimize the design of a custom propeller for a high- speed Azimut Benetti 95 RPH yacht. ## Challenge The design of a propeller is always a trade-off between competing objectives and constraints: maximizing the propulsion efficiency and ship speed while avoiding cavitation and maintaining a sufficient blade strength. The traditional lifting line / surface methodologies define the propeller shape by including simplified geometric assumptions that make them not suitable for modern fast propellers design. The application of more accurate flow solvers and the automatic investigation, possible through the parametric description of the geometry (unconventional combinations of pitch, camber, or, for instance, local hydrofoil shapes), proves to be a successful design alternative for a high-speed propeller. ## Solution Following this new approach, the optimization of a reference propeller with modified rake distribution was driven by the MOGA-II, the genetic algorithm included in the automation workflow in modeFRONTIER. The experimental data collected at the cavitation tunnel confirmed the reliability of both the Boundary Elements Method and RANSE numerical approaches. A dedicated full-scale sea trials, performed with propellers manufactured by Detra, showed that the cruise speed achieved with the optimized propeller is 1 kn higher than the baseline propeller speed, geometry by while the cavitating behavior was also significantly enhanced. “The result is remarkable, especially keeping in mind that the increase of cruise speed, together with the enhancement of comfort onboard, is crucial to the perception of luxury yacht customers”, said Francesco Serra, R&D Office, Azimut Benetti Group. ## Benefits modeFRONTIER helped build an optimization framework to interact with the parametric description of the geometry to define each new blade shape and employ flow solvers to quantify how each propeller fulfills the constraints and the objectives of the design. “Starting from a set of 48 blade parameters to alter the reference propeller geometry, the use of MOGA-II algorithm allowed to compute and test 50,000 different geometries in about 5 days to achieve a satisfactory Pareto convergence and choose optimal candidates (one for any rake distribution) for RANSE analyses” said Michele Viviani, Associated Professor at DITEN Department, Genoa University.
A CAD-Mesh mixed approach to enhance shape optimization capabilities
In this joint webinar, ESTECO and RBF Morph present an innovative CAD-Mesh mixed approach to enhance shape optimization capabilities. Riccardo Cenni from SACMI describes how engineers at SACMI Ceramic Engineering Department leveraged modeFRONTIER, RBF Morph and ANSYS Workbench to develop an hybrid methodology combining CAD and mesh based approach overtaking the limits of the shape optimization based on the single disciplines. The approach helped find better solutions for the SACMI industrial component analyzed and turns out to be promising for future optimization projects. Agenda: Overview on ESTECO and its technology Overview on RBF Morph and its technology Introduction to SACMI and the engineering challenge Shape optimization: the CAD-based, the Mesh-based and the mixed approach Optimization results and takeaways
Introducing VOLTA part 2 | Democratization
This webinar introduces you to key concepts and provides an overview of VOLTA - the ESTECO platform for SPDM and design optimization - and insights on exploiting enterprise engineering data and managing the entire simulation process. VOLTA acts as the engineering hub, where teams benefit from customizable data structures and fine-grained permissions to ensure efficiency for each role involved. Simulation experts can avoid the burden of managing “work in progress” data with the advanced version control system that traces, organizes and makes all kinds of simulation-related data accessible: from models to library files, methodologies, key results and reports. Watch the video and learn more about the VOLTA concepts: Project, Model, Plan, Evaluator and Session, Folder Based Structure, Dataset and Executed Sessions, Tags, Sharing and Notification System. Click here for the webinar Part 1