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Introduction To FEA/FEM
EIMA RACE 2014

Product life cycle

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Method to Solve Engineering Problem

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FEA PROCESS
Pre Process
HyperMesh

Modeling
FEM

Creates meshing
Assigning material and element property
Simulation setup (loading and boundary condition)

Solving
Optistruct/Radioss
Post Process
HyperView/HyperGraph
Review results

Visualization

Introduction to Meshing
Discretization

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Introduction to Linear Analysis

Static & Dynamic

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Application in EIMA RACE:

Engine & Chassis - OptiStruct Linear Static to determine the global stiffness
behaviour of the model, this include the global torsion & bending.
- modal analysis, to understand the first mode frequency, to better
understand the dynamic response of the structural before details design &
fabrication.
Crash Box and Anti-Penetration Plate or Full car impact crash Radioss
Block: Front Crash and measure the intrusion. This can be useful for safety
evaluation.
Bodywork & Overhang Frequency response can be implemented here
Concept Design - Solid Thinking Inspire

More infos..
http://www.altairuniversity.com

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Poster Sample for competition

MOHD FAMI BIN ABU

DR. ING. SHAHRUL AZAM ABDULLAH@AB. AZIZ
TITLE : RE-DESIGN REAR KNUCKLE OF PERODUA ECO-CHALLENGE CAR USING TOPOLOGY
OPTIMIZATION ANALYSIS APPROACH
OBJECTIVE
RESULT

To optimize an improved design of the current rear

knuckle used in Perodua Eco Challenge (PEC) car by
reducing the weight or mass of the knuckle, ensuring
a proper way of material distribution, using OptiStruct
without affecting its functional/working conditions.
The optimized design has to meet the requirements
with respect to stress and displacement.

COMPARISON OF EXISTING AND OPTIMIZED DESIGN

EXISTING DESIGN

OPTIMIZATION FLOWCHART

OPTIMIZED DESIGN

CONCLUSION
CAE analysis and optimization tools save development time
and reduce costs in the conceptual design phase for new and
failed parts. Topology optimization has the highest
importance in the development process of all optimization
methods as it works in the very early phase of the design
process.
Application of optimization technique using OptiStruct on
this profile resulted in a weight reduction of 142gram and
maximum stress is 10.5mpa. This show that the new design
is lower in weight and have higher strength.

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GMI German Malaysian Institute (GMI)

Mohd Shafizal B. Mohd Ruslan

Application of FEA method for Sheet Metal Forming through Altair HyperForm
Sheet Metal Forming Effect On Automotive part
METHODOLOGY

ABSTRACT
Sheet metal forming operations are one of the most common technological processs, but still the tool and the process
design is a difficult task. The most frequent defect in sheet metal forming operation is material breakage, wrinkling and
shape defect due to spring back. Numerical simulation aids in evaluating the product manufacturability and predicting the
defect in the early stage, thus minimizing the time and cost for a process development and production (Mangesh
Dagwar,Y.N. Yadav 2005).
This project aims to develop a methodology for accurately predicting and forecast of forming effect in design process to
reduce product variation through Finite Element Method (FEM). Through Altair HyperForm application we can identified
formability effect such as wrinkle, crack or fracture and compare with actual try out.

Determination of
design factor

Geometric
definition (CAD)
Ongoing
Review
Literature

RESULTS and COMPARISON

No.

Final actual tryout

Final virtual tryout

1.

0.19mm

45.2% = 0.18mm

No.

First actual tryout

First virtual tryout

1.

0.29mm

45.2% = 0.27mm

:first virtual formability results

Project material
selection

Model FE Analysis
approach

Cushion pan cad data

Altair HyperForm
Post processing
One step analysis
Die design
Incremental analysis

CONCLUSIONS
From the results, the formability result between actual try out and
virtual try out can be investigate, verified and evaluate before final
modification of the tool geometry.
Some findings of the project are summarized as follows:
1. Element mesh from simulation generates result of crack and
wrinkle that occur at product that can be comparing with actual
try out
2. Greater blank holder force will induce greater stress especially
at the necking radius region and the stress distribution will spread
wider along the metal sheet.
3. An incremental analysis had been done, it show very significant
on to the sheet metal flow whereby it predict base on actual case.
4. Binder force or (BHF) and shoulder radius shall be specially
designed in order to maintain a smooth flow of material to
maintain a good quality of final product.

No

Satisfied/
Objective
achieved?

Yes

Result & Discussion

: final virtual try out

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