Altair Engineering: Maximizing the Efficiency of Nonlinear Analysis at Jaguar Land Rover

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Nonlinear simulation is vital for the development of safe, reliable and profitable products and the engineering teams of major manufacturers like Jaguar Land Rover need fast and efficient resolution solutions to ensure delivery of these high performance products.

Tim Mumford, senior engineer for strength and durability at Jaguar Land Rover (JLR) recently presented his team’s use of Altair® OptiStruct® for the nonlinear analysis of complex automotive products. You can see the full presentation here.

Mumford leads a group called the Sustainability Role within Body CAE (BCAE), which focuses on maintaining product performance and quality under various expected loads on the vehicle. The BCAE team assesses load cases from five main sources: aerodynamic load, lifestyle, hygiene, operating loads, and elevated speed and temperature. From performance driving with high-g turns and potholes to fording in water and towing loads, the BCAE team assesses nearly 1,000 individual load cases in total, considering 300 components held together with approximately 3000 joints, welds, rivets and bolts. With the volume and complexity of their work, the team needs an extremely efficient and repeatable workflow to perform the required nonlinear analyzes.

Joint sustainability assessment

One tactic the Jaguar Land Rover BCAE team has implemented to increase efficiency is to combine multiple load cases into one submission. This unique approach allows them to maximize their resolution efficiency while minimizing modeling and post-processing efforts as well as strain on high-performance computing resources.

In the past, CAE codes evolved with obvious strengths and weaknesses that required manufacturers to perform, for example, dynamic and vibration simulation with different software than that used for contact and plasticity. A major challenge was the silos of expertise this created, as well as the time and effort required to create and convert models to work with multiple tools from different software vendors. OptiStruct offers a unique ability to share models across multiple solver disciplines to enable engineers to take a more holistic approach to problem solving. OptiStruct supports geometric, material and contact nonlinearity, so that a wide range of load cases can be evaluated within a common modeling and simulation framework. A common modeling approach improves the ability to share files between JLR’s engineering teams, improves confidence in the mesh by eliminating unnecessary user rework, and ensures that the model is accurate and constantly up to date.

The efficiency gains of OptiStruct’s workflow can be seen in this elastic plastic palm simulation load example. Land Rover’s rugged product line is known for its capabilities in exotic off-road environments, and JLR performs rigorous testing to ensure the vehicle can withstand unconventional loads such as a person climbing on the roof. from the car, perhaps to get a better view of the African savannah.

This lifestyle load case uses a rod and plate to approximate the pressures that can be applied to the vehicle’s roof panel by someone’s hand. A highly nonlinear geometric load is applied to different areas of the panel to analyze the structural response. This is a particularly complex simulation since the roof panel is moved until it exhibits elastic instability or a dent.

Simulation of elastic plastic palm with nonlinear analysis Altair OptiStruct

Historically, each of these palm simulation load cases had to be done one at a time. In OptiStruct, JLR is able to run multiple simulations sequentially with a single job submission, consuming a single set of licenses and speeding up the delivery of analysis results. Post-processing is also facilitated since all the individual sub-cases are present in a single solver file. OptiStruct also offers continuous or discrete stress histories in a single submission, so the user can choose which sub-cases should depend on the history. This allows the analysis of complex strain-dependent load cases that pass the loading from one sub-case to the next, but still gives engineers the ability to examine independent cases from a strain-free condition unloaded without separate these runs or create a restart event.

With the freedom to use a common model across a range of linear and nonlinear analyzes, and solver features to improve workflow efficiency and solver throughput, OptiStruct helps JLR ensure that components of their vehicles operate to their exacting specifications and deliver the superior quality their customers expect.


You want to know more ?

Below is a series of free webinars demonstrating why manufacturers are switching from non-linear solvers in place to Altair OptiStruct. Through this series, which includes presentations from Jaguar Land Rover and Prodrive, you will learn how to maximize simulation resources, reduce product development time, and save significant costs through nonlinear analysis in OptiStruct.

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Altair Engineering Inc. published this content on July 19, 2021 and is solely responsible for the information it contains. Distributed by Public, unedited and unmodified, on July 19, 2021 04:07:10 PM UTC.


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