Challenge
In the season of 2010/2011 the Team Elbforace decided to switch from a combustion engine to an electrical powertrain concept. This brings in additional weight due to the use of accumulators and AC converters. To optimize the race car performance, the design of the remaining components of the car had to be optimized to a minimum weight.

Overview
Since simulation and optimization are growingly becoming more important in the everyday work
life of an engineer, the IFB Stuttgart has been offering a class in lightweight design for several
years, using HyperWorks to teach students all the fundamentals they need to know about FE,
pre- and post-processing, and optimization tasks. This lecture enables the students to design
weight optimized components in a state-of-the-art design process and allows them to gain
experience in the usage of modern CAE tools.

Challenge
In order to predict the structural performance of prostheses, such as artificial knee joints (Fig. 1), engineers perform FE simulations based on ideal CAD models of the implant. In reality, however, various imperfections exist. For example, the manufactured joint can show geometrical deviations, nonhomogeneous
material distribution, internal cavities, inclusions or delamination. To investigate the effect of the imperfections on performance, the manufactured component is scanned in a computer tomograph. In the past, it was very difficult to create high-quality FE meshes based on CT data, because of the size and the level of detail in a CT model. A good FE mesh is needed to obtain accurate results from the simulation

In this video interview, Basti Hennecke from the H2Motion Team (University Munich / Germany) provides some insight in their work with HyperWorks and the collaboration with the Altair Team.

The Challenge: Remove Weight and Improve Performance
Reducing weight while improving performance is an essential approach in the design and construction of Formula Student vehicles. Both Stuttgart teams, therefore, employed OptiStruct, the finite-element based technology for structural optimization found within the HyperWorks software suite, to optimize their entries and gain equal benefits for two very different cars with similar optimization requirements.
The Rennteam designs, develops and builds a completely new internal-combustion vehicle each year. Some parts are based on former models and optimized each year, while other parts require entirely new designs. The weight of the Rennteam’s 2012 race car was targeted to between 175 and 185 kg.
OptiStruct proved to be the perfect tool for these requirements.

Challenge
In 2011 the KA-RaceIng team’s major goal was to improve the maintainability of its racing car. To get a better access to the engine and the suspensions, the concept of a hybrid vehicle frame was chosen. The team aimed to combine a tubular steel frame in the rear of the car with a CFK monocoque, thus replacing a pure CFK monocoque solution, which was used in the previous racing season. Since the steel of the tubular frame brings in additional weight, the challenge was to keep the overall weight on the same level while taking advantage of the combined solution in terms of maintainability during the race and low production costs.

Challenge
• Need to create high fidelity finite element models
from computed tomography (CT) scans
• Geometry input only available in STL format
• Mesh requires cleanup and quality improvements
are necessary in order to achieve accurate results

Challenge
• Need to create high fidelity finite element models
from computed tomography (CT) scans
• Geometry input only available in STL format
• Mesh requires cleanup and quality improvements
are necessary in order to achieve accurate results