Developing Power Keeping JSF Pilots Innovating Better Products Tools with Simulation Cool in the Cockpit with Optimization Tools IDEAS AND STRATEGIES IN PRODUCT DEVELOPMENT NASA Develops Wireless Sensors to Detect Lightning Strike Damage to Composite Aircraft Winter/Spring 2015 | An Publication HyperWorks Unlimited® Fully managed HPC cloud appliances for CAE 1820 E. Big Beaver Road Troy, MI 48083-2031 www.C2Rmagazine.com Editorial Director Beverly Beckert [email protected] Publisher Michael J. Kidder [email protected] Media Services Manager Sam Schulenberg [email protected] Creative Director Cavedweller Studio [email protected] Audience Development Manager Maria Miesik [email protected] Concept To Reality is published semi-annually for Altair Engineering, Inc. by Penton Marketing, a unit of Penton. HyperWorks Unlimited HyperWorks Unlimited Virtual Appliance Physical Appliance 1300 E. 9th Street Cleveland, OH 44114-1503 Subscription Services To subscribe to Concept To Reality, visit www.C2Rmagazine.com/subscribe Send address changes to: Beverly Beckert Penton • Unlimited use of Altair’s HyperWorks CAE suite 1300 E. 9th Street Cleveland, OH 44114-1503 • Pre-packaged, fully-configured, no IT support required • Single pane of glass, secure access to HPC resources © 2015 Altair Engineering, Inc. All rights reserved. • Dynamic scalability to support varying CAE demand All trademarks, company names and • Simulate anywhere – remote modeling, analysis, visualization product names referred to throughout • Value-based, pay-for-use model for small and large enterprises this publication are the properties of their respective companies. All rights reserved. Visit altair.com/cloud to learn more Printed in the U.S.A. about simulating in the cloud with Altair. Innovation Intelligence® Altair_Cloud-C2R_Advert_032017_03.indd 1 3/20/15 3:23 PM Winter/Spring 2015 Contents 12 Features 04 Simulation Powers Development of Professional Power Tools CAE is a core element in developing high-end, long-lasting professional power tools at DeWalt, a Stanley Black & Decker brand. NASA Develops Wireless Sensors to 08 Detect Lightning Strike Damage to Composite Aircraft Computational electromagnetic software enables a team of researchers at NASA’s Langley Research Center to develop wireless resonant sensors that can measure and mitigate lightning strike 04 damage to composite aircraft. 12 Chiller Unit Keeps Joint Strike Fighter Pilots Cool A model-based embedded development system enables AMETEK to design, simulate, create firmware for and validate a chiller unit 08 16 control system. 16 Optimization Technology: Leveraging a Solid Foundation to Innovate Better Products For more than 20 years, steady improvements in the OptiStruct solver platform have enabled users in a range of industries to tackle increasingly complex design challenges. Departments LETTER FROM THE CEO: Ad Index 02 Coupling Topology Optimization with 3D IFC .........................................................................Altair Printing Can Spur Design Innovation 3 ..............................................................solidThinking 3D printing’s symbiosis with topology optimization enables greater creative expression while maintaining structural integrity and 7 ......................................................................FEMFAT performance attributes. 15 ....................................................................... Fluidon IBC .......................................................................Cradle IN THE NEWS BC ..........................................................................Altair 19 Stay up to date on Altair’s latest activities WINTER/SPRING 2015 | CONCEPT TO REALITY | 1 Letter from the CEO Coupling Topology Optimization with 3D Printing Can Spur Design Innovation With today’s rapid advancements in James R. Scapa Over the past 20 years, Altair has pioneered Chairman and CEO, Altair additive manufacturing (commonly known as and globally led the advancement of topology 3D printing), the manufacturing industry is on optimization technology. Delivered through our the cusp of an innovation explosion. This shift OptiStruct® and solidThinking Inspire® software promises to challenge our conventional thinking brands, our technology allows designers and and practices and even revolutionize how we pro- engineers to discover completely new shapes to Wduce products and how we design. meet aggressive packaging, lightweighting and For the design and engineering community, structural performance objectives. 3D printing this will mean fewer and some different creative provides new opportunities to fully explore the limitations inherent with traditional manufac- design space – unconstrained – for even greater turing methods. To fully realize the potential of savings and increased performance. additive manufacturing, a fundamental rethink- For example, a unique capability of 3D print- ing of the development ing lies in its ability to manufacture hollow process is required to take shapes with complex external geometry using advantage of the enormous tiny cells known as lattice structures. OptiStruct 3D printing’s symbiosis with design freedom it offers. now extends topology optimization to assist in Never before has simula- the efficient blending of solid-lattice structures topology optimization enables tion, especially topology with smooth transitional material volume. optimization, been more To enable more efficient data transfer for pro- greater creative expression while relevant to the design duction, Altair is working closely with several community, allowing software and hardware partners – including most maintaining structural integrity and development of the most of the 3D printer equipment manufacturers – to performance attributes. innovative, lightest weight accommodate various requirements of the 3D products of our time. printing process. Forward-thinking com- We invite you to learn more about Altair’s panies have long employed technology to support 3D printing – and how topology optimization to create innovative, light- it can improve design innovation – by visiting weight, and structurally efficient concepts. It is www.altair.com/3Dprinting. To see how the stra- particularly well-suited for use with 3D printing, tegic use of simulation can drive performance, since topology optimization tends to create free- quality and efficiency in product development, form, organic structures that are often difficult to please enjoy the applications shared in this issue construct in their literal form using traditional of Concept To Reality. manufacturing methods. 3D printing offers symbiosis with topology optimization, enabling greater creative expression while maintaining structural integrity and performance attributes. 2 | CONCEPT TO REALITY | WINTER/SPRING 2015 Design for the Freedom of Additive Manufacturing What if you could start your design process with the ideal structural part and then use the freedom of additive manufacturing to make that part a reality? With solidThinking Inspire®, this is now possible. Learn more at solidThinking.com/InspireC2R © 2015 solidThinking, Inc. All Rights Reserved. An Company Design Strategies Simulation Powers Development of Professional Power Tools CAE is a core element in developing high-end, long-lasting professional power tools at DeWalt, a Stanley Black & Decker brand. By Evelyn Gebhardt Since the invention of the firsthand-held power tools more than 100 years ago, the industrial power tool industry has evolved to a very competitive and challenging market. There is a high and increasing demand for long-lasting quality tools offering power, quality and safety. These tools are used under the harshest conditions and are expected to work without any Sperformance loss over years with little maintenance. Global and regional competition to build better tools is very high. Because of the long life cycle of power tools, a short time to market with new advancements is important for brand loyalty and staying ahead of the competition. DeWalt, a Stanley Black & Decker brand, is a leading manu- facturer of industrial/professional power tools with more than 300 power tools and equipment products as well as 1,000 power tool accessories, including corded and cordless drills, saws, hammers, grinders, routers, planers, plate joiners and sanders as well as lasers, generators, compressors, and nailers, among others. DeWalt tools can be found wherever tools are sold, globally. The DeWalt brand has three development sites – one in the United States, one in China and one in Germany. The German development site in Idstein designs, develops and manufactures hammer drills for the DeWalt brand, handling everything from the initial concept to the engineering and the manufacturing. A team of engineers executes the simulation/ computer-aided engineering (CAE) tasks, collaborating closely with the hammer drill design teams at the Idstein facility. CAE Increases Global Competitiveness Eight years ago, the DeWalt engineers took a major step to expand the use of CAE technology within their estab- lished product development process. During the learning and early adoption phases, CAE was not relied upon heav- DeWalt, a Stanley Black & Decker brand, is a leading manufacturer of indus- ily within DeWalt’s mature, proven development cycle. Since trial/professional power tools such as this jackhammer. The company relies on then, staff expertise and organizational confidence have grown CAE technology within its product development