Simulated Success: Finite Element Methods by Altair

Before manufacturing any structural component of our car, rigorous analytical calculations must be conducted to justify the engineering choices made. However, the equations and theoretical models governing these calculations are inherently simplified and fall dramatically short of capturing the true complexities of real life. This is where the Finite Element Method (FEM) proves invaluable. By leveraging highly advanced numerical techniques, FEM iteratively solves elaborate systems of equations, subsequently providing highly accurate simulations of how structures deform and behave under various loading conditions. 

Altair's powerful suite of products has revolutionised our FEM capabilities, empowering our engineers with high-precision simulations that supplement their data validation techniques and design considerations. Their products boast AI-augmented visualisation tools for 3D modelling that massively enhance computationally intensive calculations. This considerably accelerated our design phase, allowing for the exploration of more complex designs. Altair was particularly transformative in developing our composite monocoque chassis - the core frame of the car, where torsional resistance, structural integrity and weight optimisation are paramount.

Initial simulations were conducted using Altair HyperWorks, whose robust pre- and post-processing capabilities streamlined the validation of analytical calculations, accelerating the development process. The monocoque structure consists of a series of sandwich panels, dictated by classical laminate theory—a domain within solid mechanics that defines the behaviour of composite structures. Composite materials are notoriously challenging to analyse due to their multi-layered configurations, often requiring computationally intensive solutions. However, with the tight timelines of our Europe campaign, such time-intensive calculations were simply not feasible.

To tackle this, we turned to Altair ESAComp, one of the industry’s leading tools for composite analysis. Built on the principles of classical laminate theory, ESAComp is designed to handle multi-ply stack-ups across diverse materials, efficiently producing results for a wide range of initial conditions and load scenarios.

Our monocoque was designed with an aluminium honeycomb core, which is sensitive to minor and unpredictable variations during manufacturing. Despite this, optimal performance was ensured thanks to Altair ESAComp’s extensive capabilities. From the early stages of material selection to determining ply orientation, Altair’s tools facilitated a smooth transition from concept to reality, reducing the uncertainties inherent in composite manufacturing. Notably, ESAComp’s advanced optimisation features allowed us to input physical parameters, such as material properties and ply counts, and receive simulations that bracketed both the lightest and strongest cases. This enabled us to refine our design further, allowing us to strike an optimal balance between weight and structural integrity.

Another critical FEM tool that played an essential role in our design process is topology optimisation. This powerful computational method allows a structure’s geometry to be modified while preserving its structural integrity and performance, thus helping our engineers perfect their designs. The ability to iteratively refine a design for optimal material distribution is key, especially when balancing competing priorities like strength, stiffness, and weight - key considerations when designing carbon wheel shells.

In Formula Student, where every gram counts, ensuring that the wheels are as lightweight as possible without sacrificing mechanical properties is crucial. Topology optimisation enabled us to precisely tailor the wheel structure, removing unnecessary material without compromising on strength or safety. Altair OptiStruct was an invaluable tool on HyperWorks to achieve that goal. What set OptiStruct apart was its unique capability to perform composite topology optimisation - something that no other commercially available software can do. This allowed us to account for the complex layering of plies, ensuring that our wheels performed optimally across a variety of loading conditions.

The use of OptiStruct’s composite topology optimisation not only resulted in lighter, stronger wheels but also drastically reduced the number of iterations required to finalise the design. Without the ability to optimise every aspect of the wheel’s geometry, achieving such a precise balance of performance and weight would have been a much slower and more resource-intensive process.

This year, the bevy of products offered by Altair has been key to the design of Monash Motorsport’s M24. Their services empower us to engineer our wide array of unique components for our car, demonstrating their instrumental support of our team. We would like to thank them for their continued generosity and look forward to future successes.