Altair Case Studies Imperial Auto's Successful Validation of O-Ring Contact Pressure using Altair OptiStruct™ Solution

	Imperial Auto's Successful Validation of O-Ring Contact Pressure using Altair OptiStruct™ Solution Altair

Imperial Auto's Successful Validation of O-Ring Contact Pressure using Altair OptiStruct™ Solution

Altair

Technology Category	Functional Applications - Manufacturing Execution Systems (MES) Sensors - Level Sensors
Applicable Industries	Automotive Cement
Applicable Functions	Product Research & Development Quality Assurance
Use Cases	Time Sensitive Networking Virtual Prototyping & Product Testing
Services	Hardware Design & Engineering Services Testing & Certification
Challenge	Imperial Auto, a leading manufacturer of ‘Fluid Transmission Products (FTPs), faced a significant challenge in their product design and development processes. The company, which supplies parts to some of the world's most reputed Engine, Automotive, and Off Highway and Farm Equipment OEMs, found it crucial to be innovative in their design processes, particularly in the manufacturing of fluid transmission pipes. The company was struggling to optimize fluid flow and minimize fluid loss. They also needed a secured, predictable, and confirmed process that would generate accurate results in their innovation efforts. One of the major challenges they faced was in the design and building of an assembly component where they had to check the 'O' ring leakage that could withstand required air pressure of 3 kg/ cm2. The team had to build several prototypes to confirm the 'O' ring leakage, a process that was unreliable and time-consuming. Read More
About Customer	Imperial Auto, established in 1969, is one of the world's largest integrated manufacturers of ‘Fluid Transmission Products (FTPs). The company operates eight manufacturing and assembly plants in India and has a strong global presence in their market. Imperial Auto is a key supplier to leading Engine, Automotive, Off Highway and Farm Equipment OEMs worldwide and has multiple overseas warehousing facilities to serve their clients seamlessly. The company is committed to manufacturing world-class quality products and has made significant investments in R&D initiatives. Imperial Auto has a robust workforce of 3000 employees and holds respected quality and environmental certifications such as ISO / TS 16949:2009 and ISO 14001:2004. Read More
Solution	In response to these challenges, Imperial Auto sought a solution that could reduce turnaround time, minimize prototype iterations, and improve design and product quality. After examining several simulation products, the team chose Altair’s HyperWorks, as its features were an exact fit for their needs. The team utilized the meshing capabilities of Altair HyperMesh™ to mesh the model and established contact between the 'O' ring and the pipe and the cylinder bore. They then analyzed the result using the Non-linear Quasi Static analysis method and simulated the physical behavior of the product. In the final stage, the team used Altair HyperView™ to interpret the analysis results in relation to contact requirements. The team also implemented Altair OptiStruct™ for design optimization activities, which helped to reduce design weight. Read More Log in to view content
Contents

Technology Category

Functional Applications - Manufacturing Execution Systems (MES)

Sensors - Level Sensors

Applicable Industries

Automotive

Cement

Applicable Functions

Product Research & Development

Quality Assurance

Use Cases

Time Sensitive Networking

Virtual Prototyping & Product Testing

Services

Hardware Design & Engineering Services

Testing & Certification

Challenge

Imperial Auto, a leading manufacturer of ‘Fluid Transmission Products (FTPs), faced a significant challenge in their product design and development processes. The company, which supplies parts to some of the world's most reputed Engine, Automotive, and Off Highway and Farm Equipment OEMs, found it crucial to be innovative in their design processes, particularly in the manufacturing of fluid transmission pipes. The company was struggling to optimize fluid flow and minimize fluid loss. They also needed a secured, predictable, and confirmed process that would generate accurate results in their innovation efforts. One of the major challenges they faced was in the design and building of an assembly component where they had to check the 'O' ring leakage that could withstand required air pressure of 3 kg/ cm2. The team had to build several prototypes to confirm the 'O' ring leakage, a process that was unreliable and time-consuming.

About Customer

Imperial Auto, established in 1969, is one of the world's largest integrated manufacturers of ‘Fluid Transmission Products (FTPs). The company operates eight manufacturing and assembly plants in India and has a strong global presence in their market. Imperial Auto is a key supplier to leading Engine, Automotive, Off Highway and Farm Equipment OEMs worldwide and has multiple overseas warehousing facilities to serve their clients seamlessly. The company is committed to manufacturing world-class quality products and has made significant investments in R&D initiatives. Imperial Auto has a robust workforce of 3000 employees and holds respected quality and environmental certifications such as ISO / TS 16949:2009 and ISO 14001:2004.

Solution

In response to these challenges, Imperial Auto sought a solution that could reduce turnaround time, minimize prototype iterations, and improve design and product quality. After examining several simulation products, the team chose Altair’s HyperWorks, as its features were an exact fit for their needs. The team utilized the meshing capabilities of Altair HyperMesh™ to mesh the model and established contact between the 'O' ring and the pipe and the cylinder bore. They then analyzed the result using the Non-linear Quasi Static analysis method and simulated the physical behavior of the product. In the final stage, the team used Altair HyperView™ to interpret the analysis results in relation to contact requirements. The team also implemented Altair OptiStruct™ for design optimization activities, which helped to reduce design weight.

Impact #1	The implementation of Altair HyperWorks provided Imperial Auto with a reliable and efficient solution to their challenges. The software enabled the team to interpret results regarding contacts for various parameters and scenarios such as Contact Status, Contact Forces, and Contact Pressure. It also allowed the team to confirm the requirement of the 'O' ring to prevent leakages and ensure that the required air pressures were within the allowable specifications. The use of Altair HyperWorks suite on similar projects has increased the team's enthusiasm to explore more capabilities of the solution. The software acts as a one-stop-shop for their requirements, reducing their prototype count, shortening the iterative process, and reducing the final turnaround time. This has led to increased customer confidence and satisfaction.

Impact #1

The implementation of Altair HyperWorks provided Imperial Auto with a reliable and efficient solution to their challenges. The software enabled the team to interpret results regarding contacts for various parameters and scenarios such as Contact Status, Contact Forces, and Contact Pressure. It also allowed the team to confirm the requirement of the 'O' ring to prevent leakages and ensure that the required air pressures were within the allowable specifications. The use of Altair HyperWorks suite on similar projects has increased the team's enthusiasm to explore more capabilities of the solution. The software acts as a one-stop-shop for their requirements, reducing their prototype count, shortening the iterative process, and reducing the final turnaround time. This has led to increased customer confidence and satisfaction.

Benefit #1	70% reduction in overall product development time
Benefit #2	40-50% savings in product development cost
Benefit #3	Significant reduction in the number of prototypes built to reach the target quality of the product

Benefit #1

70% reduction in overall product development time

Benefit #2

40-50% savings in product development cost

Benefit #3

Significant reduction in the number of prototypes built to reach the target quality of the product

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Overview

Imperial Auto's Successful Validation of O-Ring Contact Pressure using Altair OptiStruct™ Solution

Operational Impact

Quantitative Benefit