Altair Case Studies RIMAC Automobili: Leveraging Simulation for Structural Design of Innovative Hypercar

	RIMAC Automobili: Leveraging Simulation for Structural Design of Innovative Hypercar Altair

RIMAC Automobili: Leveraging Simulation for Structural Design of Innovative Hypercar

Altair

Technology Category	Analytics & Modeling - Digital Twin / Simulation Robots - Autonomous Guided Vehicles (AGV)
Applicable Industries	Automotive Construction & Infrastructure
Applicable Functions	Product Research & Development Quality Assurance
Use Cases	Structural Health Monitoring Vehicle Performance Monitoring
Services	Testing & Certification
Challenge	Rimac Automobili, a leading developer and manufacturer of electrification systems for global automotive companies, faced a significant challenge in the structural design of the monocoque for the Rimac C-Two, the largest single carbon fiber part in the automotive industry. The main challenge was the material, a lightweight, carbon fiber reinforced with epoxy resin. As this carbon fiber is an orthotropic and brittle material, its representation in a finite element (FE) material card is very difficult. One of the most important parameters in designing EV is weight. The lighter the vehicle, the more increase in vehicle range which can lead to a higher acceptance of EV. Following a lightweight approach in the development process of their concept hypercar C_Two, the Rimac engineers were tasked to design the monocoque as a single carbon fiber part with an unprecedented size. Read More
About Customer	Rimac Automobili is a technology company that develops and manufactures key electrification systems for global automotive companies. Founded in 2011 by CEO Mate Rimac, the company has an impressive list of clients ranging from automotive OEMs, tier one suppliers, and emerging players. In addition to providing innovative electric vehicle (EV) technology that meets environmental and safety regulations, Rimac has recently introduced a second generation of its own electric hypercar – Rimac C_Two. The company is headquartered on the outskirts of Zagreb, Croatia, and employs more than 600 people. Rimac’s development departments include eight structural CAE engineers who work with HyperWorks to support the structural design of the car. Read More
Solution	To overcome this structural challenge, Rimac engineers utilized Altair HyperWorks. The goal was to achieve the closest correlation between real and virtual testing to minimize failure. The development process began with the part proposal and based on the results of the simulations run, the CAE team developed a proposal with design engineers. The model was then updated and tested again at each component level until the team saw perfect correlation between simulations and physical performance to achieve a design that performed as expected. The simulations performed by the vehicle engineering CAE design team involved 123 load cases. This was at component, system, and vehicle level, as well as linear, non-linear, static and dynamics simulations. The time frame for the whole development project was 5 months. In addition to providing software licenses and specialist support, Altair introduced HyperWorks Unlimited virtual appliance (HWUL-VA), which is part of the Altair innovative cloud offer. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Robots - Autonomous Guided Vehicles (AGV)

Applicable Industries

Automotive

Construction & Infrastructure

Applicable Functions

Product Research & Development

Quality Assurance

Use Cases

Structural Health Monitoring

Vehicle Performance Monitoring

Services

Testing & Certification

Challenge

Rimac Automobili, a leading developer and manufacturer of electrification systems for global automotive companies, faced a significant challenge in the structural design of the monocoque for the Rimac C-Two, the largest single carbon fiber part in the automotive industry. The main challenge was the material, a lightweight, carbon fiber reinforced with epoxy resin. As this carbon fiber is an orthotropic and brittle material, its representation in a finite element (FE) material card is very difficult. One of the most important parameters in designing EV is weight. The lighter the vehicle, the more increase in vehicle range which can lead to a higher acceptance of EV. Following a lightweight approach in the development process of their concept hypercar C_Two, the Rimac engineers were tasked to design the monocoque as a single carbon fiber part with an unprecedented size.

About Customer

Rimac Automobili is a technology company that develops and manufactures key electrification systems for global automotive companies. Founded in 2011 by CEO Mate Rimac, the company has an impressive list of clients ranging from automotive OEMs, tier one suppliers, and emerging players. In addition to providing innovative electric vehicle (EV) technology that meets environmental and safety regulations, Rimac has recently introduced a second generation of its own electric hypercar – Rimac C_Two. The company is headquartered on the outskirts of Zagreb, Croatia, and employs more than 600 people. Rimac’s development departments include eight structural CAE engineers who work with HyperWorks to support the structural design of the car.

Solution

To overcome this structural challenge, Rimac engineers utilized Altair HyperWorks. The goal was to achieve the closest correlation between real and virtual testing to minimize failure. The development process began with the part proposal and based on the results of the simulations run, the CAE team developed a proposal with design engineers. The model was then updated and tested again at each component level until the team saw perfect correlation between simulations and physical performance to achieve a design that performed as expected. The simulations performed by the vehicle engineering CAE design team involved 123 load cases. This was at component, system, and vehicle level, as well as linear, non-linear, static and dynamics simulations. The time frame for the whole development project was 5 months. In addition to providing software licenses and specialist support, Altair introduced HyperWorks Unlimited virtual appliance (HWUL-VA), which is part of the Altair innovative cloud offer.

Impact #1	The use of Altair HyperWorks enabled Rimac to successfully design the monocoque for the Rimac C-Two, with the final design proposal resulting in a prototype that was used in six crash tests, demonstrating the excellent simulation results. The correlation between the physical tests and the previous FE simulations allowed the team to confidently finalize the monocoque design. In addition to significant time and cost savings, the use of simulation also drove innovation at Rimac, pushing engineers to the next level when creating new products. Furthermore, Rimac benefited from Altair's HyperWorks Unlimited virtual appliance (HWUL-VA), part of Altair's innovative cloud offer. Despite initial skepticism, Rimac realized the benefits of unlimited access to this powerful infrastructure, which helped complete the project on time and gain an understanding of the number of resources needed for its new cluster.

Impact #1

The use of Altair HyperWorks enabled Rimac to successfully design the monocoque for the Rimac C-Two, with the final design proposal resulting in a prototype that was used in six crash tests, demonstrating the excellent simulation results. The correlation between the physical tests and the previous FE simulations allowed the team to confidently finalize the monocoque design. In addition to significant time and cost savings, the use of simulation also drove innovation at Rimac, pushing engineers to the next level when creating new products. Furthermore, Rimac benefited from Altair's HyperWorks Unlimited virtual appliance (HWUL-VA), part of Altair's innovative cloud offer. Despite initial skepticism, Rimac realized the benefits of unlimited access to this powerful infrastructure, which helped complete the project on time and gain an understanding of the number of resources needed for its new cluster.

Benefit #1	Significant time savings
Benefit #2	Material savings
Benefit #3	Less expensive prototypes

Benefit #1

Significant time savings

Benefit #2

Material savings

Benefit #3

Less expensive prototypes

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Overview

RIMAC Automobili: Leveraging Simulation for Structural Design of Innovative Hypercar

Operational Impact

Quantitative Benefit