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  • Multidisciplinary Design Optimization of Vehicle Weight Reduction

    In this study from ESTECO North America, a six-step MDO process is illustrated by solving a 2001 Taurus weight reduction problem with two formulations AAO and CO. The chosen optimization platform is modeFRONTIER plus SOMO. Conclusions show the advantages to using AAO methodology in MDO.

  • Design of a Meta-Material with Targeted Nonlinear Deformation Response

    This thesis aims to demonstrate the possibility of designing a meta-material to match a nonlinear deformation response. Application of this method was successful in generating a meta-material to meet the response of the rubber pad in an M1 Abrams tank. The optimization method using modeFRONTIER can serve as a framework for future designers to develop meta-materials for nonlinear targeted responses

  • Sensitivity analysis of CFD method with modeFRONTIER

    In this thesis, the development of a new defroster duct system prototype is carried out. The suitability of using modeFRONTIER for sensitivity analysis has been investigated coupling ANSYS/FLUENT as a main solver. To study the numerical solution of the windscreen de-icing process, a computational fluid dynamics (CFD) method has been used. 

  • The Product Innovative Design Methodology Integrating Reverse Engineering with Optimization - A Case Study on Automotive Styling

    Although many CAD systems exist, in the initial design phase of a product, it’s still a challenge to obtain a shape that meets aesthetic and physical performance requirements simultaneously. An innovative design methodology integrating reverse engineering (RE) with optimization is presented to settle this problem. RE is used to convert a clay model to a spline-based surface model. The final solution is found through a multi-objective genetic algorithm from modeFRONTIER.

  • Thermal Analysis of a Diesel Piston and Cylinder Liner using the Inverse Heat Conduction Method

    This Master’s thesis developed a thermal analysis model of a diesel piston that is used in Volvo Cars engines, which enhances the possibilities to determine the complete thermal loads of the car engine and can be used as a boundary condition when performing combustion CFD-simulation. 

  • Rapid deployment of remote laser welding processes in automotive assembly systems

    Remote laser welding (RLW) is emerging as a powerful and promising joining technology (one of the KETs) in vehicle manufacturing. However, potentials of RLW are currently underexploited, mainly due to challenges in system and process design, part variation, fixturing, offline programming, as well as process monitoring and control. The RLW Navigator framework was applied in a detailed automotive pilot study which yielded promising results.

  • Evaluation of Railway Vehicle Car Body Fatigue Life and Durability using Multi-disciplinary Analysis Method

    An integrated fatigue life and durability evaluation method based on multibody dynamics simulation (MBS) and finite element analysis for a locomotive car body is presented. A multi-disciplinary optimization algorithm is developed to handle the conflicting requirements of lightweight and good fatigue resistant car body structure designs. 

  • Influence of Body Stiffness on Vehicle Dynamics Characteristics in Passenger Cars

    This study aims to analyze how vehicle dynamics are affected by local and global car body stiffness. The influence of these parameters in vehicle handling, steering and ride attributes are examined through CAE analysis tools and compared to results from physical tests. The software used for the graphical visualization and correlation of large data sets of results from the performed DOE is modeFRONTIER.


    ​ESTECO and TASS International present the successful integration of their technologies to optimize a rear-seat restraint system considering a diverse population.​​​

  • Experimental Characterization of External Gear Machines with Profile Asymmetric Teeth

    This paper describes the benefits of introducing gears with asymmetric teeth in EGMs, or external gear machines. The optimal profile of the gear is tested using a numerical optimization procedure run in modeFRONTIER and HYGESim with the following objective functions: delivery flow pulsations, internal pressure overshoots, localized cavitation effects and volumetric efficiency.


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