Post Graduate Program in CAE

• In this module, you will be introduced to the CAE domain along with an introduction to FEA basics. You will learn the Graphical User Interface(GUI) of the ANSA tool.
• You will get to know about different solvers and types of analysis carried out using them.
• You will be introduced to basic tools that will help you with geometric cleanups and other deck setups in ANSA.
• The topics covered in this module are 
  • Introduction to FEA
  • ANSA GUI
  • Geometric Tools and Topology Cleanup
  • Types of CAE Process Tools for Structural CAE
  • Types of Elements
  • Different Tools used in TOPO Deck

• In this module, you will study the fundamentals of Finite Element Analysis (FEA). FEA is a generic technique used to solve boundary value problems.
• FEA finds a lot of applications in structural analysis.
• In this module, we will discuss the math behind FEA, along with the following topics 
  • 5Ws of Finite Element Analysis
  • Types of engineering problem-solving methods
  • CAE process types
  • Model setup

• Strength of materials
  • Stress, Pressure, Strain
  • Lateral Strain - Why does it happen
  • Poisson’s Ratio - Practical Application
  • Shear
  • Modulus of Rigidity
  • Moment of Inertia
  • Kinetic Energy, Rotational Kinetic Energy
  • Continuity equation
  • Shear Force and Bending Moment
  • Beams and Truss - Theory and Problems
  • Materials and it is Mechanical Properties
  • Stress and Strain Curves
  • Theory of Failures
  • Vibration
• Finite Element Analysis
  • FEA - Significance and Scope
  • Applications in Various Industries - Examples
  • Types of Analysis
  • Implicit and Explicit - An Overview
  • Degree of Freedom
  • Governing Equations
  • Shape Functions
  • Gaussian Quadrature
  • Boundary Conditions
  • FEA Crash Course - Tool-Based Questions

Week 02 - ANSA Part 1

• Introduction and GUI in ANSA
  • Tool knowledge in ANSA
  • Basics of FEA
  • What is Meshing?
  • Significance of Meshing
  • Elemental Errors
  • Types of Elements in Meshing
  • How to choose and When to choose elements
• Midsurfacing and Methods of Meshing
  • Types of Midsurfacing Techniques
  • Rearrangement of Construction lines
  • Different meshing strategies
  • Manual and Auto Meshing in sheet metal component
• Mesh Quality improvement
  • Various different quality criteria and working with them in ANSA
• Tool Practice

Week 03 - ANSA Part 2

• Mesh Evaluation
  • Things to remember for obtaining a good mesh
  • Important checks to perform
• Time Management in ANSA
  • Various strategies for Time management while working on the component
  • Tips and Tricks on How to approach a general Tool test
• Tool Practice

Week 04 - HyperMesh Part 1

• Introduction
  • HyperMesh - Introduction
• Meshing in HM
  • Meshing Fundamental
  • Mid Surface extraction methods
  • Meshing methods for mesh flow
  • Quality criteria - Checks and fixes
  • Tool Test approach
• Mesh Improvisation
  • Various different quality criteria and working with them in HyperMesh
• Evaluating FE
  • Things to remember for obtaining a good mesh
  • Important checks to perform
• Tool Practice

Week 05 - HyperMesh Part 2

• Time Management
  • Various strategies for Time management while working on the component
  • Tips and Tricks on How to approach a general Tool test
• Tool Practice

• In this module, you'll learn the basics of FEA, various types of simulations, and their significance, and also develop a mathematical understanding of the implicit and explicit schemes. 
• The topics that will be covered in this module are
  • Introduction to FEA 
  • Type of FE Simulation 
  • Explicit and Implicit mathematical definition

Week 02 - LS-PREPOST Deep Dive

• In this module, you will learn about the LS-PrePost and the LS-DYNA user manuals. You will also be learning about the file handling in LS-PrePost, an overview of various cards, and finally, running a Tensile-Test simulation.
• These are the topics that are covered in this module.
  • Brief about the Pre-Process
  • Hands-on training on the LS-DYNA User Manual
  • Running an example 
  • Post-processing the results 
  • Input and output files in LS-DYNA
  • Keywords and input text editing 
  • Multiple RUNs on the same file in the same folder
  • Hands-on with the output files (ASCII output) in the text editor.
  • Exploring binary and ASCII options in database keywords
  • Node keyword – Brief 
  • Part keyword – Brief
  • Materials
  • Section
  • Control cards – default parameters
  • Contact
  • LS-PrePost
  • Building the solver deck for a simulation (Plate Model)
  • Post-processing the results
  • Modeling the cube under pressure
  • Modeling the tensile stress of a specimen

Week 03 - Keywords, Timestep and more

• In this module, you will learn a few new keywords in detail.
• You will learn about the hourglass energy, material keywords in LS-DYNA, methods for calculating Young’s Modulus, the basics of the timestep concept, and various control keywords.
• These are the topics that are covered in this module.
  • Brief on keywords
  • Brief on *INCLUDE keyword
  • Insight of NHTSA
  • Hourglass energy
  • Materials introduction
  • Elasto-plastic material and various cards
  • Material testing
  • Calculation method for Young’s Modulus
  • Power law
  • Verification
  • Deploy
  • Timestep basics
  • Control Card
  • Control Timestep
  • Control Termination
  • Control Shell
  • Control Solid
  • Control Hourglass
  • Control Energy
  • Control Contact
  • Control Accuracy
  • Boundary Condition
  • Constrain
  • Specifying output files
  • Understanding contacts
  • Various types of contacts

Week 04 - LS-PrePost GUI and Weld Modelling

• In this module, you will learn in-depth about the LS-PrePost GUI. You will also be introduced to weld modeling in LS-DYNA and methods to model spot welds and debugging. You will also learn how to model a cross-section and its application.
• The following topics are covered in this module:
  • LS-PrePost GUI
  • LS-DYNA GUI application
  • Node and element selection
  • Application crash, metal forming
  • Element direction align
  • Post-processing
  • Node intrusion depending on the regulation
  • Introduction to Spot-Weld in LS-DYNA
  • Hands-on practice on Spot-Welds
  • Solving a simple problem to learn the Spot-Welds and then Post-Processing it.
  • Modeling Spot-Weld using Spot-Weld constraint card.
  • Modeling Spot-Weld using Spot-Weld generalize constrain card
  • Debugging Spot-Weld
  • Spot-Welds modeling using solid elements
  • Introduction to Cross-Section
  • Modeling a Cross-Section
  • Application of Cross-Section

Week 05 - Implicit Simulations

• In this module, you will learn about the implicit problem and how to set up an implicit simulation. You will also learn about the memory allocation in LS-DYNA, the concept of convergence in implicit simulation, various keywords used in implicit simulation, MORTAR contact, and defining the loading in implicit simulations. 
• These are the topics that you will learn about in this module.
  • Introduction to implicit problems
  • Implicit and explicit comparisons
  • Memory in LS-DYNA
  • In core/out-of-core 
  • Double precision and MPP.
  • The tensile test-simple implicit problem
  • Timestep in implicit problems.
  • Convergence in implicit.
  • Implicit keywords 
  • Implicit and explicit switching 
  • Timestep adjusting 
  • Control-implicit-solver (Non-linear solver)
  • The implicit problem, hands-on with a bumper demonstration 
  • Power law plasticity 
  • MORTAR contact
  • MORTAR contact theory 
  • SOFT card - intro 
  • Implicit loading 
  • Element formulation for implicit analysis
• In this project, you will gain hands-on experience in using the *include, *INCLUDE_TRANSFORM, and *DEFINE_TRANSFORMATION and understand how to model a pedestrian head impact simulation and calculate the HIC value. 
  • Overview of the pedestrian impact simulation
  • Understanding the HIC value 
  • HIC calculation - LS-PrePost
  • Understanding *INCLUDE, *INCLUDE_TRANSFORM,*DEFINE_TRANSFORMATION 

Week 06 - LS-DYNA Best Practices & Types of Analyses

• In this module, you will learn about the best practices in LS-DYNA that are particularly relevant for CAE simulation engineers in the industry.
• Also, the students will learn the concept of mass scaling in-depth and the difference between verification and validation.
• The topics that will be covered in this module are as follows:
  • Best Practices in LS-DYNA
  • Setting up the model 
  • How to decide the type of analysis (static, quasi-static, or dynamic) 
  • Dealing with the coupled problem 
  • Deciding the ELFORM for the problem
  • Solving the model types of errors and their fixes
  • MASS scaling 
  • Post-Processing-Introduction (verification and validation) 
  • Post-Processing a typical explicit model 

Week 07 - Material Modelling using LS-DYNA

• This module mainly deals with material modeling using LS-DYNA. You will understand how to model a material card from the raw data from the material testing lab. You will understand in-depth material modeling techniques and will also learn how to model a hyperelastic material in LS-DYNA. You will also learn about the contact mechanics and the various contact types in LS-DYNA.
• The topics covered in this module are,  
  • Material introduction
  • Material testing
  • Modelling materials
  • Elastic-plastic materials
  • Material modelling from the raw data
  • Hands-on hyperelastic material ( Mat-law 77 )
  • Contact mechanics
  • Types of contacts
  • Full contact parameters
  • Contact parameter - SOFT
  • Segment projection
  • Initial penetration
  • Tied contacts
  • Contact output

Week 08 - Crash and Safety

• This module focuses on the crash and safety domain where you will be introduced to the industry trends in crash and safety.
• And the topics you will learn are,
  • Vehicle crash safety 
  • Crash mechanics
  • Design for crash 
  • The vehicle development process
  • Knowledge of simulation engineers
  • Regulation and NCAPS 
  • Score calculation 
  • Model preparation: Static vs Crashworthiness 
  • General guidelines for crash model preparation 
  • Mesh and mesh quality 
  • Model organisation and integration 
  • Parameterization
  • Forming data

Week 01 - Introduction to FEA

• What is FEA? and Why FEA?
• Advantages and industrial applications of FEA
• Different types of FEA analysis
• Pre-requisites of FEA
• Basics of Approximate and Exact solution methods

Week 02 - Methods of FEA

• Weighted residual techniques
• Basics of Petrov-Galerkian
• Potential energy approaches

Week 03 - Basics of FEA

• Meshing/Discretization
• Types of Elements in FEA
• Terminologies like Nodes, Elements etc.
• Introduction to Stiffness matrix, Plane stress and Plane strain conditions

Week 04 - 1D Element (Bar element)

• Stiffness Matrix of 1D element
• Nodal Displacements
• Nodal DOF
• Stress and Strain Calculations
• Shape functions
• Homogenization of Problems
• Case study Problem

Week 05 - 2D Element

• Stiffness Matrix of 2D element
  • Nodal Displacements
  • Nodal DOF
  • Stress and Strain Calculations
  • Shape functions
  • Stiffness matrix of CST elements

Week 06 - 3D Element and FEA characteristics

• Stiffness Matrix of higher order 1D element
• Stiffness Matrix of LST element
• Stiffness Matrix of 3D element
• Nodal Displacements
• Different non-linearities in FEA
• Basic types of material models
• Factors influencing Solution of FEA

Week 07 - Basics of ANSYS

• Introduction to ANSYS
• Material Models
• Meshing techniques
• Solving Simple Static Problems

Week 08 - Equations of Motion

• Study of Basic Equations of Motions
• Mass Matrix, Stiffness Matrix
• Time dependance of Analysis
• Physics of Crash
• Study of Mathematics related to Crash

Week 09 - Explicit and Implicit FEA

• What are Explicit and Implicit analysis
• Basic Applications
• Advantages and Disadvantages of methods
• Difference between Explicit and Implicit methods
• Time steps, Hourglassing and Contacts used
• Mathematical approaches used by Explicit and Implicit analysis
• Case Studies:
  • Hydroforming of Automotive Structures
  • Modelling of Shape memory alloys

Week 10 - ANSYS

• Case Studies:
  • Crush Analysis of square/rectangular tube using ANSYS
  • Impact of ball/bullet on Steel thin plate

Week 01 - Basics of Crashworthiness Physics, FEA Concepts and CAE Process

• In the first module you will learn about different types of analysis, the difference between implicit and explicit analysis, different non-linearities and, along with this, you will also bust the myth that ‘strong structure equates safe structure" by teaching you about:
  • Meaning of crash safety for a vehicle.
  • The Law of conservation of energy is applied to a car crash.
  • Basic concepts of FEA, such as linear-nonlinear, static-dynamic, implicit-explicit analysis, their differences, and the guidelines on how to choose a method for a given FEA problem are explained.

Week 02 - Introduction to HyperMesh

• HyperMesh is one of the most popular Finite Element Preprocessor used to generate meshes
• of complex models. In this module, you will learn the GUI of HyperMesh, various elements available in FEA like 1D, 2D, and 3D elements, how to choose the element depending on the geometry by covering topics such as:
  • Overview of Pre-Processors and their importance in FEA Processes
  • Primary introduction to GUI of HyperMesh, toolbars, and basic operations

Week 03 - Geometry Editing in HyperMesh

• Learning to mesh geometries is an important step in performing FEA. Therefore, we will extensively cover the topic by which the students can understand, geometry clean up, tools available for geometry cleanups,
  • Using an edited geometry to generate a mid-surface and an appropriate 2D mesh with regards to mesh flow, trias, and mesh size, by various methods.
  • Using the geometry tools to clean up the distorted geometry.

Week 04 - Meshing – 1D, 2D & 3D and Mesh Quality Check

• In this section, you will learn about 1D, 2D, and 3D meshing, what mesh quality is and how to improve it, before exporting the meshed model to the specific solver.
  • Using an edited geometry to generate a mid-surface and an appropriate 2D mesh with regards to mesh flow, trias, and mesh size, by various methods
  • Using the geometry to create a 3D mesh using various methods.
  • Meaning of mesh quality and ways to control and improve it
  • Types of 1D elements, their specifications, and creation
  • Exporting a meshed model from HyperMesh in the specified solver format

Week 05 - Introduction to Radioss

• In this section, you will learn what an explicit solver is, what an engine file and a starter file are, and their significance, as well as what an out file is and how to read this out file.
  • Overview of Radioss: An Explicit FEA Solver for Crashworthiness
  • Essential Radioss input files, their significance, and format
  • An overview of output files and their significance

Week 06 - Element Properties and Materials

• In this section, you will learn about the various element formulations available for different types of elements in the Radioss and their applications, how to assign thickness to the component, and also various parameters available in the property card and their significance.
  Similarly, you will also learn about the various material cards available in Radioss and their use cases along with their failure criteria.
  • Application of thickness and dimensional properties, integration points for 1D, 2D, and 3D elements
  • Study and application of concepts such as material intrinsic properties, failure criteria, non-linearity, plasticity, and hyper-elasticity into a material model.

week 07 - HyperCrash, HyperView and HyperGraph

• In this section, you will learn about a new application that was developed by Altair exclusively to set up crash simulations, and along with this, you will be learning the GUI of Hypercrash. You will also be introduced to Hyperview and HyperGraph, where you will learn how to post-process the simulation results.
  • An Introduction to HyperCrash, a specialized preprocessor for Radioss
  • Introduction to HyperView and HyperGraph as post-processing tools in the FEA process

Week 08 - Interface (Contact) Modelling

• Interface modeling will be a complex topic that you can find in any solver. Here you will learn what contact is and how it works, what the different parameters you need to look into while defining a contact in a model are, and what the different types of contacts are and their use cases.
  • Concepts of an interface between given components, penalty formulation method, contact stiffness, gap, penetration, interference, and tied interfaces
  • Creation of various types of interfaces and removing any errors or interferences

Week 09 - Boundary Conditions Setup

• In this section, you will learn how to set up a proper boundary condition for any given simulation, what the different types of loading conditions are, and the different types of joints available in Radioss
  • Setup of static and dynamic loading conditions such as velocity, acceleration, a constraint on degree of freedom, rigid walls, spot welds, and seam welds.

Week 10 - Simulation Control

• In this section, you will learn about the concept of the time step and how it can be optimized to increase the speed of the simulation, and also the concept of mass scaling. You will also understand the various control cards available in Radioss and their use cases.
  • Control of simulation in terms of the time step, accuracy, run time, types of outputs

Week 11 - Checks and Debugs

• In this section, you will learn the various checks you should do before running the simulation and also how to debug a simulation along with its approach.
  • Using diagnostic methods, check for and debug any errors in the model.

Week 12 - Airbag and its Modelling in FEA

• In this section, you will exclusively learn about the physics of an airbag in crash scenarios and how to model them in Radioss. You will be learning about two types of airbags (with vent and without vent).
  • The concept of an airbag in FEA, its modeling methods and challenges with an example

Week 13 - Occupant Injury Criteria

• In this section, you will learn how the injury criteria are calculated in the actual crash test environment and how they affect the rating of the vehicle. You will also learn about the dummy standards that are used in crash testing.
  • Various occupant injury criteria are currently being considered while determining the crashworthiness and safety performance of a car.

Week 14 - Crashworthiness Standards

• In this section, you will learn about the standards followed in different ENCAPs
  • The basic elements of the most popular crashworthiness standards, the criteria used to determine crashworthiness performance, and methods to measure this in the FEA model are all studied.

Week 01 - Basics of Strength of Materials - FEA Perspective

• Introduction to Strength of Materials
• Stress-Strain Relationship
• Elasticity
• Hooke's Law and Poisson's Ratio
• Bending Moment Equation and Principle Stress

Week 02 - Finite Element Methodology

• Mohr's Circle
• Theories of Failure
• Different Methods to Solve Engineering Problems
• FEA/FEM
• Degree of Freedom
• Types of Elements
• Fully Integrated vs Under Integrated Elements
• Cantilever Problem
• Types of Analysis

Week 03 - Basics of Ansys SpaceClaim and Workbench

• Basics of Ansys
• Basic Functions of Ansys SpaceClaim
• FEA of Cantilever Beam using Ansys
• Modal Analysis

Week 04 - Structural and Contact Analysis

• Analysis of Backhoe Loader Bucket
• Contact Analysis of Differential Unit's Housing

Week 05 - Dynamics Analysis and Modal Analysis

• Error Solving in Convergence
• Modal Analysis
• Dynamic Analysis and its Types
• Eigenvalue Problems
• Participation Factors

Week 06 - Frequency and Impact Analysis

• Modal Analysis of a Beam with Prestress
• Modal Analysis of a Backhoe Loader Bucket
• Modal Analysis vs Frequency Response Analysis
• Modal and Harmonic Analysis of a T-Shaped Model
• Frequency Response of the T-Model and a Simply Supported Beam

Week 07 - Transient and Rigid Body Analysis

• Impact Test
• Explicit Vs Implicit
• Energies Definition
• Time Step Calculation
• Stress-Strain Curves

Week 08 - Impact Analysis - Applications

• Impact Analysis of a Phone
• Impact Analysis of a Car Frame

Week 09 - Transient Analysis - Applications

• Transient Analysis of Rack and Pinion
• Rigid Body Dynamics: Problem of Backhoe Loader Bucket

Week 10 - Pre-tension Process

• Pre-tension Concept
• Pre-tensioning of Bolt of Jack
• Report Preparation

Week 01 - Introduction to vehicle crash and safety

• Introduction
• Active and passive safety
• Physics in crash and safety
• Evolution of safety in automobiles
• Importance of crash and safety in an average automobile
• Occupant and Pedestrian safety

Week 02 - Active Safety Features

• Introduction to Active safety
• Anti-lock Braking system
• Stability and Traction Control
• Brake assist & Emergency braking
• Collision avoidance
• Autonomous cruise control
• Cameras (Image processing)
• Car to Car connect

Week 03 - Passive safety Features (structure)

• Introduction
• Crumple zones - Front
• Crumple zones - Rear
• B pillar structure and doors
• Roof structure
• Materials for passive safety
• ICE vs Electric car structures

Week 04 - Passive safety Features (Occupant & Pedestrian)

• Introduction
• Seats and Seat belts
• Driver and Passenger Airbag
• Head restraint
• ISOFIX child mount
• Door trims
• Occupant monitoring
• Pedestrian safety

Week 05 - Future of Crash and safety

• Introduction
• Autonomous (driverless) vehicles
• Regulation changes
• Hyperloop
• Crash and safety in future mobility