Using Integrated Simulation to Optimize Heavy Equipment Design

Heavy equipment manufacturers want to design products that are durable and perform at their peak under a variety of conditions. To accomplish this, Altair provides an integrated multi-disciplinary simulation environment to virtually test and optimize equipment performance and therefore, help reduce design and development costs. Using simulation-driven design, studying the full dynamics of a product or system is possible, from motion analysis to complete lifecycle durability testing.

Technical Document

Guide to Weld Certification

Welded assemblies are widely used across industrial sectors. The design processes in rail, construction, marine, heavy machinery, pressure vessel construction, and many other industries rely heavily on regulations, codes, and norms such as FKM, DVS-1612, and Eurocode-3. This guide describes the evaluation and standard based certification of welded constructions by combining CAE methodology with relevant norms and regulations in a guided and standardized workflow.


A New Workflow for Rapid Fatigue Life and Durability Prediction

This session is suited for part-time analysts and simulation experts that want to explore the fatigue life of their latest design, or fatigue simulation specialists interested in seeing the latest fatigue solutions available. Join us and see how Altair HyperLife can enable you to identify potential durability issues, evaluate damage and cycles to failure faster, to ensure durability targets are hit without time-consuming and expensive redesigns.


Fatigue Design for Welded Structures

This session is suited for design and engineering teams interested in running fatigue analysis on welded structures. Altair HyperLife gives users the flexibility to run both traditional weld fatigue calculations, and also evaluate welds to specific standards and regulations such as FKM, EC3, and DVS1612. Join us and see how Altair’s solutions can streamline model build for welded structures, quickly enable users to assess weld performance to meet a variety of industry requirements, and avoid costly rework or repairs in later life.


HyperLife 2020

In this course, you will have the opportunity to learn about HyperLife and the tools and processes available for fatigue analysis. Modules contained within the course provide detailed descriptions of the tools and workflows within HyperLife. You will also have the opportunity to watch and perform hands-on exercises within each module.


Altair HyperLife™ – Temperature Influence

The fatigue strength of a material reduces with an increase in temperature. Temperature influence can be accounted by applying the temperature factor Ctemp to modify the fatigue endurance limit FL.

Tips & Tricks

Altair HyperLife™ – Safety Factor Estimation

Safety factor is calculated based on the endurance limit or target stress (at target life) against the stress amplitude from the working stress history. HyperLife calculates this ratio via two criteria’s.

Tips & Tricks

Altair HyperLife™ – Vibration Fatigue

Vibration fatigue analysis can be performed with loading options to predict fatigue in the frequency domain.

Tips & Tricks

Altair HyperLife™ – Modal Superposition

Fatigue analysis can be performed when modal stresses and modal participation factors are available in two different file inputs.Modal stresses are multiplied by modal participation factor, then summed at each point in time. The modal stress file (geometry) is supported for the H3D file format.HyperLife 2020.1 supports OP2 file support for Modal Superposition The supported modal participation factor file formats are PCH and MRF. Currently, only time domain results (from transient analysis) are supported.

Tips & Tricks

Altair HyperLife™ – Damage and Life Results Contour Per Event

Damage and Life contours are available to plot per Event in the Results Explorer. This output is optional and activated in the Preferences dialog. Output event wise results helps to interrogate the fatigue results to determine which event(s) and subcases are contributing to the fatigue life.

Tips & Tricks

Altair HyperLife™ – Weld Certification

HyperLife Weld Certification is a specialty module for fatigue strength assessments according to common design codes/norms and guidelines welded structures.

Tips & Tricks

Design components exposed to high cycle loads

Altair HyperLife is an easy to learn fatigue analysis software developed in a solver-neutral framework. It provides a comprehensive set of tools for fatigue analysis, with direct interfaces to all major FEA result files. With an integrated material library, HyperLife enables the prediction of fatigue life under repetitive loads that occur in a variety of industrial applications. In this webinar, you learnt how Altair HyperLife can seamlessly be integrated in a development process from multibody dynamic load extraction over structural topology optimization and redesign to a detailed fatigue analysis. The results are used in Altair Inspire Studio to create high quality renderings for presentations.


Altair HyperLife New Feature Overview

HyperLife is a new Fatigue application that is being released with version 2019. See an overview of this new product and the features it contains.

Product Overview Videos

Altair HyperLife Execute the Fatigue Setup

The Evaluate tool allows you to run the Fatigue Analysis, and subsequently load your results in the Results Explorer to visualize the Damage and Number of Cycles to Failure contour.

Product Overview Videos

Altair HyperLife Creating Fatigue Events

The Load Map tool serves as a typical Signal processing utility where you can import repetitive load history files. You can also create a simple constant amplitude or block loading cycles with a single click.

Product Overview Videos

Altair HyperLife Fatigue Modules Selection

A collated icon enables you to choose the type of fatigue analysis to be run.

Product Overview Videos

Altair HyperLife Material Assignment

The Material tool allows you to create, store, and manage the Fatigue material property assigned to parts. This tool is preloaded with a library of Fatigue material properties, from which you can choose from. You can also load materials from your own database or create new materials in the session.

Product Overview Videos

Altair HyperLife Stress Life Analysis

Uniaxial and Multiaxial assessment options with multiple Mean stress correction theories. Various stress combination methods are available for Uniaxial assessment. Critical plane implementation for Multiaxial assessment.

Product Overview Videos

Altair HyperLife Seam Weld Fatigue Analysis

Structural stress method implementation for Seam welds idealized with plate or shell elements. The approach is based on VOLVO method. Supported weld type is FILLET weld and the weld lines (root and toe) are automatically identified.

Product Overview Videos

New Features in Altair HyperLife

Series of new feature videos for Altair HyperLife within the Altair HyperWorks 2019 release

Product Overview Videos

Altair HyperLife Product Overview

HyperLife is an easy-to-learn fatigue analysis software developed on a solver-neutral framework. It provides a comprehensive toolset for durability analysis, directly interfacing with all the major finite element analysis (FEA) results files. With an embedded material library, HyperLife enables prediction of fatigue life under repetitive loadings experienced in a wide range of industrial applications.

Product Overview Videos

Altair's New, Modern Fatigue Solution: HyperLife

Before a product ever goes to market, companies must understand how their products will behave during and beyond their expected use cycle. Building a brand perception of product quality relies on consistently durable products, regardless of when and where they are produced, time after time. Additionally, high development costs and expensive warranty claims can be mitigated by integrating fatigue simulation into the product development process. There are many tools on the market to simulate the durability and fatigue life of products, but what sets some solutions apart? Learn how HyperLife enables you to differentiate your products through quality and beat competitors to market with quicker engineering decisions.


Altair HyperLife Datasheet

Altair HyperLife is a comprehensive and easy to use durability analysis tool directly interfacing with major FEA result files. With an embedded material database, HyperLife offers solutions for fatigue life predictions under static and transient loading across a range of industrial applications.


Fatigue Approach and Types

Select the fatigue approach and type in HyperLife.

Quick Start

Stress Life Analysis

This video shows the typical workflow to perform a stress life analysis in HyperLife.

Quick Start

Seam Weld Fatigue

This video shows the typical workflow to perform a seam weld fatigue analysis with HyperLife.

Use Cases

Spot Weld Fatigue

This video shows the typical workflow to perform a spot weld fatigue analysis with HyperLife.

Quick Start

Material Model Assignment

Assign material from database or create your own material in HyperLife

Quick Start

Altair HyperLife Load Map

Create load history events in HyperLife

Quick Start

Run and Evaluate Results

Run analysis and evaluate results in HyperLife

Quick Start

Solving heavy industry challenges with Altair's next generation simulation suite

This presentation illustrates how Altair’s latest simulation product updates can facilitate and accelerate customers’ product design cycles by addressing specific tasks for both designers and engineers, from part to system level structural design, spanning from concept- to detailed development stages.

Within the context of an excavation scenario, we will show a range of solutions with a focus on the following:
- optimization of an excavator arm with regards to structural performance and fatigue life assessment under realistic loading conditions,
- rapid, early loadcase evaluation and improvement of structural robustness by performing detailed design exploration of a truck trailer assembly,
- improvement of Roll-Over-Protective Structure test results of an excavator cabin by applying Altair’s innovative C123 optimization,

A technical overview of aforementioned solutions is followed by relevant software demonstrations of updated model build & exploration workflows within the new HyperWorks user interface, integrated Inspire solutions for Motion & Structural analysis, along with automatic CAD redesign & CAD parametric optimization processes.

Presented at the ATCx Heavy Equipment in May 2021.

Speaker: Alexander Gnech, Technical Manager, Altair

Duration: 20 minutes

Conference Presentations