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CAD integrated tools are accelerating product development by incorporating various aspects of physics through coupling with computational aided engineering (CAE) packages. One of the most challenging coupled-physics is fluid-structure interaction (FSI), which integrates the coupled response of fluid flow with a deforming structure. Many automotive design problems involve some form of FSI, but the coupling effects often are simplified or ignored because of complexity and lack of coupled solution technology. To address this, Altair HyperWorks offers a fully integrated coupled finite element analysis (FEA) capability, so called Direct-Coupled FSI (DC-FSI). The DC-FSI technology, available in HyperWorks 11.0.230, can be used in a wide variety of applications such as hydraulically damped rubber mounts, door seals, shock absorbers, design of valves and rubber diaphragms that restrict flow, and antilock braking systems.

Structural optimization techniques are more and more used in the design of automotive structures and components. Manufacturing considerations have always been an obstacle to use optimization techniques in a more efficient way. This paper presents to distinguished techniques to include manufacturability in the optimization process. The first technique described is a manufacturing constraint for topology optimization. The second one is the use of topology optimization to reduce the number of spot welds in a vehicle.