ANSA is an advanced multidisciplinary CAE pre-processing tool that provides all the necessary functionality for full-model build-up, from CAD data to ready-to-run solver input file, in a single integrated environment. In FEA analysis the workflow can be categorized into 3 phases such as pre-processing, solving, and post-processing. This course purely focuses on pre-processing/modeling a component for FEA analysis. If you are someone who is interested in the CAE domain this course will help you to get into the industry as a CAE modeler/mesher.

Anyone who enrolls in this course will be able to learn a CAE Preprocessing Tool which includes tasks such as geometry clean up, midsurfacing, 1D, 2D and 3D meshing operations, connections establishments, morphing, etc. By learning how to use this tool you will be able to model/mesh any components that are required in the FEA Domain.

At the end of this course, you will be skilled in 1D, 2D ( shell meshing ), 3D ( solid meshing ), and also in connectors. There are several complex models in the course work that will help you in practicing the techniques taught in this course.

After completing this course you will be able to apply for various CAE roles within the automotive sector and other industries.

WEEK 1 & 2

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

WEEK 4

Manual Mid-Surfacing-Plastic Trims and Cast Parts

In this module, you will be learning about extracting the mid surface and working on a plastic part. Plastic parts are of variable thickness therefore, extracting the mid surface and assigning the thickness is more tricky while compared to the sheet metal component.

You will study the following topics in this module,

• Manual mid-surfacing for plastic trim components & cast parts, 

• 2D meshing, quality checkup 

• Different tools used in mesh deck

• A plastic part is given for practice

WEEK 5

Solid Meshing(Tetra & Hexa)

In this module, you will learn the different tools and techniques to generate the Tetra mesh for a given geometry. You will also learn the different methods involved in generating a Hexa mesh. You will also understand the quality checks for Tetra elements and how to rectify failed tetra elements.

You will study the following topics in this module,

Establishing Solid (Tetra) meshing on 2 different components

• Solid (Tetra) Meshing, 

• 3D meshing quality criteria,

• Volume mesh deck

  
  

Introduction to Solid (Hexa) meshing

• Solid (Hexa) meshing,

• Volume mesh deck

WEEK 6

In this module, you will be introduced to connections in ANSA. This enables the user to generate FE models for durability, NVH, and crash analysis. Connections are now efficiently designed with the help of the tool. You will also generate connections for the automotive seat & front door.

These are the topics that you will learn in this module,

   Different types of connectors such as:

 - Two Nodes RBE2 

 -  Cluster RBE2

 -  RBE2-CBUSH-RBE2

 -  RBE2-HEXA-RBE2

 -  Nut and Bolt representation

 -  Seam weld data representation

   Different operations such as

 -  Converting and Realizing operations 

 -  Connection Manager operations

 -  Assigning mass to a node

WEEK 7

In this module, you will learn about batch meshing, casting methods, and its applications in industries. Batch meshing/casting method will help you to model the component efficiently and quicker than if you tried to model them manually. But these tools do not guarantee the best results always, there will areas where you need to manually check the results.

You will study the following topics in this module

• Introduction to casting & batch meshing operations
• Auto mid surfacing and meshing by using casting and skin methods

WEEK 8

In this module, you will learn about a few morphing techniques in ANSA. ANSA allows a full-fledged morphing menu which is completely integrated with ANSA's interface. The functions of the morphing menu can be used to efficiently re-shape both FE and/or geometry-based models.

You will study the following topics in this module,

• Direct morphing

• Box morphing 

• Hatches

• Morphing was done in FE model

• Morphing done in CAD geometry

The first module you learn will learn about different types of analysis, the difference between Implicit and Explicit analysis, different non-linearities and along with this we will also bust the myth that ‘strong structure equates safe structure’ by teaching you about:

• Meaning of crash safety for a vehicle
• Law of conversation of energy 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

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:

1. Overview of Pre-Processors and their importance in FEA Processes
2. Primary introduction to GUI of HyperMesh, toolbars and basic operations
   

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,

1. Using an edited geometry to generate mid-surface and appropriate 2D mesh with regards to mesh flow, trias and mesh size, by various methods
2. Using the geometry tools to clean up the distorted geometry
   

In this section, you will learn what is 1D, 2D, and 3D meshing, what is mesh quality and how to improve them, and exporting the meshed model to the specific solver.

• Using an edited geometry to generate mid-surface and 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

In this section, you will learn what is an Explicit solver, what is an engine file and a starter file and their significance and also what is an out file and how to read this out file.

• Overview of Radioss- An Explicit FEA solver for crashworthiness

• Essential Radioss input files, their significance, and format

• Overview of output files and their significance

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 for the component, and you will also understand various parameters available in the property card and their significance.

Similarly, you will also learn 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

In this section, you will learn a new application that is developed by Altair exclusively to set up the crash simulations - HyperCrash. You will be learning the GUI of Hypercrash. You will be introduced to Hyperview and HyperGraph where you will learn how to post-process the simulation results

• Introduction to HyperCrash, a specialized pre-processor for Radioss

• Introduction to HyperView and HyperGraph as post-processing tools in the FEA process

Interface modeling will be a complex topic that you can find in any solver. Here you will learn what is a contact and how it works, what are the different parameters you need to look into while defining a contact in a model, what are the different types of contacts 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

In this section, you will understand how to set up a proper boundary condition for any given simulation, what are the different types of loading conditions, and 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

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

In this section, you will the various check you to do before running the simulation and also you will understand how to debug a simulation along with its approach 

• Checking and debugging any errors in the model using diagnostic methods

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)

• Concept of an airbag in FEA, its modeling methods, and challenges with an example

In this section, you will learn about how the injury criteria are calculated in the actual crash test environment and how it affects the rating of the vehicle. You will also learn about the dummy standards that are used in crash testing. 

• Various occupant injury criteria currently being considered while determining the crashworthiness and safety performance of a car

In this section, you will learn about the standards followed in different ENCAPs 

• Study of basic elements of most popular crashworthiness standards, the criteria used while determining the crashworthiness performance and ways to measure this in the FEA model

In this module, you learn the basics of FEA, various types of simulations along with their significance, and also develop a mathematical understanding of the implicit and explicit schemes.

The topics that will be covered in this module are, 

1. Introduction to FEA 
   
2. Type of FE Simulation 
3. Explicit and Implicit mathematical definition

In this module, you will learn about the LS-PREPOST, the LS-DYNA user manual. 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,

1. Brief about the pre-process
2. Hands-on training on the LS-DYNA user manual 
3. Running an example 
4. Post-processing the results 
5. Input and output files in LS-DYNA
6. Keywords and input text editing 
7. Multiple RUN on the same file in the same folder
8. Hands-on the out files (ASCII output) in the text editor
9. Exploring binary and ASCII options in database keyword
10. Node keyword – brief 
11. Part keyword – brief
12. Materials
13. Section
14. Control cards – default parameters
15. Contact
16. LS-PREPOST
17. Building the solver deck for a simulation (plate model)
18. Post-Processing the results
19. Modeling of  a cube under pressure
20. Modeling the cube under pressure
21. Modeling the tensile stress of a specimen

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, basics of timestep concept, and various control keywords.

These are the topics that are covered in this module,

1. Brief on keywords
   
2. Brief on INCLUDE keyword
3. Insight of NHTSA 
4. Hourglass energy
5. Materials introduction 
6. Elasto-plastic material and various cards
7. Material testing
8. Calculation method for Young’s Modulus
9. Power law
10. Verification 
11. Deploy
12. Timestep basics
13. Control card
14. Control timestep 
15. Control termination 
16. Control shell 
17. Control solid 
18. Control hourglass
19. Control energy 
20. Control contact 
21. Control accuracy 
22. Boundary condition 
23. Constrain
24. Specifying output files
25. Understanding contacts  
26. Various types of contacts

In this module, you will learn in-depth about the LS-PREPOST GUI, you will be introduced to Weld modeling in LS-DYNA and methods to model the spot welds and debugging, along with learning how to model a cross-section and its application.

The following topics are covered in this module,

1. LS-PREPOST GUI
2. LS-DYNA GUI application 
3. Node and element selection
4. Application crash, metal forming 
5. Element direction align 
6. Post-processing 
7. Node intrusion depending on the regulation
8. Introduction to spot-weld in LS-DYNA 
9. Hands-on practice on spot-welds 
10. Solving a simple problem to learn the spot-welds and then post-processing it.
11. Modeling spot-weld using spot-weld constraint card.
12. Modeling spot-weld using spot-weld generalize constrain card
13. Debugging spot-weld
14. Spot-welds modeling using solid elements
15. Introduction to cross-section 
16. Modeling a cross-section 
17. Application of cross-section

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, you will learn the concept of convergence in implicit problems, various keywords used in an implicit simulation, you understand about MORTAR contact and defining the loading in implicit simulations. 

These are the topics that you will learn in this module, 

1. Introduction to implicit problems
2. Implicit and explicit comparison 
3. Memory in LS-DYNA
4. In core / out-of-core 
5. Double precision and MPP
6. Tensile test - simple implicit problem
7. Timestep in implicit problems 
8. Convergence in implicit 
9. Implicit keywords 
10. Implicit and explicit switching 
11. Timestep adjusting 
12. Control-implicit-solver (Non-linear solver)
13. Implicit problem, hands-on with a bumper demonstration 
14. Power law plasticity 
15. MORTAR contact
16. MORTAR contact theory 
17. SOFT card - intro 
18. Implicit loading 
19. Element formulation for implicit analysis

In this module, you will learn about the best practices in LS-DYNA that are particularly relevant for CAE simulation engineers in the industry, you will also understand 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, 

1. Best practices in LS-DYNA
2. Setting up the model 
3. How to decide the type of analyses (static, quasi-static, dynamic) 
4. Dealing with the coupled problem 
5. Deciding the ELFORM for the problem
6. Solving the model - types of error and their fix
7. MASS scaling 
8. Post-Processing - Introduction (verification and validation) 
9. Post-Processing a typical explicit model 

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 about 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, 

1. Material introduction 
2. Material testing 
3. Modeling materials 
4. Elastic-plastic materials 
5. Material modeling from the raw data
6. Hands-on hyperelastic material ( Mat-law 77 )
7. Contact mechanics
8. Types of contacts
9. Full contact parameters
10. Contact parameter - SOFT 
11. Segment projection 
12. Initial penetration 
13. Tied contacts 
14. Contact output 

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, 

1. Vehicle crash safety 
2. Crash mechanics
3. Design for crash 
4. Vehicle development process
5. Knowledge of simulation engineer 
6. Regulation and NCAPS 
7. Score calculation 
8. Model preparation static vs crashworthiness 
9. General guideline for crash model preparation 
10. Meshing and mesh quality 
11. Model organization and integration 
12. Parameterization
13. Forming data  

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

1. 5Ws of Finite Element Analysis 
2. Types of engineering problem-solving methods
3. Types of CAE process
4. Model setup 

In this module, you will study the meshing software - HyperMesh.

HyperMesh is a highly capable simulation software and in this module, you will learn the various tools and features that HyperMesh has to offer. 

In this module, you will learn of the following topics

1. Geometric tool and tools menu introduction
   
2. Basic geometric tools
3. Geometry cleanups (includes auto cleanup) 
4. Midsurface creation

While dealing with complex 3D components, it is important to remove small features and holes that are inevitable when designing a CAD model. You will be introduced to the batch mesher macro that will be instrumental in accomplishing this. 

In this module, you will study the following topics

1. Criteria files for geometry cleanup 
   
2. MNode's creation & node edit
3. Point edit
4. Edge edit

1D Meshing is a great way to speed up the simulation time without compromising on accuracy. There are different types of 1D elements - each featuring its own shape function and characteristics.

In this module, you will learn the following

1. 5Masses, bar, rod, rigid, RBE3, springs, gaps 
   
2. Connectors, HYPER BEAM, linemesh, linear 1D
3. Edit, element, split, replace, detach
4. Order change, configuration edit, element type

In this module, you will learn to perform surface clean-up on a given geometry and to extract the mid-surface using an in-built tool - Auto-mid-surface. You will also learn how to clean up the surface manually because relying only on the auto-mid-surface option may give rise to a distorted surface while dealing with a complex geometry

Here is a list of topics that you will learn in this module.

1. Surface clean up 
2. Midsurface generation 
3. Handling distorted surfaces

In this module, you will learn the basics of 2D meshing, how to mesh a surface, how to re-mesh a meshed surface using elements, and how to attain mesh flow in the geometry. You will also learn how to handle the tria elements in the model.

These are the topics that you will learn in this module,

1. 2D meshing introduction 
2. 2D basic tools
3. Mesh flow
4. Handling tria elements

In this module, you learn about quality checks and understand the different quality-checks that HyperMesh offers. You will also learn how to fix areas that failed a quality check.

Here, is a list of key concepts that you will learn in this module.

1. 1D element quality check
2. 2D element quality check
3. Understanding the quality parameters for 2D meshing

In this module, you will learn how to do manual mid surfacing when the auto-mid surfacing option fails. You will also learn how to handle geometry if they are symmetrical, normals check in the model and its significance, and free edges along with their significance.

The following topics are covered in this

1. Manual mid surface 
   
2. Handling symmetric geometry 
3. Free edge checks
4. Normals check

In this module, you will learn the different tools and techniques to generate a hexa mesh for a given geometry. You will also learn a variety of techniques to generate tetra meshes. You will also understand quality-checks for tetra elements and how to rectify areas that have failed these checks.

The following topics are covered in this module.

1. Hexa meshing 
   
2. Tetra meshing
3. Different methods of tetra mesh generation.
4. Quality check 3D element 

Sometimes, meshes are made with both 2D and 3D meshes that are interspersed. Connectors help the computer understand that the interface is between two different kinds of meshes. Connectors are time-saving features that are a requirement in large models. In addition to this, connectors offer a way to let the computer know that two components have been seam welded.

These are the topics that you will learn in this module,

1. Seam weld
   
2. Spot weld 
3. Bolt connection 
4. Spring element 
5. Adhesive modeling - HEXA 

In this module, you will understand the uses of batch meshing and its applications in industries. You learn about the parameter file and criteria file, how they can be optimized for the requirement. 

Here is a list of key concepts that you will learn in this module.

1. Understand quality parameter and criteria files
   
2. Optimizing these files according to the requirement

In this module, you will learn about morphing which can be done using constraints, volumes, and geometry. You will also be working with manipulation of TCL commands, running a TCL command using the inbuilt run options. 

1. Morph constraints
   
2. Morph volumes
3. Map to geometry
4. Basic macro generation using TCL commands

In this course, you will be learning the solid modeling and surface modeling tools of the SOLIDWORKS CAD software. SOLIDWORKS is one of the most dynamic software used primarily in R&D sectors. SOLIDWORKS is widely used in the concept generation stage of production. It gives designers real-time experience in product modeling.

In this course, you will be learning the fundamentals 

At the end of this course, you will be fluent in both solid as well as surface modeling tools. After completion of this course, you will understand the basics of SOLIDWORKS covering part modeling, assembly modelings, photo-realistic renderings. 

You will discover to create professional mood boards and initial ideation sketches in Adobe Photoshop. You will learn how to import & blend images, add watermarks and color. You will also learn how to create an American chopper and how to render it in Photoshop.

You will be introduced to SOLIDWORKS and will learn how to customize the shortcuts. You will learn the solid modeling techniques in SOLIDWORKSwhile modeling the Transmission belt, Kickstand, and Fenders. You will also learn how to add appearance to the parts.

In this module, you will learn how to create advanced sketches using patterns such as sketch and curved driven patterns, projected, and composite curves. You will also learn how to create complex shapes while modeling wheels, chassis, and engine.

You will be learning the use of mates to provide relationships between parts in an assembly. Advanced mates such as angle mates are provided to limit the rotation of parts.

In this module, you will learn how to add decals, lights, and cameras as a preprocessing step for the final rendering. You will be taken through the complete rendering process with PhotoView 360 and SOLIDWORKS Visualize. You will be creating high-quality images during final rendering.

You will be learning about the surface modeling features in SOLIDWORKS. You will learn how to create the part using the reference surface. Advanced surface modeling features will be taught while creating various parts of the Yacht such as hull, the superstructure, and seats. You will learn how to add the decals and appearances for the parts and assembly.

• Sketching tools
• Surface modelling tools
• Types of tools to create the surfaces
• Blueprint setups
  

• Splines
• Spline vectors
• Equal curvature for splines
• Constraining the splines
• Projected curve creation
• Composite curve generation 

• Types of surfaces
• Boundary surfaces
• Lofted surfaces
• Filled surfaces
• Ruled surfaces
• Reference planes
• Surface trims
• Surface knit
• Move/copy surfaces
• Mirror surfaces
  

• Revolve boss
• Extrude cut
• Linear and circular patterns
• Fillets
• Chamfers
• Split Bodies
• Creation of wheels

• Inserting the parts
• Mates in assembly
  
• Sub-assembly creations
  
• Difference between Float and fix parts
• Importing sub-assemblies to other assemblies
• Application of Decals
  
• Appearances adjustment