100 AI-Powered

Engineering Use Cases

Everything Solvable
Contents
03 / Background
04 / Introduction
05 / Objective
06 / How to Use This Book
07 / AI-powered Product Lifecycle: From Conceptualization to End-of-life Management
08 / Altair: Your Preferred AI-powered Engineering Partner
09 / AI-Based Physics Predictions
Altair® physicsAI™ Use Cases
13 / Predictive Analytics
Altair® RapidMiner® Use Cases
21 / AI-Based Reduced Order Modeling
Altair® romAI™ Use Cases
32 / AI-Based Design Exploration and Response Surface Methodology
Altair® HyperStudy® Use Cases

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Background
This convergence of simulation and data analytics not only promises to revolutionize how engineers operate but also holds
the potential to transform digital information into tangible digital assets. Altair’s commitment to assisting organizations
in navigating this digital transformation journey underscores its role as a catalyst for change in the engineering domain,
fostering a culture of innovation and progress.

By bridging the gap between the world of simulation and the realm of data analytics, Altair is poised to deliver actionable
insights that transcend organizational silos, empowering engineers to make strategic decisions that drive business growth
and operational excellence. As organizations embark on this digital transformation journey, Altair stands as a trusted
partner, guiding them towards a future where data is not just a resource but a strategic asset that fuels success and propels
them towards new frontiers of engineering excellence.

Altair is driving the convergence of design and simulation with Altair® HyperWorks®, data analytics and AI with
Altair® RapidMiner®, and high-performance computing (HPC) with Altair® HPCWorks™ under the umbrella of “AI for All.”
This vision aims to make powerful simulation technology accessible to all engineers. Here’s how:

• Simulation Analysts and Engineers: Utilize Altair’s solutions to predict simulation results and solve complex design
challenges by using historical data and AI-powered analysis.

• Non-Simulation Engineers (Mechanical, Electronic, etc.): Leverage Altair’s AI to seamlessly integrate with existing
workflows, enhancing product design, automating solution development, and accelerating design iterations.

• AI for All Users: Gain access to valuable insights from Altair’s AI solutions, which offer AI-driven design guidance
that are agnostic to specific physics or industries, enabling real-time predictions for diverse applications.

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Introduction
The engineering landscape is undergoing a paradigm shift, driven by the rapid integration of Artificial Intelligence (AI).
From design and development to testing and maintenance, AI is ushering in unprecedented efficiencies and capabilities.
This ebook examines 100 compelling use cases of AI-powered engineering, demonstrating how this technology is transforming our
approach to engineering the world around us. For newcomers to AI-powered engineering, we recommend our companion e-guide,
“AI for Engineering: Your Roadmap to Getting Started,” which provides practical advice and foundational insights for adopting AI
in your organization.

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Objective
The primary goal of this ebook is to illuminate the practical applications of AI in engineering.

By presenting 100 diverse use cases, we aim to provide engineers, designers, and decision-makers with concrete examples
of how AI can be leveraged to tackle complex challenges, accelerate development cycles, and achieve superior results.

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How to Use This Book
This ebook isn’t just a collection of problems and solutions – it’s a springboard for your next breakthrough. Dive into these 100 real-world
use cases, each showcasing the transformative power of AI. Explore how AI is used to conquer challenges, and discover how you can
replicate that success.

Don’t just read – be empowered! See these applications as blueprints, inspiring you to tackle your own unique challenges and propel
your engineering projects to new heights.

Altair’s flexible, unit-based licensing empowers you to go beyond these 100 inspiring use cases. This innovative model grants access
to all the essential AI tools. No need to worry about acquiring individual licenses – you have everything you need at your fingertips to
conquer not just the present, but the future of AI-powered engineering.

Everything solvable. Ask anything. Solve everything.

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AI-Powered Product Lifecycle:
From Conceptualization to End-of-Life Management
The incorporation of AI in engineering transforms traditional product development into a streamlined, dynamic process

• Conceptualization and Design: In the early stages of product development, leveraging AI enables teams to analyze and interpret
existing data to shape initial concepts. For instance, an automotive company might use AI to select optimal materials for the vehicle’s
body that balance weight, durability, and cost, such as choosing between different grades of steel, aluminum, or composites based
on predicted performance and environmental impact.

• Detailed Design and Prototyping: As designs progress towards prototyping, AI tools, equipped with fast physics predictions,
analyze potential outcomes of design choices, predicting performance under various conditions.
An aerospace company could use AI to simulate airflow over a new wing design, predicting how small changes affect
lift and drag, thereby optimizing the design before any physical prototypes are constructed.

• Testing and Optimization: During the testing phase, AI facilitates a deeper understanding of test results, identifying why certain
designs may not meet expectations. For example, a consumer electronics manufacturer might use AI to analyze why a new
smartphone model overheats under certain conditions, allowing engineers to quickly adapt the design and cooling solutions.

• Manufacturing and Maintenance: In the final stages, AI assists in refining manufacturing processes and predicting maintenance needs.
A machinery manufacturer could employ AI to predict when CNC machines are likely to fail or require maintenance, scheduling
preemptive servicing that minimizes downtime and maintains production quality.

• End-of-Life Management: AI continues to play a vital role as products approach their end of life. It helps in predicting the optimal
timing for product retirement and facilitates the efficient recycling or repurposing of materials. For example, in the electronics sector,
AI can help companies determine the best process for dismantling used smartphones and recovering valuable materials like gold
and copper efficiently.

This seamless integration of AI across all stages not only accelerates the development cycle but also enhances the quality and sustainability
of products. By adopting AI-powered engineering, businesses can transform how they design, develop, maintain, and responsibly retire
their products, ensuring they are prepared to meet future challenges and market demands.

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Altair: Your Preferred AI-powered Engineering Partner
Altair stands as a beacon of advanced AI-powered engineering solutions, seamlessly integrating best-in-class simulation, artificial
intelligence (AI), high-performance computing (HPC), and data analytics to provide a market-leading user experience. Built on
an open and programmable architecture, our tools offer unprecedented flexibility and control, allowing users to push the boundaries
of innovation. Leveraging our deep expertise in computational science, Altair serves as a strategic partner, uniquely equipped to tackle
the toughest engineering challenges and drive groundbreaking innovations.

Our platform supports the full spectrum of AI integration—augmenting, embedding, and enabling AI within engineering workflows.
This democratizes technology through intuitive, no-code/low-code analytics and AI workflows, making advanced capabilities accessible
to all engineers. We structure our AI-powered engineering tools around four fundamental pillars: Descriptive, Predictive, Causal, and
Prescriptive Analysis. Each pillar is designed to empower engineers with the intelligence needed to tackle modern challenges and seize new
opportunities. This holistic approach optimizes every project phase, fostering innovation and driving excellence in all engineering endeavors.

By providing the essential data backbone for AI enterprises, Altair not only supports but accelerates the journey towards digital
transformation, ensuring that every solution is both innovative and actionable.

• Descriptive Analysis: Go beyond traditional data interpretation with Altair’s AI-powered tools that simulate and model current
conditions and historical data. Understand product behavior under varied scenarios to make data-driven decisions efficiently.

• Predictive Analysis: Anticipate future challenges and opportunities with our sophisticated predictive tools. By modeling the potential
behavior of products under various conditions, these tools help you forecast future stresses and deformations, ensuring your designs
are both innovative and robust.

• Causal Analysis: Dive deeper into the ‘why’ with causal analysis. Altair’s AI algorithms analyze changes in behavior and performance,
revealing the underlying causes of stress increases and component failures. This insight allows for more informed decision-making
and enhanced design optimization.

• Prescriptive Analysis: Shape the future by not only predicting outcomes but also advising on the best course of action. Our prescriptive
tools suggest concrete steps to improve performance or mitigate risks, turning potential issues into opportunities for innovation.

Through this ebook, we invite you to explore the countless possibilities that AI brings to engineering, all demonstrated through Altair’s
market leading technologies and expertise.

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AI-Based Physics Predictions
Altair® physicsAI™ Use Cases
Overcoming Bracket Design Complexity
Accelerate Design Processes with Automated Classification
and Physics Predictions

Challenge Historical data

• Diverse Topology: Dataset with varying topology Training Data Test Data

• Manual Classification: Lots of time spent manually

classifying dataset

Solution
• Automated Classification: Use Altair® shapeAI™ classifier
to group data.

• Fast Physics Predictions: Train Altair® physicsAI™

on historical simulation data

Value Real-time exploration

• Result Prediction: Predict results on new, unseen CAD Data
CAD/CAE model

• Knowledge Transfer: Facilitate knowledge transfer

across different categories

Dataset generated by: MIT DSL, http://digitalstructures.mit.edu/

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Conquer External Aerodynamic Challenges with AI-Powered Physics
Unleash Speed & Accuracy - From 12+ Hours
to Minutes with Historical Data & AI

Challenge Historical data

• Large Model: Over 2 million elements with Training Data Test Data
extended solver times (12+ hours)

• Limited Data: Small training dataset (12 models)

Solution
• AI-Training: Train Altair® physicsAI™ on historical
simulation data.

Value
• Predictive Modeling: Accurate predictions on new,
unseen CAD/CAE model
Real-time exploration
• Performance Insights: Precise aerodynamic
performance assessments ML Runtime 3 min CFD Runtime 750 min

• Time Efficiency: Significant time savings

(minutes vs hours)

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Hood Impact Analysis
Enhancing Hood Impact Simulations with Altair® physicsAI™

Challenge
• Variable Impact Locations: Multiple potential impact
points to analyze

• Complex Simulations: Transient, large deformation

simulations required.

Solution
• PhysicsAI Training: Utilize Altair® physicsAI™ trained
on extensive simulation data.

Value
• Predictive Accuracy: Accurately predicts outcomes
on unseen, new CAD/CAE models

• Speed: Delivers predictions in seconds, not minutes

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Predictive Analytics
Altair® RapidMiner® Use Cases
Integration of AI/ML in Simulations
Advancing Aircraft Skin-Stringer Design with AI/ML
in the Initial Design Phase

Challenge
• Complex Calculations: Designing airplane skin requires
advanced knowledge and calculations

• Buckling Risk: Excessive bending can lead to failure

• Frequent Inspections: Regular checks are crucial

to catch issues early

Solution
• Advanced CAE Tools: Perform structural analysis
and faster design

• AI/ML Optimization: Predict and optimize designs

to save time and costs

• Predictive Maintenance: Ensure safety with data-driven

maintenance based on historical data

Value
• Speed: Faster identification of optimal skin designs

• Efficiency: AI/ML aids in creating stronger, efficient

airplane skins with data-driven decisions

• Savings: Automates tasks and detects issues early,

saving time and money.

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NVH Performance Assessment
Data-Driven Strategy for Quick
NVH Performance Assessment and Decision-Making

Challenge
• Early NVH Detection: Addressing NVH issues early is vital
for brand image, especially with fleet electrification

• Design Impact: Quickly analyze NVH performance

by altering design variables to ensure structural reliability

Solution
• Data-Driven Analysis: Use data and ML to create an
application for understanding the effects of design
variables on NVH performance

• No-Code Implementation: Leverage no-code ML models

and interfaces to analyze NVH metrics 100x faster than
traditional methods

Value
• Early Issue Detection: Enhance brand image
by addressing NVH issues early in the design stage

• Accelerated Analysis: Speed up NVH performance

analysis and decision-making

• User-Friendly Tools: Provide a no-code application

for efficient NVH metric analysis and improved
product lifecycle

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Steel Sheet Defects Detection
Object Detection on Surface Defects
of Hot-rolled Steel Strips

Challenge
• Quality Control: Ensuring steel quality is challenging
and impacts product cost and processing accuracy

• Processing Impact: Poor steel quality affects subsequent

processing precision

• Part Rejections: High losses due to part rejections.

Solution
• Defect Detection: Use computer vision to detect
and classify defects in steel sheets

• Real-Time Analysis: Integrate the trained model into

a dashboard for real-time inferencing.

Value
• Improved Quality Management: Enhance steel quality
control, reducing costs and improving processing accuracy

• Reduced Losses: Minimize part rejections

and associated losses

• Efficient Monitoring: Enable real-time defect detection

and analysis through a user-friendly dashboard

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Predictive Modelling for Headlamp Leveling Test (AIS 008)
Data-Driven Strategy to Transform Vehicle Testing Process

Challenge
• Regulatory Compliance: Headlamp checks (AIS 008)
at the DR4 stage involve time-consuming physical
loading of the vehicle with dead weights

Solution
• ML Predictive Models: Train ML regression models using
historical data to identify best model

• Sensitivity Simulator: Deploy an ML-based simulator

for analysis

• Dashboard Integration: Incorporate the final model

into a user-friendly dashboard to test the output on
new vehicle parameters

Value
• Faster Compliance: Streamline the headlamp
compliance process

• Improved Decision-Making: Offer precise predictions

for quick adjustments

• User-Friendly Access: Allow easy parameter testing

and adjustments via a dashboard

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Data Driven Digital Twin
Vehicle HVAC System Usage Analysis and Failure Classification
Using Vehicle Telemetry/Field Data

Challenge
• Customer Insights: Analyze HVAC usage and customer
behavior in various conditions

• Control Optimization: Adjust controls for diverse scenarios

• Failure Diagnostics: Identify and resolve system failures

through root cause analysis

Solution
• Digital Twin: Harness data from operational vehicles
or systems (test or in-service) to create a digital
representation of the physical HVAC asset

• Predictive Analysis: Build Digital Twin to forecast HVAC

system conditions

• Root Cause Analysis: Perform analysis to identify

and resolve system failures using data-driven insights

Value
• Informed Decisions: Aids decision-making in development

• Optimized Performance: Enhances HVAC

operational efficiency

• Continuous Development: Enables iterative improvements

through feedback loop

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Smart Grid Energy Management Systems
An AI-Layered with Multi-Agent Systems Architecture
for Prognostics Health Management of Transformers

Challenge
• Grid Energy Management Complexity: The integration
of distributed energy resources and storage systems
complicates grid management, posing challenges at
various grid stages

• Transformer Failures: A need for automation in identifying

and categorizing transformer failures, including bushing,
oil preservation, and core issues

Solution
• AI-Powered Diagnostic System: Deploy an AI-based
system using smart sensors to analyze transformer health,
incorporating diagnostic algorithms, Health-Index, and
Life-Loss estimations

Value
• Increased Grid Reliability: Enhances stability and reduces
downtime by predicting and diagnosing failures

• Optimized Maintenance: Streamlines maintenance

strategies, lowering costs and extending equipment life

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Battery Analytics: Life (SoH) Prediction
Accurately Determine Battery State of Health
and Remaining Useful Life Using Field Data

Challenge
• Data Utilization: Use field data to predict battery
RUL and SoH

• Environmental Influence: Account for environmental

and load conditions

• Measure Battery Life: Challenging to measure

battery capacity accurately in real-time, crucial
for RUL assessment

Solution
• SoH Prediction: Create a model to forecast battery
RUL using data

• Real-Time Adaptation: Implement models that adjust

in real-time to environmental and operational conditions

Value
• Battery Optimization: Assess and optimize battery life
for improved performance

• Fleet and Asset Management: Boost uptime and manage

warranty and value proactively

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AI-Based Reduced Order Modeling
Altair® romAI™ Use Cases
Multi-disciplinary Optimization of Avionic Systems
Application of AI/ML to Expedite Complex Systems

Challenge
• Complex Interactions: Modeling different disciplines
and their interactions

• Optimization Constraints: Optimizing a multi-disciplinary

problem with numerous constraints

• High Computational Load: Managing computationally

intensive simulations

Solution
• Efficient ROM Creation: Use Altair® romAI™ to create
efficient (up to 10x) and accurate (>99%) reduced order
models (ROMs)

• Workflow Integration: Seamlessly integrate the ROMs

into the current workflow

• Constraint Optimization: Perform multidisciplinary

constraint optimization using Altair® HyperStudy®

Value
• Reliability Improvement: Up to 600% improvement
in Mean Time Between Failures (MTBF)

• Energy Efficiency: Up to 6% improvement in

Environmental Control System power efficiency

Von Dtom - Eigenes Werk, CC BY-SA 3.0

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Fast Strength Verification for Airworthiness Certification
Application of AI/ML to Expedite Verifications

Challenge
• Verification Speed: Need to quickly verify airworthiness
specifications at various gust profiles and altitude levels

Solution
• Efficient ROM Creation: Utilize Altair® romAI™ to develop
accurate dynamic Reduced Order Models (ROM) from
a single high-fidelity transient simulation

Value
• High Accuracy: Achieve verification accuracy greater
than 99%

• Faster Verification: Boost the verification process

up to 10 times faster

• Enhanced Insight: Gain a better understanding

of physical behavior through advanced modeling

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Estimation of the Remaining Moisture Content
in Cloths During Operations
Application of AI/ML from Test Data

Challenge
• RPM Optimization: Optimize drum RPM in spin cycles
to enhance water and energy efficiency

Solution
• Dynamic Modeling: Deploy Altair® romAI™ for
dynamic model creation from minimal tests, enabling
effective prescriptive analysis on moisture retention
in clothes over time

Value
• Enhanced Accuracy: Outstanding accuracy of the model
even outside the bounds of the data used for the training

• Operational Efficiency: Code generation allows for

embedding the dynamic model directly into the
washing machine, enhancing operational efficiency
and resource management

Model results for training data Model results for test data out
of training bounds

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Linen Weight Estimation from Sensor Data
Applying AI/ML to Create a Virtual Sensor for Resource Efficiency

Challenge
• Resource Optimization: Reduce water and energy
consumption in washing machines

Solution
• Virtual Sensor Creation: Create a virtual sensor
to estimate the dry weight of linen from sensor
data using AI/ML models

Value
• Energy and Water Saving: Achieve significant energy
and water savings

• Hardware Deployment: Possibility to deploy the solution

in hardware, creating a virtual sensor

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Operational Digital Twin for Sheet Metal Forming
Enhancing Process Control and Reducing Waste with Altair® romAI™

Challenge
• Process Divergence: Identify causes of divergence from
nominal conditions in the sheet metal forming process

Solution
• Digital Twin: Build an operational Digital Twin for
monitoring and improvement with Altair® romAI™

• Data Integration: Train ROM with simulation data to

analyze sensor data and identify divergence causes

• Real-Time Dashboard: Use a dashboard for real-time

monitoring and information

Value
• Improved Control: Enhanced process control
and monitoring

• Waste Reduction: Reduce waste production by over 15%

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Advanced What-If Analysis for Sheet Metal Forming
Boosting Efficiency with Enhanced ROM Techniques

Challenge
• Understanding KPIs: Quickly understand the variation
of KPIs as a function of material properties and operating
conditions (pad force, die friction)

Solution
• High-Fidelity Modeling: Use Altair® Radioss® for
the high-fidelity modeling of the forming process

• Automated Data Generation: Utilize Altair® HyperStudy®

and Altair® Compose® for the automatic generation of
training and test data based on a fractional DOE (MELS)
applied to the Radioss simulations, from which KPIs are
automatically calculated with Compose

• ROM Generation: Generate the ROMs for KPI estimation

using Altair® romAI™

• ROM Hosting: Host ROMs with Altair® Activate®, which

calculate KPIs on both the product and the press machine
to ease the what-if analysis

Value
• Run Time Reduction: Achieve a run time reduction
from 4 hours to 1 second, enabling a fast and easy
what-if analysis

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Optimization of the Heat Pump Controller
Enhancing Performance and Efficiency through Advanced Control Strategies

Challenge
• Controller Optimization: Optimize the controller
of electro-valves used in heat pumps across various
building types

Solution
• Model Identification: Identify an accurate model of the heat
pumps using Altair® romAI™ , enabling virtual testing
of different control strategies

• Data Processing: Automatically process and adjust

field data used for training/testing, extracted from
the IoT platform, using Altair® Monarch®

• Controller Design: Host the identified ROM model and

design the optimized controller using Altair® Activate®

Value
• Increased Efficiency: Achieve over 8% increase
in heat-pump efficiency

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Aerodynamic Evaluation of Different Airfoil Designs
Utilizing CFD and ROMs for Efficient and Accurate Airfoil Analysis

Challenge
• Extended and Costly Simulations: Traditional CFD
simulations for multiple airfoil designs are time-intensive
and require significant computational resources

• Coefficient Variation Analysis: Difficulty in assessing

coefficient variation for different airfoil designs in transonic
and inviscid flow

• Complex Data Management: Challenges in managing

and comparing large datasets from various airfoil designs

Solution
• CFD Data Collection: Conduct CFD simulations to collect
training and test data

• ROM Creation: Create ROM to estimate the pressure

coefficient of an airfoil based on its design

• Integrated Analysis: Use ROMs to quickly and accurately

compare the coefficient variation of airfoil designs

Value
• Time Efficiency: Drastically reduced simulation times
from 140s to <3s

• Improved Workflow: Streamlined data management

and analysis process for handling multiple airfoil designs

• Good Generalization: Excellent generalization capability

for modeling highly non-linear aerodynamic phenomena

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Evaluate Thermodynamics of a Heater
Rapid Analysis of Linear Actuator Time Constants Using CFD-Based ROMs

Challenge
• Time-Consuming Analysis: Enable quick study of the time
constant of a linear actuator when using different springs

• Dynamic Simulation Complexity: Accurately model

thermo-fluid dynamics for various spring configurations

• Integration Challenges: Efficiently integrate dynamic

models into system-level simulations

Solution
• Data Generation: Use Altair® AcuSolve® to generate
training and test data

• Model Creation: Build dynamic ROMs

(Reduced-Order Models) with Altair® romAI™

• System Integration: Integrate the ROMs with the controller

in a system-level simulation using Altair® Activate®

Value
• Efficiency: Achieve extreme efficiency with run time
reduction from 6800s to 1s

• High Accuracy: Maintain excellent accuracy >98%

compared with high-fidelity simulations

• Reduced Simulation Needs: Require only one transient

CFD simulation to generate the training data

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Improving Passenger Thermal Comfort Simulations
Calculating Cabin Temperatures Through CFD-Based ROMs for System Simulations

Challenge
• Complex Thermal Dynamics Integration: Difficulty
in real-time coupling of CFD and system-level simulations

• Simulation Model Fidelity: System simulation model

lack accuracy when using equations

• Extended Computational Time: Long run time

of CFD simulations required for romAI data collection

Solution
• Comprehensive Data Gathering: Run CFD simulations
to collect detailed data

• Advanced Model Development: Build Altair® romAI™

models using dynamic and static ROMs

• Seamless Integration: Deploy romAI models

in Altair® Twin Activate™ for system simulation

Value
• Real-Time Insights: Achieve real-time coupling
of CFD and system simulation for immediate feedback

• Improved Precision: Increased accuracy in system

simulation leads to informed design decisions

• Faster Turnaround: Significantly reduced CFD run times

speed up the development process

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AI-Based Design Exploration
and Response Surface Methodology
Altair® HyperStudy® Use Cases
Rattle Performance Optimization
Optimizing Design Parameters to Reduce Automotive Rattle
with Machine Learning

Challenge
• Noise Issues: Rattle noise negatively affects customer
satisfaction, increasing warranty claims and reducing
brand loyalty

• Complex Design Variables: Numerous parameters

influence rattle performance

• Optimization Difficulty: Eliminate or minimize

rattle noise effectively

Solution
• Parameter Identification: Perform DOE to identify
the most influential parameters

• ML Modeling: Use machine learning models to accurately

capture rattle phenomena

• Design Optimization: Optimize design parameters using

machine learning models to find optimal solution

Value
• Rapid Evaluation: Quick evaluation across a larger
design space

• High Accuracy: Achieve accuracy comparable

to traditional solvers

• Accelerated Optimization: Multi-objective optimization

completed within seconds

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Digital Twin for 2-Wheeler Batteries
Empowering Electrification with Real-Time Virtual Sensors
to Measure Battery State

Challenge
• Sensor-Free Monitoring: Develop a digital twin to
monitor supplier-procured batteries in real time
without physical sensors

Solution
• Digital Twin: Create physics-based digital twins
of a battery pack using real-time sensor data

• Data Acquisition: Collect motor current and RPM

in real time using IoT sensors from the physical asset

• Predictive Modeling: Connect a 1D physics-based digital

twin model to predict KPIs like SOC, SOH, voltage,
and current

• In-Service Monitoring: Stream and visualize all battery

KPIs in real time

Value
• Real-Time Monitoring: Continuously monitor critical
battery KPIs without physical sensors

• Proactive Maintenance: Use performance insights

for timely maintenance and optimization

• Cost Savings: Reduce the need for physical sensors,

lowering costs and simplifying battery management

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Head Injury Criterion Value Predictions
Quick Design Insights for Fewer Iterations
and Optimal Resource Utilization

Challenge
• High Computational Demand: Simulations are
compute-intensive, repeatable, and iterative.

• Regulatory Requirements: Even small changes

necessitate simulations for verification.

• Time-Consuming Process: Iterative verifications

are lengthy.

Solution
• AI and Data Analytics: Use AI to train models with
historical simulation data from various vehicle variants
and versions

• Automated Data Extraction: Automate the extraction

of independent and dependent variables from simulation
input and result files

• ML Enabled Verifications: Designers and CAE engineers

use trained ML models for rapid verifications

Value
• Faster Verification: Reduce design verification
time through early AI-based verifications and
concept evaluations

• Resource Efficiency: Decrease the use of expensive

resources (software, hardware, and experts)

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Real-Time AI Monitoring for Smart Manufacturing
Overcoming Process Challenges in Injection Molding
with AI/ML Diagnosis and Improvement

Challenge
• Quality Issues: Frequent defects of manufactured parts

• Efficiency Gaps: High cycle times and excessive waste

• Process Complexity: Huge number of parameters

making diagnosis difficult

Solution
• Real-time Monitoring: Using sensors and AI for
continuous process adjustments

• Predictive Analytics: ML algorithms optimize settings

to prevent defects

• Automated Adjustments: Dynamic system responses

based on AI insights

Value
• Quality Improvement: Reduction in defects and higher
product quality.

• Operational Efficiency: Decreased cycle times and waste

• Cost Savings: Reduced downtime

and operational expenses

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Making Better Megacastings
Response-surface-method (RSM) based
crash optimization using AI/ML

Challenge
• Complex Design: Intricacies in megacasting design
and manufacturing.

• Data Overload: Necessity for processing extensive

simulation data

• Sustainability Objectives: Develop lighter products with

superior multidisciplinary performance (crash, NVH, etc).

Solution
• Multidisciplinary Design Exploration: Analyze design
requirements and manufacturability from multiple designs

• AI/ML Clustering: Utilize AL/ML to identify

top-performing designs

• Structural Optimization: Utilize lightweighting strategies

that maximize energy absorption and minimize
deformation to avoid ruptures

Value
• Design Freedom: Enhance products’ lightweight potential
with expanded design flexibility and material properties

• Operational Efficiency: Reduce losses associated

with part quality and improve resource utilization

• Faster Time to Market: Accelerate product development

for quicker market entry

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Everything is solvable at Altair.
Ask anything, solve everything with AI that lets you work
1000x faster with the tools you already use.

Contact Our Experts Today.

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