Case Study: IVECO achieves faster testing, reduced weight and cost for truck components with Altair HyperWorks

HyperWorks and APA Streamline Testing of Truck Components at IVECO Australia

Iveco, the Australian commercial vehicle manufacturer, faced the challenge of reducing size, weight and FEA solving time while improving component durability to avoid costly redesigns during physical testing. To address durability and vibration issues—notably for the chassis-mounted battery box—Iveco turned to Altair solutions, using the HyperWorks suite (HyperMesh, OptiStruct) and nCode DesignLife accessed through the Altair Partner Alliance.

Altair implemented a virtual testing workflow: HyperMesh for detailed meshing, OptiStruct for modal and stress analysis, and nCode DesignLife for DSP and transient modal fatigue. The Altair solution raised the battery box’s first natural frequency from 24 Hz to 74.3 Hz, eliminated stresses exceeding the steel UTS, significantly reduced strain energy in critical areas and achieved the required fatigue life—delivering weight and cost savings, faster development cycles, and easier FE model sharing across Iveco divisions.

Iveco

Larson Lawrence

Engineering Specialist