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Passion for engines and a great push towards innovation

hpe coxa

From Formula1 racing to aerospace and top-class industrial automation. Hpe activities, in collaboration with Coxa, are the feather in motor valley mechanics’ cap, investing as many resources as possible to train new generation experts.
During 2010 Hpe, founded at the beginning of the new millennium by Piero Ferrari, decided to acquire Coxa, a company with over 20 years’ experience in high-precision mechanic manufacturing.
Hpe-Coxa, specialized in design and production in highly technological sectors, can now boast a constantly growing turnover, that reached 21 million Euros in 2013, whose 30% obtained on international markets (Sweden, Germany and the United States). The work-force is constituted by 145 employees, 60% engineers, 30% specialized workers and 10% staff.
In relation to the automotive sector (in which “motorsport” represents a 30% of the total activities), Hpe-Coxa works with customers like Ferrari, CNH, Harley Davidson, Maserati, EADS, Ducati and Piaggio, being also the reference partner for Finmeccanica (Ministry of Defense) and, as far as the automatic machines is concerned, for Tetrapak and GD.

“We offer niche technology from design to production” states Andrea Bozzoli, General Manager. “We take care of every single detail, from the design of the prototyped engines for Formula 1 to the production of precision mechanic components for aerospace”. “Considering the quality of the product, our niche activity is oriented to the most advanced markets”, Ing. Ferrari explains, “Our business lines are high engineering, design & production of automatic machines, prototypes creation for both Formula 1 racing and motorsport. Being one step forward our competitors is the most challenging target we have and the crisis has made us even more passionate.”

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CAE driven product development: how ANSYS and modeFRONTIER speed up the design process
HPE S.r.l. has introduced ANSYS and modeFRONTIER softwares in its own activities since 2006. Being usable over a wide range of application fields, such softwares fit very well the wide virtual prototyping requirements needed by HPE, according to the numerical tools have to be used for structural, fluid-dynamics, process & manufacturing analyses purposes. Further, the integration of ANSYS, and all other tool typically used by HPE, in modeFRONTIER platform allowed to maximise the efficiency of numerical approach, both in terms of full exploitation of software/hardware resources (no CPU time is wasted since modeFRONTIER works in background modality), and in terms of capability to understand how the investigated phenomena behave and then to pursue the best performances.
So far several applications have been performed by using ANSYS and modeFRONTIER technologies.
The first remarkable one was a simulation of a Sodium cooled exhaust valve. The core was a FE thermal analysis model on ANSYS, quite simple by itself, but the environmental set, including fluid dynamics data from one-dimensional CFD, a second ANSYS thermal analysis model and several EXCEL sheets for pre and post processing, was rather complex. Linking the whole bundle was possible thanks to modeFRONTIER, which granted the correct workflow and allowed a quick solution in few iterations.

One of our most recent applications was an optimization of a 3-d airbox connection. Inlet and outlet were rigorously defined but how the two were communicating, aside of a few envelope conditions, was absolutely free. A modeFRONTIER optimization was carried out based on two objectives, pressure drop and flow uniformity, leading to a 4% uniformity enhancement and a 15% pressure drop lowering with respect to the initial solution, previously obtained as a result of several manual iterations.

Since the flow analysis was very time-consumptive, a first DOE on a bunch of SOBOL cases was performed to define a Response Surface (RS): the intensive optimization was then performed on the RS itself, thousands of cases in few minutes. Finally, a refinement genetic optimization on the real model, starting from a population of some RSM Pareto solutions, revealed the true Pareto frontier whence the best solution was chosen.



The most typical applications are counter-web optimization for engine shaft balancing, total mass reduction of mechanical components (in both elastic and elasto-plastic cases) and parameter tuning for mass reduction models in multi-body analyses. Further applications are geometry optimizations of an air filter components, oil consumption statistical analysis in journal bearings and also calendar optimization for resources scheduling.

Articolo pubblicato sulla Newsletter EnginSoft Anno 11 n°2


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