Computer-based Engineering in the Automotive Industry

The automotive industry has been using computer-based engineering since the 1980s.

Initially simulations were limited to structural verification of single components, with the first simulations for production processes such as foundry, deep-drawing and plastic molding. Since then, technological advancements have made the computer processing power available at lower costs. This has led to the virtual simulation, of both components and complex systems, with a high degree of confidence, making it an integral part of the product design and development process for both the OEM and tier 1 and tier 2 suppliers to the automotive industry.

For the last several years the industry has been investing in simulation based engineering projects and OEMs and their suppliers are now putting more emphasis on multiobjective optimization.

Today, numerical simulation models are indispensable tools for: reducing the time to market and product development costs, especially in the design phase of a product when crucial choices are made and where the subsequent reversal of those choices can prove to be extremely costly; facing new technological challenges related to:

the use of new materials such as light alloys, high strength steel, composites and nanomaterial coatings
new manufacturing processes and joining technologies
new methane, biogas, fuel cell, hydrogen or electric fuel systems that are either running solely on that fuel or as a hybrid system
new vehicle architecture for city driving or hybrid vehicles
optimization, driven by the need for improved components, systems and the entire vehicle – this has inevitably led to the use of numerical simulation in the design phases as opposed to using it just in the verification phase

EnginSoft has been a player in virtual simulation since its inception. With years of consultancy projects behind it in the automotive industry, EnginSoft boasts a broad range of multi-disciplinary expertise which spans from mechanical and resistance analyses, deformability and durability, crash analysis and ride comfort to the thermal, fluid dynamic, acoustic, electromagnetic and optical fields. Using the best commercial tools for the job, and writing custom routines when necessary to complete the job, we cover simulation and the optimization of the entire production processes.

Engineering Simulation in the Oil & Gas Industry

The upstream sector also known as the Exploration and Production (E&P) sector, normally covers the exploration and discovery of sources of crude oil and gas both onshore and offshore. It also covers the drilling of exploratory wells and the operation of these wells to extract the discovered energy source and bring it to the surface for transportation to refineries.

The main physical aspects that can be simulated when building an upstream virtual model include:

Reservoir and geology simulation (basin modeling and simulation, well data interpretation, near-well modeling of multiphase flow simulation, utilizing, for example, reservoir simulation software)
Production phase simulation (completion processes, liquid/gas production processes, well distribution systems, etc.)
Subsea systems design and analysis (pipeline lay analysis, simulation and analysis of mechanical-structural components and devices, stress analysis and design of pressure components, etc.)
Offshore structures design and analysis (simulation and analysis of fixed and floating offshore structures, structural verifications and code checks, revamping of existing fixed offshore structures based on the stochastic fatigue approach, simulation and analysis of pressure vessels and pressure components, vessel and pipeline dynamic motion analyses for S-laying or J-laying pipeline configurations).

The downstream sector refers to the extracted hydrocarbons in their liquid form (petroleum) or in their gaseous form (natural gas) being refined and the subsequent distribution of derivative products such as fuels, petrochemicals, lubricants and residuals for use in by-products.

The main physical aspects that can be simulated when building a downstream virtual model include:

Heat and mass transfer in distillation columns, heat transfer equipment
Bulk liquid storage structures for both atmospheric and low temperature/cryogenic storage
Pressure drop evaluation
Mist eliminators
Process furnaces
Fluid dynamic analysis of coker and vacuum towers
Evaluation of inlet feed devices to reduce the liquid entrainment and velocity to improve vapor distribution
Understanding of risers, regenerators, and cyclones for the FCC process
Investigation of flow patterns and FSI in horizontal and vertical piping
Flow rate meters/flow meters
Gravitational separators
Petrochemical storage and process vessels
Refinery process units
Petrochemical facilities
Gasification plants, hydrogen generating plants
Equipment simulation optimization

EnginSoft's primary areas of expertise in the Oil & Gas and Offshore Industry is in the upstream and downstream sectors. Our expertise ranges from geotechnical-geomechanical engineering (including reservoirs simulation and exploitation) to fluid mechanics engineering; from structural engineering to analysis and simulation, design and assessment. To initiate a discussion, please contact us with your specific requirements.

The Construction Industry

Among the many challenges faced by the industry, the following stand out:

compliance with global climate change regulations;
the safety and health monitoring of aging infrastructures, which need to be brought up to modern safety standards;
cost overruns due to insufficient analysis at the design stage of the project.

These issues are forcing the industry to invest time and resources in the following areas:

green buildings, also known as sustainable or high performance buildings; a new field that is gaining quick momentum in the discovery and implementation of processes that are environmentally responsible and resource efficient;
new manufacturing processes and materials, which are the main drivers for applied research in the field. Materials typical of other industrial disciplines, such as composite materials, are increasingly being used in the construction industry;
more detailed designs to ensure compliance with a broad range of increasingly demanding technical standards;
improved assessment and verification of the consequences of rare events associated with significant risk levels for the community in the form of improved fire, seismic and impact analysis of structures in the design phase of a project. The design phase is therefore becoming increasingly important in order to reduce hazards or unexpected circumstances which may have major consequences on the allocated budget.

Today, numerical simulation plays a crucial role in the construction industry. It provides indispensable design tools for the prototyping of new products and structures, resulting in their production at a fraction of the cost that would be incurred if extensive physical testing was used instead. Structural analysis, in which numerical simulation techniques have become the industry standard, provides a palpable example of this.

The complexity of the simulation software available, allows the engineer to deal with most application areas in the construction Industry, even those requiring multi-disciplinary fields such as soil-structure interaction and fluid-structure interaction. Optimization frameworks can be also exploited to drive numerical simulations and to obtain minimum cost solutions, which is of particular importance when facing budget constraints.

EnginSoft offers consultancy in a wide range of civil engineering applications with expertise ranging from the structural analysis of bridges and stadiums to the design of tunnels, to the assessment of offshore installations and the development of expert systems for precast components. EnginSoft is your ideal partner for specific project related consultancies and for the development of integrated tailor made design solutions.

EnginSoft and the Energy Industry

The energy scenarios and the reduction of greenhouse gas emissions underlie the development and extensive use of technology that makes the proposed goals possible. This development requires both heavy investment in research and development (public and private), and incentive policies to achieve economic self-sustainability. Precisely this requirement means that the countries should ask themselves and give clear indications of, what must be done and which technology should be deemed as a priority.

In this context the European Commission has developed a Strategic Energy Technology Plan that brings technological innovation to the center of strategies to reduce greenhouse gas emissions and ensure the security of energy supply.

The development and subsequent industrialization of all these new technologies, from the technical and scientific point of view, requires and will require in the coming years a huge commitment of intelligence, first-class technical skills, and tools for designing components and systems in the best ways.

In this context, CAE Technology and Intelligent Digital Prototyping (iDP) hold, and will increasingly hold, an absolutely determining role in whether the project ideas can be tested, optimized and validated before prototypes are built.

EnginSoft is a company that has based its competitive advantage on virtual prototyping since the 1980es, and has always been diligent in the training and formation of its technical staff in order to provide companies with the best solutions and the most suitable software for their specific needs.

EnginSoft’s strength is the multidisciplinary approach that includes all areas of Computer Based Engineering, from the manufacturing process to the detailed 3D CFD simulation of power generation components such as turbines, compressors, heat exchangers, and more.

The challenges facing the Aerospace Industry

From a structural point of view, the aerospace industry requires integrity of each component at many different operating points, from take-off/landing to the upper atmosphere to outer space, where thermal gradients on satellites are extreme and greatly affect structural calculations. In this regard, explicit dynamics simulation has become standard practice when investigating the effect of bird strike on an engine, evaluate blade containment strategies for fan blade out, or investigate the reasons for structural failure on a specific component. As today’s civil aerospace industry accounts for about 2% of the worldwide CO2 production, a lot of research is taking place to develop lighter structures employing composite materials, in order to save weight, consume less fuel and therefore reduce the overall environmental impact.

For the same reasons, new solutions for civil engines have been developed, allowing them to become more efficient in terms of fuel consumption thanks to advanced CFD modeling techniques, applied to fuel injection and cooling systems, combustion chambers and augmentor design. Aerodynamics is also an important topic of research in order to develop high-lift, efficient wing profiles both for cruise and take-off/landing operating conditions. Aerodynamic noise is also relevant here: CFD codes coupled with an acoustic solver have created a new discipline called CAA (Computational Aero Acoustic) to predict aero-acoustic noise. Another coupling takes place when CFD joins FEM in Fluid Structure Interaction (FSI), often employed to calculate the flutter phenomenon, as well as the rotor-dynamics of helicopters.

Electronic components have a high impact on the cost of aircrafts and helicopters. Therefore the field of Electromagnetism is very important for the aerospace market, as many devices can cause interference problems (we all need to turn off our mobiles at take-off and landing after all) and antennas signal integrity must be assured for navigational purposes. Finite Element Analysis and CFD is often employed for analyzing the stress/strain field on electronic components, deriving from dynamic loads as well as thermal gradients.

As aerospace is a mature industry, many components generally have had a long development history and are quite reliable and performing. Yet, the development of new, innovative technologies, along with the strife for continuous improvement of existing parts, makes FEM or CFD or EM calculations alone not enough. The real challenge is to integrate all of these technologies in a design and optimization process such as PIDO (Process Integration and Design Optimization). This is where the CAE market is moving, and that is where partnering with EnginSoft can make a real difference for your company.

At EnginSoft, we have a vast experience in multi-disciplinary simulation consulting for the aerospace industry. Some notable research/projects we have been working on lately and our areas of expertise are here reported:

Space: EnginSoft has been a key participant in MELiSSA (Micro Ecological Life Support System Alternative) and ALISSE (Alternative Life Support System Evaluator) research projects, to develop the technology required for a future biological life support system for long term manned space missions, sponsored by the European Space Agency ESA; has performed thermo-structural analysis for satellite electronics housing using ESAComp (a software for the design of composite structures, developed by Componeering, a company co-founded by Enginsoft); performed explicit dynamics simulations to optimize airbag deployment on the ExoMars rover
Aircrafts: structural optimization of composite wings; turbine inlet design and optimization; aeroacoustics of jet engines; multi-phase fluid modeling and spray atomization; design of aeroengines components such as combustors, high- and low- pressure turbines, gear pumps and breathers; bird strike and fan blade out analysis.

EnginSoft and the Consumer Goods Industry

CAE tools have nowadays become a common industry standard to rapidly give companies the strategic elements mentioned above, as well as to completely quantify the uncertainties/tolerances of the actual and simulated processes, in order to reduce waste and to conform to production quality standards (six sigma, among others).

New CAE software tools are continuosly being developed to progressively abandon the old “trial and error” method, which is slow and wasteful, in favor of an integrated, optimized process where all the design parameters are quantified and can interact with one another. Some notable examples of an integrated approach to CAE in the consumer goods industry are here reported:

in the field of household appliances, structural, thermal, fluid dynamics and acoustic analyses provide the possibility to improve performance, achieve packaging and product efficiency, and enable data-driven decision making during the design phase. The test phase, as a result, is only used on the actual prototype for a final inspection
in sporting equipment production, the use of CAE is fundamental in order to simulate the behaviour of the sporting apparatus under extreme conditions, to test new materials as well as alternative shapes/modifications aimed at improving product performance before prototype production
in the electronics field (pc, tablet, telephony), crash, thermal and electromagnetic analyses are performed using the finite element method (FEM), in order to improve the quality and duration of the produced items
in the food industry, integrating Computer Based Engineering into production flow, not only for production machinery design, but also for packaging, conservation and fine-tuning of the production process itself, can provide a lasting competitive advantage to the manufacturer

EnginSoft’s strength is the multidisciplinary approach that includes all areas of Computer Based Engineering. In fact, its expertise covers all types of analyses for both product and process, including mechanical (structural inspection, exertion, crashes), thermal, thermal-structural, fluid dynamics, acoustics, electromagnetics.

CASE STUDY

Using CAE simulation to verify the structural safety and performance of a two-wheeler’s driving mechanism

Coupled simulation methods enables more accurate evaluation

In this article, we describe how Piaggio used computer-assisted engineering simulation to evaluate the structural safety, performance and dynamic behavior of the driving mechanism of a two-wheeled vehicle under both normal and spurious operating conditions, specifically static and fast dynamic conditions.

automotive multibody

CASE STUDY

Steel Casting Optimization of a Gas Diffuser

An optimal gating and feeding system for the production of steel parts

The object of this study is a steel diffuser, which for obvious reasons needs to comply with very strict quality guidelines and industry regulations.

metal process simulation die casting metal-process-simulation magma consumer-goods

CASE STUDY

CFD Characterization of the Ventricular Assist Device HeartAssist 5® Through a Sliding Mesh Approach

Analysis to determine possible optimizations to enhance device safety and efficacy for long-term patient use

This technical article describes how high-end numerical Computational Fluid Dynamics (CFD) simulations were applied to mimic the realistic operating conditions of a Ventricular Assist Device (VADs) and analyze its hemodynamics in order to identify potential areas for optimization of the device’s performance, safety and efficacy.

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CASE STUDY

Whirlpool uses simulation to investigate improvements to vacuum cleaner performance

Simulation studies help Whirlpool identify the most useful design modifications to support its product objectives

This article describes how EnginSoft applied a Computational Fluid Dynamics (CFD) analysis, on behalf of Whirlpool EMEA, to simulate three different geometrical design modifications to the vacuum cleaner head to improve on a baseline performance that was modelled first.

appliances cfd ansys

CASE STUDY

Filming the Bloodhound Super Sonic Car Land Speed Record

Using CAE to optimise the design of a prototype for a super sonic filming drone

This detailed technical case study describes how the students arrived at a supersonic aircraft drone prototype using MATLAB and modeFRONTIER in order to reduce the time and costs of numerical and wind-tunnel testing.

automotive modefrontier optimization

CASE STUDY

Creating an accurate digital twin of a human user for realistic modeling and simulation

Multibody system simulation using biomechanical human body models in RecurDyn

This technical article describes a human body model (HBM) wizard developed for RecurDyn and discusses what is already possible and what is in the development pipeline for the near future. Biomotion Solutions provides software to quickly build HBMs in industrial-grade simulation packages.

multibody recurdyn industry4 biomechanics

CASE STUDY

Rainfall test simulation of an air conditioner’s outdoor unit using Particleworks

This article presents the simulation of rainfall on the outdoor unit of an air conditioner as a concrete example of this approach.

appliances particleworks

CASE STUDY

LS-DYNA and modeFRONTIER for Material Model Calibration at Automobili Lamborghini

The main challenge is to reproduce their structural behavior by developing suitable numerical models

While the engineers relied on modeFRONTIER's capabilities, the procedure has been to calibrate the constitutive parameters of LS-DYNA's advanced material models, and to use them for prediction, design optimization and robustness analysis.

modefrontier ls-dyna automotive composites

CASE STUDY

Conduct fatigue checks directly in Ansys Mechanical using SDC Verifier

Template-based design automates future routine work, and automated documentation facilitates report generation

A lot of steel structures such as cranes, heavy machinery and other equipment subjected to repetitive loading is highly likely to develop cracks or failures because of the fatigue damage.

civil-engineering ansys sdc-verifier

CASE STUDY

Industrial Sheet Metal Processing Company

Salvagnini chooses RecurDyn for multibody analyses

Salvagnini is a reference in applying intelligence to sheet metal working and has selected RecurDyn software for its multibody analysis requirements, becoming the 500th commercial customer of FunctionBay Inc.

multibody recurdyn

CASE STUDY

High Quality Printing with CFD

Simulation allows engineers to improve print quality, ensure operator safety and contain energy consumption

In this article, Uteco describes how it applied Computational Fluid Dynamics (CFD) to assist the design and improvement of its printing machines.

cfd ansys mechanics

CASE STUDY

Finite Elements Investigations about the Warm Hydroforming Process of Aluminum Alloys using LS-DYNA

The tensile and formability tests in warm condition

The present work investigates the Warm Hydro Forming (WHF) process of an AA6xxx series alloy (AA6061-T6) using a numerical-experimental approach.

ls-dyna metal-process-simulation

CASE STUDY

Controlled Floater for Marine Pipeline Towing

A system to simplify the towing and laying down of marine pipelines in shallow water fields

A developer of innovative equipment designed a system to simplify the towing and laying down of marine pipelines in shallow water fields.

energy modefrontier optimization oil-gas recurdyn

CASE STUDY

Improving the performance of shaped charges and passive ballistic protections

CAE models evaluated using two commercial solvers

In this technical article, the authors discuss the development of CAE models for simulating the behavior of shaped charges, devices used in various industrial sectors, against two types of target – a monolithic steel target and a multi-layer steel-ceramic target – in order to better understand the physics of penetration.

ansys ls-dyna civil-engineering mechanics oil-gas

CASE STUDY

CFD-Driven Design of a Ventilation System for Kitchen Hoods

Optimized design achieves energy efficiency and cost containment objectives

This article presents a study that the Elica Group commissioned from EnginSoft to support it engineering team in redesigning the ventilation system of its “Tilly” kitchen hood model

appliances ansys cfd

CASE STUDY

Multi-Objective Optimization of a Sailing Yacht Aluminum Mast

The optimal mast weight under specific structural strength requirements

The aim of this study was to reduce the weight of the world’s tallest aluminum mast for a new series of single mast sailing yachts manufactured by Perini Navi under the brand name Salute.

optimization modefrontier ansys marine rail-transport

CASE STUDY

Digitizing a process to standardize the analysis and evaluation of windshield wiper performance

TAE SUNG collaborates with DY Auto to develop dedicated software

This technical article describes a project that was undertaken by TAE SUNG Software and Engineering, in collaboration with DY AUTO in Korea, to establish a computerized process to conduct three-dimensional real-scale analysis of any of the three types of windshield wiper currently in use, and to establish a specific standard for evaluating wiper performance.

automotive ls-dyna ansys

CASE STUDY

Integrated Life Cycle Design for Buildings: Invest in Simulation to Increase Comfort and Environmental Sustainability at a Reasonable Cost

Sustainable building design

This article presents a business case for the use of simulation methods and technologies in the construction sector, particularly for decision-support in sustainable building design.

civil-engineering construction environmental

CASE STUDY

Lateral Buckling Analysis of a Cable-Stayed Arch

A brilliant example of how computer aided engineering can assist engineers to contrive an optimal solution to the problem of lateral buckling

The cable-stayed arch on one of the three bridges designed by Santiago Calatrava in Reggio Emilia: a brilliant example of an optimal solution

civil-engineering construction straus7

CASE STUDY

Multi-purpose ANSYS APDL script developed for analysis of matter-radiation interaction

Ability to predict thermal and mechanical behavior within specific physical parameters has multiple industrial applications

The accurate modelling of the matter-radiation interaction is essential to predict the physical behavior of the materials used, such as their fatigue lifetime. This technical article describes the development and application of this tool, using the ANSYS APDL script

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CASE STUDY

Using simulation and validation to build trust in new tools

A multibody simulation of a switch disconnector

This article describes the multibody simulation of a switch disconnector and its validation with experimental tests, undertaken by LOVATO Electric for the purpose of conducting a detailed evaluation of a potential new tool to design the mechanical part of its electrical devices.

recurdyn multibody electronics

CASE STUDY

Cost Effective High- Performance Design: Innovation is the Answer

Marelli Motori applies multiphysics simulation to cost-effectively design better, more reliable motors and generators faster

Improving efficiency while reducing cost is a very complex engineering challenge. Marelli Motori makes extensive use of CFD and FEM multiphysics simulation to do just that in the design of its electrical motors and generators.

ansys automotive cfd

CASE STUDY

Innovative and Integrated Technologies for the Development of Aeronautical Components

A more efficient simulation procedure for the design phase of Al-Si alloy components for the aeronautical industry.

The scope of this study was to determine and validate a more efficient simulation procedure for the design phase of Al-Si alloy components for the aeronautical industry.

aerospace magma metal process simulation

CASE STUDY

Fluid Dynamics Optimization of Racing Engine Inlet Ducts at Aprilia Racing

Optimising racing engine inlet ducts using fluid dynamics

Racing engines are continuously evolved and fine-tuned to allow them to achieve extraordinary levels of performance, albeit with great complexity. However, MotoGP regulations restrict engine development by constraining some of the main design parameters.

optimization modefrontier cfd ansys rail-transport

CASE STUDY

Woodrail Road Barrier Impact Analysis

The Woodrail^® road barrier is designed to improve vehicle safety blending in with the surrounding environment.

The barrier has been thoroughly tested and certified against car and bus impact conditions.

automotive ls-dyna

CASE STUDY

Acoustic assessment of an electric water pump using Ansys Workbench and Multiphysics simulation

Feasibility study of a complete acoustic workflow

This technical article describes an acoustic emissions study conducted on an electric water circulation pump used for supplementary cooling or heating functions in vehicles, by the Modeling & Simulation Pumps Department of Pierburg Pump Technology

acoustic ansys mechanics

CASE STUDY

A new methodology based on LS-DYNA for integrating product & process engineering of a steel wheel

Wheels are products with key geometrical and structural specifications.

A new methodology is presented, following an integrated process-product analysis approach, showing some benefits related to increased accuracy and the potential application of new optimization methods.

ls-dyna automotive composites

CASE STUDY

Improved blast furnace performance with material load optimization

Combining modeFRONTIER with Rocky DEM to design a better deflector saves up to 130 hours of computation time

The Arvedi Group approached the University of Trieste to find a solution to the uneven distribution of material inside the hopper of their blast furnace in Trieste, Italy.

optimization modefrontier rocky mechanics

CASE STUDY

How to optimize an external gear pump in highly constrained conditions

Meeting the engineering challenge of increasing efficiency while reducing costs

In this technical case study, EnginSoft assists Casappa to further refine an already-optimized standard series pump for an electrical motor and generator

mechanics optimization modefrontier

CASE STUDY

Improving a coffee capsule machine’s capacity and performance using multibody simulation

Improvements achieved by optimizing laws of motion governing machine components

This technical article describes a project undertaken by OPEM to optimize and validate the laws of motion governing the moving operations of a machine that produces coffee capsules, namely the cut and weld unit, the film feeder, the conveyor and the support structure.

consumer-goods multibody recurdyn food-beverage mechanics

CASE STUDY

Treating residual stresses and deformations in die castings

Virtual simulation during product and process design improves time to market and cost efficiency

This technical article illustrates the advantages of using virtual simulation to evaluate the thermal processes of die casting to reduce the formation of residual stresses and deformations in the components produced.

metal-process-simulation mechanics magma

CASE STUDY

Optimizing a cam mechanism using Adam and MATLAB

The design of a cam for high-speed production machines with various operating criteria imposes various conflicting objectives

This technical case study explains the application of a two-step methodology using the MATLAB and Adam algorithms in the modeFRONTIER software platform.

optimization modefrontier automotive

CASE STUDY

Immergas: Using CAE to improve energy efficiency, reduce emissions and costs, and shorten time-to-market

Interview with engineer Luca Cavalli, from the advanced engineering team at Immergas

In this interview, engineer Luca Cavalli, of Immergas’ advanced engineering team, discusses the technical and business benefits the company has realised since first introducing Computer-Aided Engineering (CAE) technologies into its R&D department in 1997.

ansys appliances cfd mechanics

CASE STUDY

Transient CFD Analysis of a Pelton Turbine

The performance evaluation to upgrade an existing hydropower plant

EnginSoft developed a Computational Fluid Dynamic (CFD) analysis methodology for the performance evaluation of a Pelton turbine

energy cfd ansys oil-gas

CASE STUDY

RecurDyn easily analyses the complex dynamics of a musical box

Analysis includes highly flexible bodies and extended contacts with their surfaces

This is a classic scenario that exploits the best features of RecurDyn software, such as the Full-Flex and the Geo-Contact technology.

recurdyn multibody mbd-ansys

CASE STUDY

High Pressure Die Casting Optimization of a Connecting Rod

A multi-objective engineering simulation study of the connecting rods manufacturing process

Connecting rods connect the pistons to the crank shaft in automotive engines and are vital components of the engine. Connecting rods are traditionally produced in ferrous metals by forging or die casting.

metal-process-simulation automotive magma

CASE STUDY

CFD analysis for the evaluation of the air flow within a climate control unit

Considering the value of numerical analysis for new product design

The objective of the study was to create a virtual model of Climaveneta’s new ACU171 Expanded Close Control Unit and then match the numerical results with the experimental measures.

cfd ansys appliances

CASE STUDY

Optimizing the Glass Clamping of a Pyrolytic Oven

An appreciable 30 to 40% decrease in stresses

The aim of this study was to find the best quality glass-clamping system, through parametric model optimization, for a new pyrolytic self-cleaning oven by Indesit.

modefrontier optimization consumer-goods appliances

CASE STUDY

Reliable hydraulic direct drives for improved performance

Moving particle simulation allows time and money savings in engine development

This technical article presents the study of a radial piston hydraulic motor with an outside cam arrangement for Bosch Rexroth Mellansel AB.

turbomachinery cfd particleworks

CASE STUDY

Refining the design of a spout for a laundry detergent

Particleworks enables fluid flow simulation combined with human-like behavior to improve product performance

In this case study, LION Corporation uses Particleworks to simulate fluid flow to improve the design of a new cap spout for its new HARETA brand of laundry detergent.

particleworks cfd consumer-goods mechanics

CASE STUDY

Engine Dynamics

A four-stroke engine was analyzed in depth by means of a detailed Multibody Dynamics (MBD) simulation

This type of highly-defined model provides valuable outputs: the contact analysis provides detailed information about the pressure and friction between the parts, which is useful for estimating wear

automotive multibody recurdyn

CASE STUDY

Durability and Buckling Analysis of Storage Tanks

Teknokon Machinery has developed its know-how in design and manufacturing of various types of storage tanks

By taking advantage of EnginSoft experience in Simulation Based Engineering, by means of the FEM analysis, the Durability, Structural Integrity and Buckling behavior of a new group of toxic liquid and fuel storage tanks have been investigated.

energy mechanics ansys

CASE STUDY

The design optimization of a small axial turbine with millions of configurations

The case for computerized optimization over manual design interventions

In this article, we show that the main turbine characteristics, such as efficiency and exit flow angle, can be sufficiently improved using parametric optimization.

modefrontier energy optimization

CASE STUDY

The brave new world of virtual commissioning

Current market demands require new approaches to assure business imperatives are achieved

The following article explains how this new approach to the design of automated machines can enable industrial automation OEMs and system integrators to achieve these business imperatives with the assistance of industrialPhysics simulation software.

mechanics iphysics industry4

CASE STUDY

Numerical analyses of the heat transfer processes of a key cooling system in the ITER reactor

Supporting the design of a critical system with realistic numerical simulations of heat radiation and conjugate heat transfer

The ITER reactor’s electron cyclotron heating and current drive (EC H&CD) system launcher requires an effective cooling system due to the strong thermal loads it supports. In supporting the design of this cooling system, NINE performed several numerical studies using the Ansys simulation tools

ansys energy

CASE STUDY

Circuit Breakers

Multibody simulation is the best technology to analyze the dynamic behavior of safety circuit breakers

The premium software RecurDyn was used to simulate a Double Pole Single Throw Switch using three different modeling schemes. A comparison of the results provided useful information for the designers.

recurdyn mechanics multibody

CASE STUDY

Accurate modeling and simulation of belt-type continuously variable transmissions

RecurDyn facilitates virtualization of dynamic systems governed by both contacts and large flexibility

RecurDyn software allows belt-type systems, including CVTs, to be both modelled and simulated accurately. The dedicated “Belt Toolkit”, which is an automated modeling assistant, includes all of the components found in a belt-type transmission.

automotive rail-transport recurdyn

CASE STUDY

CFX Berlin’s TwinMesh enables standardized design for new rotary lobe pumps

CFD analysis improves performance, durability and service life of pumps for Vogelsang GmbH & Co. KG

Rotary lobe pumps are the most reliable pumps in agriculture but, like all other technical equipment, they have to be optimized and constantly redesigned to continue competing in the market.

turbomachinery twinmesh

CASE STUDY

Stranding Machine

EnginSoft, in collaboration with MARIO FRIGERIO, developed a multibody model of a stranding machine

Stranding and closing planetary machines are huge pieces of equipment designed to twist multiple heavy spools of strand at noticeable speed, to manufacture large section steel ropes.

recurdyn multibody mechanics

CASE STUDY

FE modeling of a composite sandwich laminate with LS-DYNA for Aerospace applications

Laminated composite materials such as sandwich structures are widely used in the transportation industry

This project investigates how best to correctly predict the energy absorption of these non-isotropic and non-homogeneous materials, whose lamina thickness is typically of the order of 0.2 mm or less and consists of tiny fibers or particles dispersed in a matrix material.

ls-dyna aerospace composites

CASE STUDY

New process to analyze vibrational fatigue of solder joints on printed circuit boards used in electric vehicles

High degree of automation allows assessment of massive number of solder joints and electronic components

This technical article presents a simulation process to analyze fatigue in electronic parts, particularly in solder joints, on printed circuit boards (PCBs).

femfat electronics automotive

CASE STUDY

Johannesburg 2010 World Cup Stadium Roof and Facade Design

An ambitious remodeling and expansion plan for the stadium was initiated

The study analyzed these structures for strength, service and stability conditions before construction.

civil-engineering construction ansys

CASE STUDY

Greenhouse Module for Space System

This feasibility study has been carried out to investigate and develop the characteristics of a greenhouse module for a future lunar base

This project has been coordinated by the German Aerospace Center (DLR) and it is embedded in the MELiSSA framework of ESA research projects.

aerospace cfd ansys

CASE STUDY

CFD study of a Pelton turbine runner

Comparison between traditional Eulerian and novel Lagrangian approaches

This technical article, a collaboration between EnginSoft and ZECO, compares two different methodologies for the study and optimization of impulse turbines, specifically Pelton turbines, in order to evaluate which is the quicker and more reliable method.

cfd particleworks energy

CASE STUDY

Integrated Simulation of Commercial Pasta Manufacturing

The Virtual Optimization PAsta production process (OPAV) research project, which resulted in a simulation model

This study was part of the Virtual Optimization PAsta production process (OPAV) research project,

modefrontier ansys ls-dyna magma optimization food-beverage consumer-goods

CASE STUDY

Cold Forging of a Silent Block Bush Steel Sleeve

Minimize physical prototypes and reduce waste, while reducing the lead time and overall production costs

The object of this study was simulating and optimizing the cold forging process for a silent block bush steel sleeve. A silent block bush is traditionally used in the linkage system of a car suspension, in railway carriages and in agricultural machinery.

metal-process-simulation forge forging automotive

CASE STUDY

Numerical simulation of protection systems on agricultural tractors to ensure standards compliancy

Virtual testing of roll-over protection and of falling-object protection in the early design phase ensures safety performance

This technical case study describes how the ROPS and FOPS of a tractor were numerically studied in the early design phase to ensure compliance with OECD Standard Code 4 (for the cabin’s resistance to longitudinal, lateral and vertical energy or force) and Code 10 (for overhead protection from falling objects).

automotive rail-transport ls-dyna

CASE STUDY

Aviospace: The Italian Aerospace & Defense Company

Using simulation for engineering challenges in unknown or poorly understood environments

Gambacciani began his career in development of diesel engines at FIAT-GM Powertrain (now FCA) where he gains a solid experience on CAE both in the fluid and structural environment.

aerospace ls-dyna

CASE STUDY

Solving the chainsaw kickback problem with Maplesoft and ANSYS

Maximising chainsaw safety over the tool’s life by analysing the kickback problem and lifetime tool fatigue and performance

The avoidance or reduction of chainsaw kickback is a key safety feature for manufacturers. The challenges for engineers are to obtain more accurate analyses of the problem over the tool’s lifecycle.

maplesim maple mechanics ansys consumer-goods

CASE STUDY

Drag Optimization of the E-1 Electric Racecar

A FIA E-1 class racecar was being developed by Brigham Young University to set a world speed record for Electric Vehicles

The car is designed to race on the ultra-flat Salt Flats in Bonneville, Utah. The racecar weighs less than 500kg so increasing the downforce was critical. Reducing aerodynamic drag was also critical due to the power requirements of the racecar.

cfd automotive

CASE STUDY

Interview with Diego Barone, R&D Project Leader at Vin Service

Vin Service, founded in 1976, is a world leader in dispenser technology and the first Italian manufacturer of draft-wine dispensers. Its core business is in the dispensing equipment industry and in cooling systems for beverages.

ansys mechanics food-beverage

CASE STUDY

Oil flow simulation in a reciprocating engine at Honda R&D

Particleworks, an innovative particle method simulation tool, playing an important role in previously-unattainable simulation problems

In this technical article, EnginSoft and Prometech explain how they executed a highly complex computational simulation on the fluid-structure interaction of the oil flow inside a reciprocating engine, on behalf of Honda R&D.

automotive cfd particleworks

CASE STUDY

Printer

RecurDyn offers a dedicated toolkit to pre-process, solve and post-process problems involving flexible media

The final portion of the paper path of a laser printer has been studied using the Media Transport Toolkit to evaluate the influence of the corrugating roller which is used to corrugate the sheet to keep it straight before falling into the tray.

recurdyn multibody mechanics consumer-goods

CASE STUDY

RecurDyn helps ensures passenger safety in faster, higher capacity detachable chair lifts

Software facilitates dynamic studies of complex multi-body models to predict accelerations; verify, shape and size structural parts

Dynamic studies are required to predict the accelerations, verify that the cams are properly shaped, and to extract the loads to structurally size the parts.

recurdyn multibody mbd-ansys automotive

CASE STUDY

The Structural Design of Roller Coasters

An integrated CAD-CAE procedure

Engineers will normally need to evaluate a number of different designs, only one of which will result in the final construction configuration. This is why numerical simulation plays an indispensible role in roller coaster design.

ansys civil-engineering construction

CASE STUDY

Evaluation of dam performance under seismic loads with DCR time history procedure

Using the DCR time-history procedure to determine the behaviour of the dam’s 10.2M m³ of roller compacted concrete

The Grand Ethiopian Renaissance Dam (GERD) is situated along the Blue Nile River. Located 500 km north west of the Ethiopian capital Addis Abeba, in the Benishangul-Gumaz region, the GERD will be the largest plant in Africa

civil-engineering construction straus7

CASE STUDY

Advanced strategies for the flow field optimization of a medical device

How to use a hybrid method of CFD analysis for product optimization and performance improvement while reducing the computational effort and the time required to achieve the results

Further reduction of the heat loss compared to the best design of the NSGA-II first phase design optimization: a further 4% gained

cfd biomechanics ansys modefrontier optimization

CASE STUDY

Predicting the strength of composite materials using Ansys Software

Applicable from material design to product design

This technical article discusses some of the problems of using finite element method (FEM) simulation software for composite material analysis and introduces new solutions from CYBERNET with Ansys Software for solving these problems.

composites ansys multiscale

CASE STUDY

Air Cooled Heat Exchanger Systems Performance Modeling

Model of a Liquefied Natural Gas (LNG) Plant for the simulation of the Air-Cooled Heat Exchanger Systems’ (ACHE)

EnginSoft developed a 3D CFD model of a Liquefied Natural Gas (LNG) Plant for the simulation of the Air-Cooled Heat Exchanger Systems’ (ACHE) arrays and their interaction with the wind.

energy cfd ansys oil-gas

CASE STUDY

MICAD, engineering aimed at the sea’s jewels

CAE technologies in the Marine Industry

Traditional naval architecture meets the CFD analysis with the aim to improve consolidated products reaching values in terms of performance never seen before.

ansys cfd marine

CASE STUDY

Dynamic response of a buried pipeline, under the action of the fall of rocks on the soil

Safety assessment of a buried pipeline potentially subject to rockfalls

Oil or gas pipelines that cover long distances pose complex design challenges. Every environment the pipeline crosses is characterized by different potential geohazards. One of the most dangerous for a pipeline is a rockfall.

oil-gas mechanics ansys

CASE STUDY

A new heart valve replacement procedure modeled with multiphysics simulation could eliminate the need for open-heart surgery

24% operative mortality rate of open-heart surgery for older patients drives search for less-invasive aortic valve replacement technique

Since this cannot be accurately measured in an implanted stent, manufacturers decided to use Multiphysics to simulate the process to better understand the method and to calculate the forces operating on the implant in order to improve the stent design and the surgical procedure, as described in this article.

cfd biomechanics ansys

CASE STUDY

Ring Rolling of a Wind Tower Flange

A tool to reduce the level of post manufacturing defects, material wastage and overall production costs

An academic study of the hot ring rolling process at ASFO Spa, that it ended with the company using Transvalor Forge as a tool to reduce the level of post manufacturing defects, material wastage and overall production costs

energy forge metal-process-simulation

CASE STUDY

A method to conduct dynamic analyses of floating solar structures using AQWA

Structural analysis method also considers response characteristics over time

This technical paper presents an analysis process to accurately examine the environmental loads and structural stability of a Floating photovoltaic (PV) power plant. The method includes a hydrodynamic analysis of the Floating PV in its water-based environment as well as a structural analysis of its structural stability based on the characteristics of motion it undergoes.

ansys energy

CASE STUDY

New Ferry boat: Emax 2 circuit breaker tolerance analysis for maximum efficiency in panelbuilding

EnginSoft engineers help ABB optimize the Emax 2 design to allow ABB’s client IMESA to create a highly compact switchgear column for a state-of-the-art ferryboat

In this technical case study, we illustrate how EnginSoft engineers helped ABB to optimize the design of the Emax2 project.

cetol electronics mechanics tollerances eztol

CASE STUDY

Introducing Skippy: an athletic monopedal robot, designed for a repertoire of behaviors

Demonstrating the effectiveness of a systematic, complete design approach to achieve extreme, unprecedented behaviors

This article discusses a realistic multi-objective parameter optimization study of a highly athletic one-legged robot, called Skippy, in which both the parameters of the mechanism and the parameters of its optimal behaviors were sought.

optimization modefrontier biomechanics

CASE STUDY

The Fundamental Role of a Simulation-Based Approach in New High-Technology Product Development

Numerical simulation assists in all phases of product development from scoping and costing to final performance analysis

Simulation is nowadays strongly connected to new product development in most high-technology industries.

ansys electronics

CASE STUDY

Optimizing the Aerodynamic Efficiency of an Aircraft Nacelle

The optimal aerodynamic design while substantially reducing the costs

The challenge was to find the optimal aerodynamic design while substantially reducing the costs associated with traditional CFD modeling.

aerospace cfd ansys

CASE STUDY

Gravity Die Casting of Motorcycle Components

A permanent mold casting study of the mold design and mold-casting process of an aluminum alloy single-sided-swing-arm

The advent of the Naked Motorcycle has changed the way we look at motorcycle parts: they now also need to be aesthetically pleasing because they are mostly visible to the naked eye.

automotive magma metal-process-simulation rail-transport

CASE STUDY

Excavators

The influence of flexibility was considered with the use of both the Reduced Flex and the Full Flex options in RecurDyn

A multibody model of an excavator was developed to calculate the loads acting on the structure and to perform static structural verifications of the different components.

automotive multibody recurdyn mechanics

CASE STUDY

A natural remedy for hot-spot stresses

Using advanced mesh morphing to seamlessly perform bio-inspired structural shape optimization

This paper demonstrates how the biological growth method, studied by Mattheck in the 1990s, can be easily implemented for structural shape optimization finite element method (FEM) analyses using advanced radial basis functions (RBF) mesh morphing.

ansys biomechanics rbf-morph

CASE STUDY

CFD study to optimize the cooling performance of a narrow specialty tractor

Numerical modelling reveals design strengths and weaknesses prior to prototype testing, saving time and money

In this technical article, a CFD study of various designs for four different specialty tractors: two brands of specialty tractors for vineyard configurations, and two brands of specialty tractors for orchard configurations, are described.

automotive ansys cfd

CASE STUDY

Filling and compression analysis of metallic powders composed of spherical particles

The efficiency of material design can be greatly improved by using FEM-based virtual material testing analysis

This article presents an example of the analysis of a powder composed of spherical particles. Since powders have a very fine heterogeneous structure, a multi-scale approach based on homogenization analysis is proposed.

multiscale ansys mechanics

CASE STUDY

Two-step approach to numerical simulation of fire and smoke propagation

Early stage use in design aids fire protection assessment of buildings and evacuation routes faster and more cost effectively

This article explains how the simulation of a severe fire in a warehouse that had caused substantial damage was undertaken. It explores the use of the fire dynamics simulator (FDS) code, developed by the US National Institute of Standards and Technology (NIST)

civil-engineering

CASE STUDY

Tools and methodologies for generating digital twins in medical research

An overview of the latest advances of the use of CAE technologies in the medical field

This article provides a non-exhaustive overview of some of the latest advances in the adoption of CAE technologies in the medical field by citing some ongoing EU research programs.

rbf-morph biomechanics

CASE STUDY

Tolerances analysis on a nitrogen spring

EnginSoft models technical product modifications to enable Special Springs to satisfy a customer request at the minimum cost

Special Springs commissioned EnginSoft’s engineers to calculate the production cost repercussions of a technical product modification requested by an important customer.

mechanics cetol tollerances eztol

CASE STUDY

Nautilus tech by Faber Spa: The new frontier for hoods ventilation

A Finite Element Method approach applied to product development for ventilation hoods

Faber Spa, which has designed and manufactured ventilation hoods for the past 50 years, holds a key global position both in terms of production and technology. It has achieved this position through strategic investments in research and development.

ansys appliances consumer-goods cfd

CASE STUDY

Improving the design of the Air Purification Tower using 3D CFD

The Nederman Group is a world leading supplier and developer of products and solutions within the environmental technology sector. Their latest step is the use of 3D CFD which improved the performance of their Air Purification Tower by 15%!

Nederman’s Air Purification Tower is the perfect choice if source extraction is not a satisfying option.

ansys mechanics

CASE STUDY

Optimizing the performance of antennas installed on avionics platforms

Rapid and accurate evaluation of platform impact on antenna radiating characteristics is vital

This article discusses the use of the Ansys HFSS SBR+ method for wave propagation analysis that is based on specific EM propagation formulations (commonly referred to as Asymptotic Methods), and which offers an effective alternative in terms of solution accuracy and computational cost. The method’s effectiveness is demonstrated in this case study that considers the analysis of an ESM sinuous antenna installed on an avionics platform.

ansys electronics

CASE STUDY

Plastic Film Dragging

The dynamics of flexible bodies as they interactthrough contact with other bodies

In this example, these features were tested by simulating the motion of a very thin plastic film (32µm) being dragged by two rollers.

recurdyn mbd-ansys mechanics multibody

CASE STUDY

SACMI designs optimized next-generation components using automated surface sculpting

Uses Adjoint and BGM shape-modification approaches for mesh morphing

Mesh morphing has proven to be a valuable tool in parametrizing numerical models to perform shape optimization. It allows engineers to save time in generating new configurations for analysis because it does not require geometry modification and mesh re-generation.

ansys mechanics

CASE STUDY

Taking stock: the evolution of simulation around the world pre- and post-Covid-19

From its earliest days through to future post-pandemic perspectives

At this particular moment in time, this article wishes to reflect on the evolution of CAE and simulation in an effort to present a big-picture view when most of us are daily dealing with all the devil in the details in every aspect of our lives. We approached some long-standing business friends in engineering simulation from various regions around the world to help us in this task

ansys industry4 news

CASE STUDY

Numerical applications of an Ansys-based tool to analyze hybrid metal/composite lattice structures

Computationally efficient method enables design and optimization processes of axial-symmetric lattice structures to be conducted simply and quickly

This paper, by means of presenting three application cases, provides a brief description of the capabilities of a numerical tool developed for the design and optimization of hybrid metal/composite lattice structures created with 3D printing

ansys composites

CASE STUDY

Cimolai Technology chooses ANSYS to save design time and improve product quality

Cimolai Technology designs and produces special machines and plants for lifting, handling, transport and launching operations

Cimolai Technology explains the business benefits it has achieved since the installation in terms of time savings in planning, and design, and improvements in product quality and in delivery forecast ability.

ansys mechanics rail-transport marine

CASE STUDY

Getting bounced: Investigating the loads and durability of a Pogo Stick

A light-hearted coronavirus lockdown project with a useful outcome

This light-hearted technical article discusses a project undertaken between WolfStar Technologies’ Tim Hunter and Endurica’s Will Mars during the Coronavirus lockdown – to create a digital twin of a Pogo Stick in order to calculate its fatigue damage in the hands of a novice user.

sports endurica

CASE STUDY

ME Elecmetal harnesses power of Rocky DEM to improve crusher liner performance

ME Elecmetal — a global supplier of integrated wear solutions for mining, construction and industry — is among the first companies to benefit from Rocky DEM’s latest technology: the Tavares breakage model.

civil-engineering rocky

CASE STUDY

Lucid Motors boosts electric vehicle performance with modeFRONTIER

Performing multi-objective inverter cooling system optimization with modeFRONTIER

This brief article summarises how California-based electric car company, Lucid Motors, used the CAE application, ModeFRONTIER for performing Computational Fluid Dynamics (CFD)

automotive optimization modefrontier

CASE STUDY

Agricultural equipment suppliers use CAE to improve product performance, safety and desirability

CAE technologies also reduce design and testing times, and design costs

This case study describes how the company’s R&D team used ANYSYS and Spaceclaim to conduct Finite Element Method analyses to refine the design of a new model of a sprayer boom used by farmers to distribute phytosanitary products over fields for crop protection.

ansys automotive rail-transport

CASE STUDY

Lime Kiln DEM Analysis with ROCKY

CAE is key to ensuring the efficiency and technical integrity of equipment and plants in the lime industry

In the lime industry, the process engineers of Cimprogretti advise on process safety, analyse and interpret laboratory and plant data and provide specialised support to ensure the technical integrity of equipment and plants.

mechanics rocky

CASE STUDY

Testing ParticleWorks coupled with RecurDyn to simulate water behavior in water technology products

LIXIL is trying to introduce Particleworks, a meshless multiparticle simulation (MPS) computational fluid dynamics (CFD) tool in the research and development of these products.

recurdyn particleworks appliances

Computer-based Engineering in the Automotive Industry

Engineering Simulation in the Oil & Gas Industry

The Construction Industry

EnginSoft and the Energy Industry

The challenges facing the Aerospace Industry

EnginSoft and the Consumer Goods Industry

Coupled simulation methods enables more accurate evaluation

An optimal gating and feeding system for the production of steel parts

Analysis to determine possible optimizations to enhance device safety and efficacy for long-term patient use

Simulation studies help Whirlpool identify the most useful design modifications to support its product objectives

Using CAE to optimise the design of a prototype for a super sonic filming drone

Multibody system simulation using biomechanical human body models in RecurDyn

The main challenge is to reproduce their structural behavior by developing suitable numerical models

Template-based design automates future routine work, and automated documentation facilitates report generation

Salvagnini chooses RecurDyn for multibody analyses

Simulation allows engineers to improve print quality, ensure operator safety and contain energy consumption

The tensile and formability tests in warm condition

A system to simplify the towing and laying down of marine pipelines in shallow water fields

CAE models evaluated using two commercial solvers

Optimized design achieves energy efficiency and cost containment objectives

The optimal mast weight under specific structural strength requirements

TAE SUNG collaborates with DY Auto to develop dedicated software

Sustainable building design

A brilliant example of how computer aided engineering can assist engineers to contrive an optimal solution to the problem of lateral buckling

Ability to predict thermal and mechanical behavior within specific physical parameters has multiple industrial applications

A multibody simulation of a switch disconnector

Marelli Motori applies multiphysics simulation to cost-effectively design better, more reliable motors and generators faster

A more efficient simulation procedure for the design phase of Al-Si alloy components for the aeronautical industry.

Optimising racing engine inlet ducts using fluid dynamics

The Woodrail® road barrier is designed to improve vehicle safety blending in with the surrounding environment.

Feasibility study of a complete acoustic workflow

Wheels are products with key geometrical and structural specifications.

Combining modeFRONTIER with Rocky DEM to design a better deflector saves up to 130 hours of computation time

Meeting the engineering challenge of increasing efficiency while reducing costs

Improvements achieved by optimizing laws of motion governing machine components

Virtual simulation during product and process design improves time to market and cost efficiency

The design of a cam for high-speed production machines with various operating criteria imposes various conflicting objectives

Interview with engineer Luca Cavalli, from the advanced engineering team at Immergas

The performance evaluation to upgrade an existing hydropower plant

Analysis includes highly flexible bodies and extended contacts with their surfaces

A multi-objective engineering simulation study of the connecting rods manufacturing process

Considering the value of numerical analysis for new product design

An appreciable 30 to 40% decrease in stresses

Moving particle simulation allows time and money savings in engine development

Particleworks enables fluid flow simulation combined with human-like behavior to improve product performance

A four-stroke engine was analyzed in depth by means of a detailed Multibody Dynamics (MBD) simulation

Teknokon Machinery has developed its know-how in design and manufacturing of various types of storage tanks

The case for computerized optimization over manual design interventions

Current market demands require new approaches to assure business imperatives are achieved

Supporting the design of a critical system with realistic numerical simulations of heat radiation and conjugate heat transfer

Multibody simulation is the best technology to analyze the dynamic behavior of safety circuit breakers

RecurDyn facilitates virtualization of dynamic systems governed by both contacts and large flexibility

The Woodrail^® road barrier is designed to improve vehicle safety blending in with the surrounding environment.