CAE

Imagine being capable of predicting the future. Then Imagine the money and time saved as design flaws and manufacturing problems are resolved early during product development. With our advanced simulation analysis tools, predicting the future is reality.

Finite Element Analysis (FEA) is one of the most powerful virtual product design development and verification simulation tool available for predicting the behavior of complete systems, sub-systems, components or assemblies during expected or extreme use, in a virtual environment.

EES engineers can rapidly examine design variations and evaluate numerous ideas in a time frame that is much shorter than to build and physically test prototypes.

EES utilizes FEA technologies to evaluate almost any material or geometry against performance criteria. We offer a wide variety of analysis experience and our CAE has been often validated and correlated to component and system level physical testing.

Model Generation & Verification

EES can develop FEA models for all types of analysis using state of the art meshing software. This includes batch meshing capabilities for rapid mesh generation.

EES utilizes mesh quality checking tools and checklists to ensure the mesh meets customer requirements and EES meshing guidelines.

Linear and Non-Linear Statics Analysis

Linear and Non-Linear statics analysis is used for design and verification of products using a variety of structural and thermal loads. Knowing how a design will perform under different statics load conditions allows EES engineers to recommend changes prior to physical prototyping, thus saving clients both time and money.

Non-linearity includes geometric and material non-linearity effects. In the real world, most engineering problems contain some kind of nonlinear effect. Sometimes, EES uses simplified linear approximations as a faster and more efficient alternative to non-linear analysis.

Frequency and Buckling Analysis

Frequency and buckling analyses are critical components of a design and verification process. Inherent vibration modes in structural components or mechanical support systems can shorten equipment life and cause unexpected failures.

EES analysis experts can evaluate natural frequencies or critical buckling loads and recommend design changes to improve product performance.

Contact Stress Analysis

Contacts are not applied by default in most finite element analysis even though frictional contact is the most common in almost all engineering situations. Utilizing the latest algorithms in our analysis software, EES can help our clients predict the contact stresses in your application, be it an insertion/extraction, press-fit, or frictional contact, to help with design and verification.

Durability and Fatigue Analysis

Structural components such as a control arms might be strong enough to withstand a single applied load. But what happens when the part operates over and over, day after day? To predict component failure in such cases requires what’s called fatigue or durability analysis. Computer simulations determine how well parts will hold up during cyclic loading. Results are important in calculating and verifying safe part lifetimes.

Parts and structures subjected to cyclic mechanical and thermal loads will suffer from fatigue. Whether our clients design engine parts or bridges, our analyses can help them predict how fatigue will affect the overall life of the product, and identify the areas that may be critically damaged.

EES engineers use state of the art fatigue software to create and analysis design using the best approximation to often times the most realistic model for fatigue analysis.

Structural Crashworthiness

Today, amidst heightened industry and consumer safety concerns, and increased government regulations, original equipment manufacturers strive to provide maximum protection to vehicle occupants under any condition. Behind this effort is advanced virtual computer simulations using state of the art software.

EES engineers can quickly simulate FMVSS, ECE and Insurance Institute test scenarios using a variety of dummy models, deformable and rigid barriers, impactors, rams, pendulums and head forms

EES can perform vehicle simulations for a variety of global requirements:

  • FMVSS crashworthiness regulations like frontal, rear and side impact, roof crush resistance
  • ECE regulations like deformable 40% offset, frontal impact, rear impact, euro dynamic side impact.
  • Insurance/consumer requirements like IIHS, RCAR, AMS
  • Bumper Testing for both high and low speed impact tests
  • FMVSS requirements for occupant safety like Free Motion Head Impact, Seatbelt Anchorage, Child Restraints anchorage system, sled test occupant simulation, knee bolster simulation, steering control system
  • ECE regulations including luggage intrusion, steering control system, pedestrian safety
  • Airbag Folding Simulation

 

Mechanism Analysis

Analysis of mechanisms is the study of motion of different members constituting a mechanism and the mechanism as a whole entity while it is being operated or run. This study of motion involves linear as well as angular position, velocity and acceleration of different points on members of mechanisms.

Earlier design engineers used drafting equipments to graphically analyze the mechanisms. Rapid development of computer techniques have offered a number of viable and attractive solutions using computer simulations. EES utilizes state of the art software’s to evaluate all our clients mechanism analysis needs and to provide design recommendations.

Multi-Body Dynamics (MBD)

Multi-Body Dynamics programs can simulate the dynamics and control of multi-bodied mechanisms and ground/airborne vehicles. EES Analysts can do mechanism analysis ranging from a simple linkages to complex auto engine assemblies to airborne/space vehicles.

These models are designed to

  • Assess Concept Feasibility
  • Optimize Vehicle/Mechanism Design and Control System
  • Quickly Analyze System for kinematic/dynamic failure

 

Kinematics Simulations

Kinematics simulations is done with an assembly of parts that are connected together by a variety of movable joints. When one of the joints is moved it causes the assembly to move. While loads or weights are not associated with the parts, the assembly of parts is moving through some range of motion. EES engineers can quickly develop and deliver kinematic working models using software.

Design Sensitivity Analysis

Structural design sensitivity analysis concerns the relationship between design variables available to the design engineer and structural responses. Typical response include displacement, stress, strain, natural frequency, buckling load, acoustic response, frequency response among others. Based on the sensitivity of the design variables like material property, sizing, component shape, and configuration, quick recommendations on design changes can be made.

EES engineers can help you with establishing design sensitivity for your application to help with decisions like material selection, gauge, and part design or establish needs for doing linear and non-linear structural optimization

Linear and Non-Linear Optimization

Optimization refers to identifying the best solution from some set of available alternatives. In the simplest case, this means solving problems in which one seeks to minimize or maximize a real function by systematically choosing the values of real or integer variables from within an allowed set. This formulation, using a scalar, real-valued objective function, is probably the simplest example of linear optimization

Optimization theory and techniques extends to other formulations and comprises a large area of applied mathematics. More generally, it means finding “best available” values of some objective function given a defined domain, including a variety of different types of objective functions and different types of domains. When this domain is non-linear, it is formulated as non-linear optimization.

EES engineers can use a variety of linear and non-linear optimization software to optimize designs for complex requirements like roof crush and much more.

Optimization- Size and Shape

In the size optimization method, the thickness of the design variable parts are optimized. This optimization method is also called gauge optimization as it gives the optimum gauges for sheet metal parts.

Shape optimization involves developing morphed shapes or design variables which explore all the shapes available within the design space and through computational methods quickly evaluate these to provide solutions for the optimal shape.

Topology & Free Size Optimization

In topology optimization, material is taken out of locations of low stress. This method leaves material only where necessary, which gives the load path. The optimized design has holes cut in the design variable parts, which lightens the structure. In this optimization method, typically the thickness of the parts is not changed. Volume topology is often used to do concept design studies where non-intuitive designs can be quickly developed within the available design space.

During free size optimization method, the thickness of the design variable parts is reduced at locations of low stress and material is added in areas of high stress. This method leaves material only where necessary, which gives the load path. The optimized design has holes cut in the design variable parts, which lightens the structure. In this optimization method, the thickness of the parts changes continuously.

In addition, coupled size and topology optimization can be combined. Therefore, the thickness of the parts is increased or decreased based on the size optimization and the topology optimization removes material where it is not necessary for managing stresses.

Noise, Vibration (NVH) Analysis

Noise, vibration, and harshness (NVH) is the study and modification of the noise and vibration characteristics of vehicles, particularly cars and trucks.

While noise and vibration can be readily measured, Harshness is a subjective quality, and is measured either via “jury” evaluations, or with analytical tools that provide results reflecting human subjective impressions. These latter tools belong to the field known as “psychoacoustics.”

EES CAE engineers can perform NVH simulations, which includes applications like noise and vibration experienced by the occupants of the cabin.

In some cases the clients ask us to change the sound quality, i.e. adding or subtracting particular harmonics, and to design around certain frequencies.

Acoustics Analysis

Acoustics analysis deals with the propagation of sound and how to best design for certain acoustic requirements. EES engineers can help you analyze your current designs for acoustics requirements and help with design and material recommendations to improve the acoustics through specialized analysis software.

Computational Fluid Dynamics (CFD)

Computational fluid dynamics (CFD) is one of the branches of fluid mechanics that uses numerical methods and algorithms to solve and analyze problems that involve fluid flows.

EES engineers can solve problems using state of the art computers that perform the millions of calculations required to simulate the interaction of liquids and gases with surfaces defined by boundary conditions. Even with high-speed computers, only approximate solutions can be achieved in many cases. Most of current work is done for laminar or steady state flow.

However, recent advances in compute capabilities allows us to use software that improves the accuracy and speed of complex simulation scenarios such as turbulent flows.

Thermal Analysis

Thermal analysis deals with analyzing the effects of temperature on materials and design. Three types of thermal effects, namely conduction, convection and radiation can be studied using advanced computer simulations.

EES engineers have software and experience with modeling many complex thermal analyses both steady state and transient.

Coupled Thermal-Structural Analysis

Coupled thermal and structural analysis is typically applied to structures that experience operating loads at high temperatures like automotive exhaust, engines etc. EES engineers have experience with modeling a variety of coupled thermal structural analysis.

Moldflow Analysis

Moldflow analysis is a plastics flow simulation that allow our clients to determine the manufacturability of their part in the early design stages and avoid potential downstream problems which can lead to production delays and costly overruns.

EES engineers have demonstrated to clients that moldflow analysis can

  • Increase the confidence in the manufacturability of design
  • Reduce part cost by improving material utilization
  • Improve part strength and quality
  • Optimize design to client’s production capabilities
  • Help select material characteristics
  • Do advanced analysis like warpage and shrinkage

 

Metal Forming Analysis

Metal forming analysis is a virtual simulation of the process by complete simulation of press action in a stamping operation to form sheet metal parts. The analysis provides visual design verification in the virtual world without need for expensive and time consuming prototyping. All aspects of forming: Stamping, Trimming, Flanging, Hemming and Springback Analysis can be evaluated.

EES engineers have vast experience in this domain and have state of art software to assist with modeling and simulations.

Blank Sizing and Material Utilization

As a precursor to the stamping process, custom software allow EES engineers to help clients quickly do blank sizing and material utilization studies to minimize scrap.

Material Cost Reduction Studies

Material cost reduction can be achieved through a variety of methods. This includes complete design using alternate materials, material substitution and down-gauge studies, material utilization studies, among other methods. EES engineers can help evaluate client’s material needs: from furniture and other consumer products to defense and aerospace needs.

Manufacturing Analysis

Wide variety of computer simulation based evaluation is now available to model and virtually simulate manufacturing feasibility for extrusion, tube bending, hydro-forming, casting, and forging analysis. Custom software available allow EES engineers to quickly evaluate manufacturing process for client applications to help with design recommendations to improve their products from a manufacturing perspective thereby offering cost savings through avoidance of costly and time consuming trial and error test methods.

Reliability and Robustness

Reliability-based robust design for products like automobiles can be offered through mathematical and mechanical models for actual computation methods and practices on the basis of the research of failure physics and combined with the reliability-based test and statistical analysis of failure data.

EES engineers can utilize latest software to help clients develop predictive models for reliability and robustness engineering.

Design for Six Sigma (DFSS)

As part of systems engineering, DFSS is a highly disciplined process that helps a companies focus on developing and delivering near-perfect products and services.

EES engineers have applied principles of DFSS to analysis for automotive and other components for improving designs.

Stochastic Analysis

Stochastic or random vibrations occur in a variety of applications of mechanical engineering.

EES engineers can help clients answer questions about their products like

  • Simulate how structures respond to random excitation
  • Help quantify the random behavior so clients can make design decisions