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Simulation - Reducing the time and costs of physical testing

Manufacturing simulation is the use of computer modeling to virtually test manufacturing methods and procedures – including processes such as production, assembly, inventory, and transportation. This greatly reduces the time and costs that physical testing of a manufacturing system would incur.

Simulation software can be used to predict the performance of a planned manufacturing system and to compare solutions for any problems discovered in the system’s design. This makes manufacturing simulation a significantly competitive capability – allowing manufacturers to test a range of scenarios before buying tooling, reserving capacity, or coordinating other expensive production resources. By using simulation software to determine exactly what is needed, the manufacturer can avoid problems during production while also reducing scrap and rework.

In addition to validating all-new means of production early in the product lifecycle, manufacturing simulation can also be applied to existing facilities or processes to identify inefficiencies or to analyze the impact of introducing new equipment, materials, or other changes. Some common aspects of manufacturing that simulations can help with include:

  • Design and balancing of assembly lines
  • Throughput and capacity planning
  • Production logistics and material flow – including transportation management and facility relocations or additions
  • Management of inventory levels, replenishment rates, batch sizes, production planning, etc.
  • Facility layout and resource allocation
  • Clarity of work instructions and revision management
  • Programming robotics and automation equipment
  • Improving build quality and validating alternative raw materials

Simcenter for Analysis

Simcenter lets you predict the performance of your 3D geometry-based designs. In Simcenter 3D CAE products, you can import geometry from any CAD source and prepare analysis models in a unified environment for a wide range of CAE methods including finite element, boundary element, computational fluid dynamics, and multi-body dynamics.
Simcenter’s integrated high-end, multi-discipline solutions are scalable for use by general CAE analysts and discipline experts. Additionally, by linking 3D simulation to Simcenter’s 1D and testing solutions, you can achieve unmatched accuracy.

Understanding how a component or product assembly reacts under stress or vibration is critical in any industry. However, as products and materials become increasingly complex, engineers need tools that go beyond linear-statics analyses. Simcenter provides the structural analysis software you need to simulate a wide range of applications all within a single user environment. You no longer need one tool for linear statics, another to study fatigue, and yet another for nonlinear analysis. As a result, engineering departments can consolidate structural analysis tools, and you only need to know a single user interface.

Thermal management is a major consideration for a wide range of products, including industrial machinery, automobiles and consumer electronics. The objective of any thermal management solution is to maintain a product’s temperature within a range that is optimal for performance. Accomplishing this may require the removal or addition of heat, either passively or in an actively managed fashion, and this can be evaluated using thermal simulation software.
Simcenter includes comprehensive, best-in-class thermal simulation capabilities that can help you to understand the thermal characteristics of your product and subsequently tailor your thermal management solution for optimal performance.

Undoubtedly the most challenging task for durability engineers is designing fail-safe components and systems in the most efficient manner. System parts with insufficient fatigue strength may cause permanent structural damage and potentially life-threatening situations. Mistakes can cause product recalls which negatively influence not only the product but the overall brand image. Shorter development cycles and ever-increasing quality requirements have stretched test-based durability approaches to the limits. Evaluating and refining the durability performance by simulating using durability software methods is the only valid alternative.

Simcenter durability software gives you access to state-of-the art fatigue analysis methods that enable you to perform fatigue life prediction analyses quickly and accurately accounting for realistic loading conditions.

Simcenter provides industry leading computational fluid dynamics (CFD) software for fast, accurate simulation of almost any engineering problem that involves the fluids, structures and all of the associated physics.
The real-world performance of your product depends on how it interacts with fluids, either gases, liquids or a combination of both. From designers to CFD engineers to researchers, Simcenter CFD simulation software allows you to predict the most complex fluid dynamics problems virtually and turn these insights into product innovation.

Most machines and vehicles experience vibrations and other excitations that can impact their structural performance. Historically, physical testing methods have been used for understanding the structural dynamics of various products. However, testing is costly and time consuming, and perhaps not very feasible with large structures like aircraft or ships. Simulation has become a key technology in understanding the structural dynamics for automobiles, spacecraft, jet engines, ships, electronic devices and industrial machines.
Simcenter offers a comprehensive solution to understand, analyze and improve the response when a system is subjected to dynamic loading. Simcenter builds on over 50 years of dynamics analysis experience to offer you the ability to efficiently understand and avoid excessive vibrations and stresses. Dedicated capabilities are available for noise, vibration and harshness (NVH) engineering, rotor dynamics and correlation.

Understanding the engineering performance is challenging for intricate mechanical systems, like in wing flaps or landing gear, sliding sunroofs or suspensions, or photocopiers and other mechanisms. Motion simulation uses multibody dynamics to calculate the reaction forces, torques, velocities, acceleration and more for mechanical systems. You can directly convert CAD geometry and assembly constraints into an accurate motion model or create your own multibody model from scratch. The embedded motion solver and robust postprocessing capabilities allow you to study of a broad range of mechanism behaviours.

The diverse and increasingly significant role of electromagnetics in product development and design brings new challenges. In this regard, committing to deliver products that are higher in efficiency, reliability, compatibility, and durability starts with comprehending how these complex fields and waves behave and change.
Simcenter includes distinct low and high-frequency electromagnetic simulation capabilities for the unique demands in each domain. Expand your insight into the performance of electromechanical components, energy conversion, design and siting of antennas, electromagnetic compatibility (EMC) and electromagnetic interference (EMI). A range of dedicated solvers (time and frequency based, linear and nonlinear, finite and boundary element) offers a transformative CAE process, with simulations ranging from a fast, initial analysis to inherent realism for final verification.

An uncomfortable truth about modern engineering is that there really are no easy problems left to solve. In order to meet the demands of industry, it’s no longer good enough to do ‘a bit of CFD’ or ‘some stress analysis’. Complex industrial problems require solutions that span a multitude of physical phenomena, which often can only be solved using simulation techniques that cross several engineering disciplines.

Are your customers expecting quieter products? Are competitors gaining ground by using sound quality as a differentiator? Will tighter noise regulations impact your product sales? Would you like to decrease the time spent on predicting sound fields or shave off weeks on complex jobs like engine run-ups?
Acoustic software can help you conquer these challenges. Simcenter offers interior and exterior acoustic simulation within an integrated solution that helps you make informed decisions during the early design stages so you can optimize your product’s acoustic performance. A unified and scalable modeling environment combined with efficient solvers and easy-to-interpret visualization capabilities enable you to quickly gain insight into the acoustic performance of your product.

Due to the growing number of new and emerging aircraft manufacturers, there is more pressure to deliver with shorter lead times and at competitive costs. However, meeting shorter project timelines is challenged by the fact that aircraft engineering teams today use disconnected systems for load management, design, simulation, margin of safety, and flutter analysis. Additionally, 60 percent of the nonrecurring cost of a commercial aircraft is spent on the structure, which means that any improvement in the structural analysis process will have a key impact on reducing the delays and the cost overruns.
Simcenter can help you meet shorter timelines and reduce structural analysis costs with the ability to perform end-to-end aerostructure assessment in a fully integrated environment. Eliminate mistakes and ramp up productivity with ready-to-use failure prediction methods and customize your solution by integrating your internal tools and IP to streamline your aerostructures analysis processes.
Simulate the behaviour of layered composite analysis structures and their progressive degradation.
In the quest to make products lighter yet stronger, manufacturers are increasing their use of composite materials. It is also prohibitively expensive to create prototypes of products made from composites, so simulation must play a key role in the development of new products using laminate composite materials. Simcenter is at the leading-edge of composites analysis through continuous development of material models and element types. Simcenter speeds the entire process for simulating laminate composite materials through a seamless connection to composites design, accurate solvers and comprehensive post-processing.

Efficiently mesh your models using extensive modeling functions for automatic and manual mesh generation of 1D, 2D and 3D elements in addition to numerous techniques for the application of loads and boundary conditions. User-defined geometry edits, mesh and boundary conditions are all associated to the base design, which means when the base design geometry changes, you can rapidly update your model. This approach greatly reduces downstream modeling time, which results in huge time savings across a project’s many design-analysis iterations.

Reduce the time you spend preparing analysis models and spend more time evaluating results. Quickly move from multi-CAD geometry data to a complete, run-ready analysis model using unique tools for CAE geometry editing, comprehensive meshing, FE assembly management, multi-CAE solver environments, and fast simulation results post processing and reporting.

How can I reduce material in a component or change its properties while ensuring it continues to meet performance targets? Simcenter delivers engineering optimization techniques that can help you answer these this question by systematically searching for the best design that satisfies certain criteria. Reduce component weight or find the right combination of parameters to improve product performance through comprehensive topology, geometry, and parameter optimization capabilities.

As companies increase their reliance on simulation, they are seeking ways to speed-up the analysis process and increase simulation throughput. One way to increase simulation throughput is to capture repetitive CAE processes, standardize them, and then automate them. Simcenter allows you to capture the expertise of senior analysts and make it available for junior engineers in your organization to use in the form of wizards or templates.