CAE Services

We have expertise in concept design and development of Finite Element model for

  • Structural analysis

  • Thermal analysis

  • Non-linear analysis

  • Flow Simulations

  • Motion Simulation (Multi-Body Dynamics)

 

Tools: ABAQUS, Solidworks Simulation, ANSYS, Hypermesh, NX NASTRAN, Simcenter 3D, Simcenter Star CCM+

 

We work with our customers concurrently in order to help them arrive at a feasible and optimized solution. With our patented file size reduction technology, we can easily transfer large magnitude of data securely.

Computer-Aided Engineering (CAE) is a pivotal component of modern engineering practices. It has revolutionized the way engineers design, simulate, and optimize products across various industries. CAE services offer a wide range of tools and techniques that help engineers and designers analyze and refine their products in a virtual environment before they ever reach the physical prototype stage. This not only saves time and money but also ensures a higher level of product quality. In this article, we will explore the world of CAE services, their importance, and the industries they impact.

What are CAE services?

CAE services encompass a set of software and simulation tools used to perform virtual testing and analysis of engineering designs. These services allow engineers to evaluate various aspects of a product, such as structural integrity, thermal performance, fluid dynamics, and electromagnetic properties. CAE simulations can range from simple static analyses to complex dynamic simulations, enabling engineers to explore a wide spectrum of scenarios.

Key Applications of CAE Services

Structural Analysis: CAE services are extensively used to assess the structural integrity of various components, ensuring they can withstand loads and stresses. This is crucial in industries like aerospace, where the safety of passengers depends on the integrity of materials and designs.

Thermal Analysis: In the electronics industry, thermal analysis is vital to prevent overheating of electronic components. CAE tools help identify potential hotspots and optimize cooling systems.

Fluid Dynamics: CAE can simulate fluid flow in applications like aerodynamics, HVAC systems, and the design of medical devices. This is essential for designing efficient and environmentally friendly products.

Manufacturability Analysis: Evaluating how easily a product can be manufactured is a significant aspect of CAE services. This aids in cost estimation, process optimization, and avoiding manufacturing issues.

Noise and Vibration Analysis: In the automotive and aerospace industries, CAE services help reduce noise and vibrations that can affect user comfort and safety.

Material Selection: CAE can assist in selecting the right materials based on their mechanical properties, durability, and cost-effectiveness.

CAE Software and Tools

Popular CAE software includes ANSYS, Hyper mesh, Abaqus, Simcenter 3D, and Star CCM+

These tools offer various modules for different types of simulations, providing versatility in analysis.

Future Trends in CAE

AI and Machine Learning Integration: CAE is increasingly incorporating AI and machine learning to automate and enhance the simulation process, making it faster and more accurate.

Cloud-Based CAE: Cloud computing is becoming more prevalent, enabling greater accessibility and scalability for CAE simulations.

Virtual Reality (VR) and Augmented Reality (AR): VR and AR technologies are being integrated into CAE, offering engineers more immersive and intuitive ways to interact with their simulations.

The Significance of CAE Services

Cost Reduction: One of the primary advantages of CAE is its ability to reduce the need for physical prototypes. This leads to substantial cost savings by eliminating the expenses associated with manufacturing and testing multiple physical models.

Faster Time-to-Market: CAE accelerates the design and testing phases of product development, enabling companies to bring their products to market more quickly.

Enhanced Product Quality: CAE allows for more in-depth and accurate analyses, which results in improved product quality and reliability. Engineers can identify and rectify potential issues before they become costly problems in real-world scenarios.

Customization and Innovation: CAE services facilitate the exploration of various design alternatives, encouraging innovation and the development of customized solutions for specific applications.

Environmental Benefits: By reducing the need for physical prototypes and iterations, CAE contributes to a more sustainable and eco-friendly product development process.

Challenges in CAE Services

Complexity: Developing and running simulations can be complex, requiring specialized knowledge and software tools.

  1. Hardware and Software Costs: High-performance computers and software licenses can be expensive.

  1. Data Quality: The accuracy of simulations depends on the quality of input data and the precision of modeling.

  1. Interdisciplinary Skills: CAE often requires expertise in multiple engineering disciplines, making collaboration critical.

The CAE Process

Industries that benefit from CAE services

Automotive: CAE plays a vital role in vehicle design and crash testing, optimizing engine performance, and reducing fuel consumption.

  1. Aerospace: The aerospace industry relies on CAE for aerodynamics, structural analysis, and materials testing for both aircraft and spacecraft.

  1. Manufacturing: In manufacturing, CAE helps improve processes, reduce defects, and optimize machinery and production lines.

  1. Energy: The energy sector benefits from CAE services in optimizing power generation, distribution, and renewable energy projects.

  1. Electronics: CAE assists in the design of electronic components and circuits, ensuring they meet performance and reliability standards.

  1. Civil Engineering: CAE is used in civil engineering for structural analysis, earthquake simulations, and optimizing construction processes.

  1. Biomechanics: In the field of biomechanics, CAE services are employed to analyze and improve the design of medical implants, prosthetics, and orthopedic devices.

Benefits of CAE services

  1. Reduced Development Costs: One of the most significant advantages of CAE services is cost reduction. By identifying and rectifying design flaws early in the development process, engineers can avoid costly changes and iterations at later stages.

  1. Faster Time-to-Market: CAE allows for quicker design validation, leading to faster product development cycles. This is particularly crucial in industries with fierce competition.

  1. Enhanced Product Performance: CAE helps engineers optimize their designs, ensuring products meet or exceed performance expectations. Whether it’s a car’s crashworthiness or an airplane’s aerodynamics, CAE services help fine-tune product attributes.

  1. Environmental Impact Reduction: CAE simulations can also evaluate the environmental impact of products. For example, they can optimize energy consumption, helping companies meet sustainability goals.

  1. Reduced Risk: By identifying potential issues early in the design phase, CAE services mitigate the risk of costly design flaws in the later stages of development.

  1. Sustainability: CAE services support sustainability goals by optimizing designs for reduced material usage and improved energy efficiency.

  1. Innovation: Engineers can experiment with new ideas and designs more easily in a virtual environment, fostering innovation

References/Case Studies

(contact details can be provided on request)

Case Study - Stress Analysis of Steering Column

stress-analysis-steering-column-1

Problems:

  • – To design a lightweight steering column for 3W.

  • – Aluminum casting is to be replaced with Composite polymer.

  • – Meet the design specifications of Customers.

Design, Calculations & Solution:

  • – Apply Boundary Conditions

  • – Analysis of the components for Stress, Displacements, etc.

  •  – Aluminum casting was replaced by Glass-filled (30%) polymer

  • – Reduced weight by 320 gm (47%)

  • – Reduced cost by 32.5 Rs.

Case Study - Modal Analysis of Intermediate Shaft

Modal Analysis of Intermediate Shaft

Problems:

  • – To find out natural frequency and corresponding mode shapes for the Intermediate shaft of 3 Wheeler Wheel Assembly.

Design, Calculations & Solution:

  • – Verified Natural frequency & mode shapes

  • – Input for the Design team for verification

Case Study - Rubber hose Analysis

Rubber hose Analysis

Problems:

  • – To validate the hose design provided by the customer using FEA

  • – Hose to withstand 120 mmHg vacuum pressure

  • – Suggest changes if required to meet design specification

Design, Calculations & Solution:

  • – FEA performed on 3D CAD model provided by Customer

  • – Identify areas collapsing at 59 mmHg

  •  – Iterations with thicker ribs on the periphery of the hose for 78 mmHg

  • – Design further optimized till 120 mmHg

Case Study - Engine Mount Designs

Engine Mount Designs

Problems:

  • – Engine mount design for Automotive applications

Design, Calculations & Solution:

  • – System analysis using customer input

  • – Study of the engine datasheet

  • – Mount positions calculated from customer input

  • – Benchmarking process

  • – Distribution of load on each engine mount

  • – Rigid body 6 DOF analysis as per targets given by the customer

  • – Stiffness values required to optimize customer requirement

  • – Rubber Mount shape design for stiffness

  • – Mount bracket design for strength and frequency

Case Study - Optimization & Weight reduction for SPM

Optimization & Weight reduction for SPM

Problems:

  • – Reduce the weight of Nano FinishingGrind Master SPMSOO Machine

  • – Reduce base weight by 100 kg

Design, Calculations & Solution:

  • – Imported Step model in Hyper Mesh

  • – Applied Boundary Condition for Load

  • – Analysis of Deflection & Stress levels

  • – Replaced Existingframe with C Channels to Sq. tubes

  • – Modified designs of ribs, truss members & Mtg. block & plates

  • – Achieved weight reduction of 178 kg (29%)

Case Study - Rubber Component Design & Analysis

Rubber Component Design & Analysis

Case Study - Ventilation analysis for basement parking (wind velocity & temperature)

Ventilation analysis for basement parking (wind velocity & temperature)

Case Study - Reverse Osmosis Analysis

reverse-osmosis-analysis

FAQs

What is CAE?

CAE, or Computer-Aided Engineering is to utilize computer software and simulation tools to analyze and design products and systems. Which helps in optimizing product performance and reducing development costs.

What is the purpose of CAE?

The primary purpose of CAE is to simulate and analyze engineering designs before physical prototypes are built. This helps in assessing product performance, identifying potential issues, and making improvements, ultimately reducing design and production costs.

What types of simulations user can perform?

Users can perform various finite element analyses (FEA) such as thermal analysis, structural analysis, multi-body dynamics, and also computational fluid dynamics (CFD),. These simulations help evaluate factors like stress, heat transfer, fluid flow, and more.

What are the key advantages of using CAE?

Some key advantages include cost savings, faster time-to-market, improved product quality, better design optimization, and the ability to explore multiple design alternatives.

What industries can benefit from CAE?

CAE is widely used in industries such as automotive, aerospace, manufacturing, civil engineering, electronics, and healthcare where engineering and product design are essential.

How can CAE benefit product development?

CAE can accelerate product development by reducing the number of physical prototypes required, identifying design flaws early, optimizing product performance, and ensuring compliance with industry standards.

What software tools are commonly used in CAE?

Commonly used software includes ANSYS, SolidWorks Simulation, Simcenter 3D, Star CCM+, Hyper mesh, and Abaqus. The choice of software depends on the specific needs of the project.

Are CAE Services suitable for small businesses and startups?

Yes, CAE Services can be beneficial for businesses of all sizes. They can help small businesses and startups streamline their product development and compete effectively in the market.

What are the typical deliverables one can get after CAE analysis?

Deliverables may include simulation reports, visualizations, recommendations for design improvements, and optimized design models that can be used for further development or testing.

What are the costs associated with CAE Services?

The cost of CAE Services can vary widely depending on the complexity of the project, the software and hardware requirements, and the service provider. It’s essential to get a quote and discuss pricing before initiating a project.

How can I get started with analysis for my project?

You can reach out to engineering consulting firms or hire experienced CAE engineers. They will assess your project’s needs and guide you through the process.

Can CAE projects be outsourced to external companies?

Yes, many companies offer CAE Services as part of their engineering consulting services. This allows organizations to access specialized expertise without maintaining in-house CAE capabilities.

How accurate are CAE simulations compared to real-world results?

The accuracy of CAE simulations depends on various factors, including the quality of the input data and the complexity of the model. While CAE simulations are highly accurate, they are not a replacement for physical testing and should be used in conjunction with it.

How do you carry out the Project? What are the Timelines? What is the approach? What Access is required? What is the Pricing? What are the Prerequisites/Requirements?

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