Automobile:
1A. Full Vehicle Level CAE:
Crash-worthiness
Full Frontal, Offset Frontal, Side Impact, Roll over, Rear Impact and Bumper Impacts for body structure optimization (G level, intrusion level and repair cost controlling)
Head impact and knee impact on interiors for injury prediction. Stress and Durability
Stress analysis under standard road load cases like Bump, Kerb Strike, Pot Hole
Braking, Cornering, Rearward Braking etc. Complete Vehicle Fatigue Analysis using combinations of ADAMS and FEA softwares. Stiffness
Bending and Torsion Stiffness prediction for aperture distortion reduction and improving ride quality (vehicle response to driver inputs)
1B. Sub System Level CAE
Steering System – Airbag Inflation to crack the lid, head impact, body block impact, collapsible steering column design proving, modal analysis for steering vibration. (energy absorption capacity and life assessment and improvement)
Seating Systems – All Seat test simulations as per ECE of FMVSS and optimization of the design to meet the requirements. Suspension System – Mechanism simulation and DOE study to optimize the parameters like linkage geometry, stiffness, damping, camber and toe angle optimization. Stress and fatigue analysis of various suspension components like strut, knuckle etc. Driveline – Stress and Durability of transmission components, gasket analysis for engines, thermal stress analysis of the Engine components. Engine mount analysis for NVH. Exhaust system - Stress, Durability and NVH.
2. Aerospace
2A. Full Aircraft Level CAE
Crashworthiness
Landing and accidental crash events to predict the occupant endangering damages and shocks transferred to the occupants. Flutter Analysis
Flutter analysis of Aircraft. Aerodynamics
Predict the aerodynamic process acting on the aircraft taking into consideration the aero elasticity of the structure.
2B. Sub System Level CAE
Galleys – Stress analysis of Galleys made of composites, laminates and metal under normal service loads and misuse loads. Seating Systems – Stress analysis, mechanism simulation and impact analysis at the time of crash event. Landing Gear – Stress analysis, mechanism simulation and impact analysis at the time of normal and crash landing. Slats and Control System – Mechanism Simulation and feedback/feed forward control system simulation. Autopilot system simulation. HVAC system - CFD
Bird Hit - simulation various parts of the Aircraft. Engine Blade - Engine blade stress and fatigue analysis under operating conditions and accidental conditions elevated temperatures. Blade profile optimization using CFD.
3. Heavy Machinery
3A. Stress and Fatigue of Cranes and Earth Movers: Predict stress and fatigue life of the machine main frame with other function parts like boom, tracks etc. under operating and overloads. Provide remedies for failure preventions and optimize the structure for cost reduction.
3B. FOPS and ROPS of operator cabin : Analyze Falling Object Protection Structure and Rollover Protection Structure as per ISO or other applicable standards or proprietary requirements. Optimize the structure to achieve the desired performance.
3C. Dynamic Stability of whole machine:
Simulate the machine traversing over extreme terrains to check the dynamic stability which cannot be checked by hand calculation like static stability due to inherent oscillation while travelling of the slender parts like boom.
3C: Seating Systems: Stress analysis, mechanism simulation and end to end development of the seating system.
4. Wind Turbines:
4A: Stress and Fatigue Analysis of Towers: Prediction of stress, deflection and fatigue of the tower and nacelle under operating wind loads and cyclonic conditions and provide design modification suggestion to improve the strength if felt inadequate. Same applies to Cell phone towers and Wind Study Sensor mounting Masts.
4B: Dynamic Stability Analysis of Towers: Predicting the dynamic response of the tower to the wind gusts and analyzing its stability under the fluctuating wind loads.
4C: Stress and Fatigue Analysis of Blades: Stress and fatigue analysis of blades made of laminates. Pressures are predicted from CFD analysis and applied on the blades for predicting the stress. Aero elasticity of the blades can also be taken into consideration.
4D: CFD Analysis of Blades: Aerodynamic analysis of the blades and optimizing the blade NACA profile to obtain maximum power output.
5: FEA (Finite Element Analysis)
We use Finite Element Analysis for -
Stress Analysis –
Stress analysis of components of automobiles, aircrafts, off-road vehicles like tractor, cranes, harvesters, trailers etc. Full vehicle stress analysis under predefined road loads using inertia relief techniques. Stress analysis of aerospace parts made of composites and laminates. Evaluate Bending and Torsion stiffness of Automobile Structures such as BIW, Chassis, Body on Chassis etc. required for ride parameter optimization and aperture distortion study. Non Linear stress analysis for predicting permanent deformations and stress in problems like door sag analysis, denting analysis of outer panels of a car and interior trims. Sealing pressure and crushing prediction in asbestos and metal gaskets using Nonlinear FEA. Fatigue Analysis –
Life or damage prediction (S-N analysis & E-N analysis) of any mechanical component or assembly. Random vibration fatigue analysis for Automotive components under vibrations due road and engine vibration loads. Thermal cycle fatigue analysis for engine parts, turbine blades, molding dies etc. Full vehicle fatigue analysis (simulation of four poster) in combination with Adams. Vibration Analysis –
Structure response prediction to vibration inputs to predict the stability of stress required for vibration fatigue analysis. Impact and Crash Analysis –
Full Frontal impact, offset frontal impact, rear impact, side impact, roll over simulation, roof crush test, slow speed bumper impact test, pendulum impact test on bumpers, bus body rollover and pendulum test (survival space evaluation) and pedestrian impact. Head impact on interiors, Door intrusion test, Seat belt anchorage test, Knee bolster characteristic optimization, Collapsible steering performance evaluation and optimization, etc. We work as per the regulatory requirements or as per the customers specs. We are familiar with ECE, FMVSS, IS standards, EURO-NCAP and US-ENCAP requirements. Manufacturing Simulation –
Simulation of Sheet Metal Stamping Process to provide solutions to forming related problems such as tearing, wrinkling and problems related to dimensional accuracies due to spring back effect.
6: CFD (Computational Fluid Dynamics)
We have know-how and tools to perform analysis, design and optimization in the field of thermo fluid dynamics. In particular, we have experience over:
- Rotating turbo-machines such as centrifugal pumps, gas turbines, blowers, axial and centrifugal compressors, propellers and ventilators. For each machine we can calculate efficiency and performances both in standard and critical working conditions. CFD analysis may be coupled with structural analysis for taking into account deformation influence. Geometries can be optimized using parametrical models.
- Valves, including calculation of head lost, cavitations, actuator power, flow perturbation.
- Heating Ventilation Air Conditioning HVAC for automotive and civil applications
- Combustion and Heat transmission including combustion analysis of liquid and gas fuels, prediction of final emissions, heat transmission through walls and surfaces, simulation of industrial kilns, calculation of enthalpy balance, and heat exchangers.
7: MBD (Multi Body Dynamics)
We use MBD software MSC Adams for simulating mechanisms
- Automobile/Aircraft Seating systems’ folding mechanisms, Head restraint mechanisms etc.
- Industrial machinery mechanism like assembly line packaging instruments, press, special purpose machines.
- Vehicle suspension mechanisms simulation and optimization of camber angle, toe angle, strut stiffness and damping (DOE study).
- Vehicle steering mechanism simulation and optimization.
- Load prediction for component level stress analysis
8: Prototyping
We have tie ups with manufacturing vendors for building prototypes for our end – to – end projects. We have following manufacturing capabilities readily available for prototyping -
- Soft Die Making and Stamping on electric press
- Wire Cutting
- Laser Cutting
- VMC machining for machining components and dies for stamping and stamping and foam molding.
- Milling, turning, grinding and drilling
- Rapid prototyping for plastic parts
- Spring Making
- CNC Wire Bending
- CNC Plate Bending and Shearing
- Foam and Trims Manufacturing
- CO2, TIG and MIG welding
- Manual Spot Welding
