Design, Simulate then validate

Simulate then validate, emerges as new engineering methodology. Approaching each and every scenario of Design assesses then improves the performance. Mechanical simulation analysis provides a solution to designers and engineers make decisions earlier in the engineering design process. Support for multi-CAD environments and extensive finite element modeling tools, help manufacturers to study initial design intent and accurately predict product performance. Companies worldwide use Mechanical simulation analysis software and Multiphysics software to validate and optimize designs before manufacturing keeping in view- increasing efficiency, minimizing reliance on physical prototypes, reducing costs, and decreasing errors. By analyzing CFD simulations early in the product development process, engineers can detect possible errors, significantly reducing development costs and increasing profit margins for automotive companies Now CAE/ MECHANICAL SIMULATION have a wide range of its application in all Engineering branches and every domain of Mechanical engineering.

Among the CAE areas covered include:

CAD support Direct, associative data exchange with most CAD software. These CAE tools can easily get associate with CAD software to perform operations. Even some CAD software comes up with analysis tools but have limited tools. Modeling and meshing Create finite element models and meshes using tools and wizards designed to improve productivity and simulation accuracy. Below meshing techniques provided to give an overview and basic understanding of meshing.

Having prepared meshable, but not yet meshed geometry, we define material properties, loads, supports and restraints, and select a type of analysis, such as

structural, thermal, or some other. This procedure creates a mathematical model . The mathematical model now must be split into finite elements through a process of discretization, more commonly called meshing. However, loads and supports are also discretized by applying them to nodes of the finite-element mesh. The meshing process splits continuous geometry into finite elements. The type of elements created in this process depends on the type of geometry meshed, the type of analysis, and sometimes on the preferences of the person doing the modeling. For brevity, we'll discuss the two most-frequently used elements: solids and shells. It's important to clarify terminology here. For instance, "solid" has different meanings when referring to "solid geometry" and a "solid element." In a nutshell, solid CAD geometry is an FEA volume, and solid elements are created by meshing those volumes. Automatic meshing of solid CAD geometry takes place most often with tetrahedral solid elements. This is because present day automeshers can't reliably mesh complex geometries with anything. Tetrahedral solid elements can either be first or second-order elements. The user decides which to use. However, we will show that only second-order elements should be used for an analysis of any importance. First-order tetrahedral elements have four nodes, straight edges, and flat faces. Those edges and faces remain straight and flat after the element has experienced deformation under the applied load. First-order elements model the linear-displacement field inside their volume, on faces, and along edges. The linear or first-order displacement field gives these elements their name. Recall from mechanics of materials that strain is the first derivative of displacement. Therefore strain, and consequently stress, are both constant throughout firstorder tetrahedrons. The situation imposes a severe limitation on the capability of meshes constructed with first-order elements to model stress distributions of any real complexity. To make matters worse, straight edges and flat faces of the elements do not map properly to curvilinear geometry. Second-order tetrahedral elements have 10 nodes and model the second order displacement field in their volume, along faces, and edges. The edges and faces before and after deformation can be curved. Therefore, these elements map precisely to curved surfaces. Second-order tetrahedral elements model the second-order (parabolic) distribution of displacements inside their volume, on faces, and along edges. Consequently, they model the linear distribution of strains and stresses. Though they are more computationally demanding than first-order elements, second order-tetrahedral elements are used for most analyses. They represent a "happy middle" between numerical complexity and the ability to model real-life displacements and stresses.

Role played by shell elements: While solid-tetrahedral elements can mesh volumes derived from solid CAD geometry, use shell elements to mesh surfaces and when analyzing thin walled structures. Because surface geometry does not carry information about thickness, the user must provide it. Similar to solid elements, shell elements also come as first and second order. There are analogical consequences to mapping their curvilinear geometry to model displacement and stress fields. Again, only second-order shell elements should be used for analyses of importance. Certain classes of shapes can be modeled using either solid or shell elements. The type of element used for modeling tetrahedral solids or shells sometimes depends on the objective of the analysis. The nature of the geometry often dictates what type of element should be used for meshing. For example, parts produced by casting lend themselves to meshing with solid elements, while sheet-metal structures are best meshed with shell elements.

Static stress and linear dynamicsStudy structural response of design and Stress Analysis on components and assemblies. Mechanical event simulationEnhance design decisions by using multibody dynamics with support for large-scale motion, large deformation, and large strain with body-tobody contact. Computational fluid dynamics (CFD) simulationStudy thermal characteristics of designs and perform accurate, detailed fluid flow analysis. By performing highly accurate CFD studies early in the design phase, best-in-class companies can simulate the behavior of hundreds of designs under a wide range of operating condition, all before the first physical prototype is even built. The obvious result is reduction in physical testing costs. But this is only a small part of the total return from CFD simulations. Gaining a better insight in product behavior early in the development process has the following advantages:

Eliminating major design changes late in the development process: Your organization can avoid costly late-stage design changes and product launch delays. Better understanding of how products behave in the real world: Simulation helps you understand early on how your product performs under various conditions and helps to avoid product failure once its in the customers hand. Better product optimization: By optimizing product candidates early, you physically build and test only the most promising prototypes.

Multiphysics Study multiple physical factors acting simultaneously by combining results from different analysis types. Kinematics Motion analysis of Robot dynamics and link mechanism. Optimization- Of the product or process.

Software tools come in CAE have a large range and involvement of different methods in terms of their applications. Some of them majorly used.

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ANSYS NASTRAN COMSOL MULTIPHYSICS SIMULIA- DASSAULT SYSTEMES HYPERMESH-ALTAIR ENGINEERING ABACUS