TOOLTECH SOFTWARE (India) Pvt. Ltd.

Corporate Presentation

Certified to ISO 9001:2000

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Introduction TOOLTECH TOOLTECH GROUP

Concurrent design solutions in a wide spectrum of domain areas Automotive, General Engineering, Aerospace, Marine & Tooling, Oil and Gas Clear competencies in Knowledge Management European Focus: in depth understanding of cultural & business practices Flexible business model: functionality of a local company & offshore cost advantage
Chosen by Aker Yards Finland, to set up a dedicated facility for 100+ people in India

Among 1st few Asian companies to be selected as a Tier 1, Offshore Strategic Design partner by BMW AG

Similar long term Partnerships with Atlas Copco, Mann+ Hummel

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TOOLTECH TOOLTECH GROUP CORPORATE PROFILE

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Group Structure

Project Management Michigan, U.S.A Gteborg, Sweden Norway Helsinki, Finland Turku Denmark

Design Centers HO: Pune, India (Auto & General Engineering)

Employee Strength Last Year: 150 Current Year: 270

Bangalore, India (Aerospace) Tooltech Deutschland GmbH, Munich (Automotive) Tooltech Romania B2i Tooltech S.A.S. Paris, France

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Locations

Sweden Germany U.S.A.

France

Finland Romania

Tooltech Inc. (USA) Michigan B2iTooltech S.A.S. (France) Paris Tooltechsoft (Sweden) Gteborg Tooltech Deutschland GmbH (Germany) Munich

India

Tooltech Romania

Tooltech Europe Oy (Finland) Helsinki Turku

Tooltech Software (India) Pune / HQ

Tooltech Software Bangalore

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Economics of Outsourcing

6070% 100% 4050%

30-40%
Processing costs in Europe, North America excluding remote services Processing cost differential Additional management, telecom,etc. expenditure of Client Processing costs with remote services

** Source: McKinsey analysis 2002

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Corporate Rationale - India: The ITES Outsourcing Capital of the World

High
Ireland
 Infrastructure Country risks/ Govt. incentives Time zone attractiveness

Australia
Size of circle corresponds to number of knowledge workers

Singapore China

Russia

India

Mexico

Philippines

High Low
People Attractiveness
Quality of work Capabilities Cost factor
Source: McKinsey analysis 2002

Language

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Head Office Location

Pune: Indias foremost Engineering Hub
Daimler Chrysler, FIAT, Tata Motors (Trucks, MUVs and cars), BAJAJ AUTO (Twowheelers), JOHN DEERE (Farm), PIAGGIO, EXIDE, FICOSA, JOHNSON CONTROLS, TOYO, ZF STEERING Consumer Goods General Engineering

Automotive

PHILIPS, WHIRLPOOL, SHARP

ATLAS COPCO, COMAU, CUMMINS, KRUPP, SANDVIK, SECO

Forgings, Castings & Chemicals

25 Engineering Colleges

Major Defense, Electronic, Computing & Vehicle Development Research labs

World Class Telecommunication & Infrastructure Your Partners in Concurrent Engineering CAD, CAM, CAE

Clients

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Management

Board of Directors
J.K Khanna, Chairman
Well established and highly reputed Chartered Accountant and Financial Consultant based in Bombay, India.

Atul Khanna, Director and Chief Promoter

Successful entrepreneur having promoted various businesses involving international collaboration with Germany, the USA and Sweden. New project in Bioinformatics.

Mr. Vivek Annaswamy, President and Chief Mentor

Mr. Annaswamy was previously the Head of the Passenger Car business of Tata Motors and spearheaded its famed turnaround. He has also consulted on the Board of Hyundai Motors India.

Dr. Klaus Faust, Director and Managing Director, Tooltech Deutschland GmbH
Former Senior Executive in the German auto industry. Now heads a family concern, Lodenfrey GmbH, based in Munich.

G Dentler, Director
Recently retired as a Director with a German engineering company. Expertise in technology transfer.

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Key Personnel

S. Manivasagam - Head, Engineering Graduate in Mechanical Engineering, Post Graduate in Engineering Design and Doctorate in Mechanical Engineering with 17 years of experience in CAE and New Product Development of auto components and air conditioner compressors.

V. Ravindra - Manager Operations Graduate in Mechanical Engineering with 15 years experience in automobile industry and project management.

Pradeep George Manager CAD Graduate in Mechanical Engineering with 8 years experience in automotive and hydraulic components.

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Key Personnel

Harald Reukauf - Head CAE, Tooltech Deutschland GmbH Master in Mechanical Engineering from Karlsruhe University, Germany with 10 years of experience in CAE

N.B. Srinivas Head, Oil & Gas B.E. in Civil Engineering over 23 years of rich experience in Oil and Gas industry of which 22 years was in Oil and Natural Gas Corporation Limited (ONGC) in India

Murali Veeravalli Senior Project Manager CAE, BMW/Automotive, Tooltech Software (India) Private Limited BE and M.Tech in Mechanical Engineering with more than 13 years of focused CAE experience

S. Gunaseelan Manager CAE, Tooltech Software (India) Private Limited ME in Engineering Design and BE in Mechanical Engineering with 9 years of experience in Research and Development mainly in Pumps industry

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Key Personnel

Anil Talwani - Country Manager Finland Graduate in Mechanical Engineering with 12 years of Marketing experience in sectors including industrial, heavy engineering, OE, hydraulic components and material handling both in India and Germany. Abhay Jahirabadkar - Country Manager Sweden Graduate in Production Engineering with 9 years experience in design and development of assembly fixtures, off high way equipments, industrial gear boxes and machine tool components. Kurt Isaksson Senior Advisor, Sweden Former president of SAAB Rosemount AB, well known for his views on globalization in the Swedish industry B. V. Patil - Country Manager USA Diploma in Tool and Die Making with 10 years experience in mold, Tool Design and Manufacturing.

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Activities

CAD

CAE

CAM

Concurrent Engineering Concept Design Product Development

FE Model Creation & Assembly Linear Static Analysis Non linear Analysis Dynamic Analysis NC Tool Path Generation for 2.5 5 Axis Post Processor Development for 2.5 5 Axis

Tool Design Modal Analysis Mechanism Design Raster to Vector Conversion Reverse Engineering Fatigue Analysis Software Customization Crash Analysis Software Porting CFD Analysis Steady State & Transient Thermal Analysis NVH Analysis

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CAD Skill Sets

Autodesk  AUTOCAD  MDT  Inventor

UGS  Unigraphics  SolidEdge  I-DEAS

PTC  ProEngineer

Software Capabilities
Aveva  Tribon Adobe  Illustrator

DASSAULT SYSTEMES  Solidworks

DASSAULT SYSTEMES  CATIA V4  CATIA V5

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Capabilities CAE

Software Capabilities
Pre/PostPre/Post-Processor  Hypermesh  Ansa  I-DEAS  Patran  FEMOD  ANSYS  Animator Solvers  Abaqus  LS-Dyna  Ansys  Nastran  Pamcrash CFD  Pre- Processor: Gambit  Solver & Post-Processing: Fluent T-Grid

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Concurrent Engineering Project Methodology

Assignment of a dedicated team Assimilation of Clients industry + product expertise Replication of Client engineering methods and Quality Standards Onsite Project Coordinator for seamless outsourcing project integration Secure FTP sites for file transfer and online collaboration.

Effective Client Communication through: Teleconferencing Collaborative net meetings & brain storming sessions Email and PowerPoint graphics Regular onsite visits / onsite collaboration

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Interaction Example
Will there be any change on the flange accordingly?
**mm As per the model New ** data Old data

From TT

At the new manifold should be the same flange than in the old one. Make a smooth transition from the cross-sectional area of the flange to the cross-sectional area of the new runners (inbetween the first ** mm) The outer dia of the rotary valve hole has to be ***. We cant maintain this dimension (**) because of its intersection with the Plenum. Hence the outer dia is kept **. The inner dia is **mm. The outer diameter of the rotary valve should be **mm We have changed this radius form 50mm to 49.9mm. Will this be OK? This change is made to avoid modeling problems during surface merge. Thats OK! The radius is changed to **mm from **mm to accommodate tulip radius of **mm with **mm wall thickness. Will this slight change in Plenum volume OK? Yes, thats OK!

From MH

From TT

From MH

From TT

From MH

From TT

From MH

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Concurrent Engineering Project Methodology

The Outcome

A seamless extension of the Clients design office without the additional manpower and infrastructure investment.

Client retains control

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Project Management
 Common Project Management Information System (PMIS) for all CAD & CAE Projects - Common portfolio templates and checklists used for new project - When required, Client templates and checklists used  Phase I - Project Initiation: - Project Requirement Specification - Detailed Project and Resource Plan - Input Data Verification  Phase II - Project Execution: - Client approval for each deliverable and gateway - Change Requests recorded / Corrective actions initiated - Outgoing data routed through QC team, using Client-approved checklists - Periodic project monitoring and status reports  Phase III - Project Delivery: - All deliverables pertaining to identified milestones / gateways submitted through FTP sites, - Encryption of all data files before submission / Passwords given through different media Figure 1: Sample PMIS folder

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Tooltech Competitive Advantages

Engineering our core competence; not an annex to software development Small, nimble and quick reacting organisational structure Capital Adequacy : Regular investment in people, hardware, software & systems to support necessary ramp ups Proven concurrent engineering approach: buddy system, effective & simple collaboration methods Experience in setting up & ramping up dedicated teams for diversified Clients - Team sizes: 2-5 members / 5-10 members / 10+ members Project facilitation through local offices in the market that we operate in. European focus: - In depth understanding of work, cultural & business practices  BMW AG  Autoliv B.V. & Co. KG  Mann+Hummel  Atlas Copco

 Aker Yards Finland

Due to non disclosure agreements we are not permitted to disclose all client names and details

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CASE STUDIES

In accordance with Non disclosure and Confidentiality agreements, certain Client names & confidential project information are omitted. All names, information & diagrams that follow, are mentioned with prior permission of the concerned Client.

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Dedicated India Engineering Facility Client: Aker Yards, Finland

Tooltech has been chosen by Aker Yards Finland, one of the worlds largest shipyards, to set up a Dedicated Facility Ramp up: 100+ people in 1 year . Hulls Superstructures Engine Rooms Machine Drawings

Current team size: 20 people Facility & Manpower Ramp Up Ahead of Schedule

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CAD
Current Projects include: Detail Design & Production Drawings of Hull in a Ro Ro Vessel Software: Tribon & AutoCAD Input : Classification Drawings of Hull in DWG formats Available drawings in Kronodoc Project Specifications Generation of 3D Model of Hull in Tribon Approval/Checking of basic hull structure, mainly position & scantlings Detail Design/Modeling of Hull in Tribon Approval/checking of production drawings Nesting and part list generation Production drawings Nesting and part list generation

Scope:

Output:

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Design & Manufacture of a VIP Military Helicopter Interior Client: Indian Government Defense Aeronautical Agency
Awarded first of its kind full programme contract for the design & manufacture of a World Class VIP Helicopter Interior. To be certified to FAR Part 25 Concept Design, Development, Cabin Noise Reduction, Weight Optimisation Original design to be led by Tooltech & German Aircraft Interior Specialist. Manufacture (panels, sound insulation, carpets, etc) outsourced to a Bangalore based Aero Structures Company Project management & full programme responsibility with Tooltech Software used: Catia V5

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CAD
We partner with Mann+Hummel GmbH, Germany to design Air Intake Plastic Manifold Assemblies
Software used: ProEngineer Creation of a 3D solid Model Definition of runner length & profile Definition of runner cross section considering section area Definition of Plenum considering volume Resolve issues of Tooling & Plastic Welding Supply of 2D manufacturing drawings

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CAD
We partner with BMW AG for the Design of Various Interior & Exterior Components

Software Used: CATIA V4 & V5

Engine shields Underbody covers Floor covers Fender covers Sunroof systems

Bumper covers Air guides Sound isolation systems Heat isolation systems

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CAD
Design of Fabricated Structures Client: Atlas Copco, Sweden
Tooltech has experience in the design of fabricated structures for:

a. Mining Equipment c. Earth Moving Equipment

Design, Assembly and Detailing of fabricated base structures for mining equipment

b. Handling Systems d. Rock Drill Boomers

Models of the fabricated structures highlighting weld joints

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CAD
Master Model creation of Plywood Manufacturing Machine Components Client: Machine Manufacturer, Finland
Software used: ProEngineer Master Model creation of the following components of a Plywood Manufacturing Machine Scope Creation of 3D models and 2D drawings for different versions of a Veneer feeder mechanism. Creation of a master model to incorporate different versions of the feeder a. This master model can be retrieved by the client from a database. b. Client design requirements can be fed into the master model. c. New designs would be available with a time reduction of upto 75% Vacuum Belt Conveyor Out Feed Conveyor Vacuum Feeder Crossing Station Arch Conveyor Alignment Conveyor

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CAD
Design of Reduction Gear Box Client: Marine Equipment Manufacturer, Norway
Software used: Inventor 10, MathCAD Input: Technical Specifications such as Torque, RPM and Space Availability

Scope: Designing of 2 stage reduction gear box of 1:60 ratio using helical gears. MathCAD calculations for AGMA certification. Creation of 3D models & 2D manufacturing drawings with required technical details. Output: 3D model of all parts used in Gear Box 2D manufacturing drawing with technical specifications Calculations in MathCAD for certification

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CAE
Fatigue Analysis of Engine Assembly Client: Diesel Engine Manufacturer, Finland
Software: Hypermesh, Abaqus, FEMFAT FE Modeling: Crankcase, Bed Plate, Cylinder Head Bolts, Valve Seats Hexa elements with critical requirements such as: No. of elements over Cylinder Bores Mesh pattern around Crankcase Bearing and Cylinder Head Bolt Holes Diameters of Bolts for precise pre-tension loads Mapped meshing (second-order Tetra elements) on contact regions of seat and bolts. Model size : approx. 1 million DOF Analysis: Multi-step and Non-Linear Analysis (consisting of assembly loads, firing pressure and thermal loads) using Abaqus Standard 2-3 load cycles analysed. At the end, FE model unloaded in a specific order Results imported in FEMFAT for evaluation of low cycle and high cycle fatigue using Haigh s theory for uni-axial and multi- axial loads. Analysis cycle repeated to achieve desired results.

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CAE
Static & Buckling Analysis of a Turbine Casing Client: Aero Engine Manufacturer, Germany
Software used: ABAQUS, ABAQUS/CAE, Hypermesh FE Modeling of symmetric sector using 2nd order brick elements Static Analysis *TIE Contact between casing and bolts Gas pressure, vane loads Extraction of severe temperature fields from Transient Analysis Multiple thermal loads

Modal Analysis Hot and cold conditions hot state temperature field as preload Temperature-dependent properties Campbell diagram plots

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CAE
Elastic Buckling Analysis Bending and twisting loads, hot state temperature field as preload Results in the form of Interaction diagrams Plastic Buckling Analysis Riks Method of Analysis Load Vs. Displacement plots for pre and post buckling range

Plot of Deformation

Plot of Stresses

Plot of Buckling Mode Shape for Twisting Load

Plot of Plastic Strain for Plastic Buckling Analysis

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CAE
Crash Simulation Client: BMW AG, Germany
FE Modeling of following vehicle sub systems Body in White Drive line assembly (except front and rear axis assembly) Front and rear bumper assembly. Door assembly (excluding interiors) Bonnet and front panel assembly.

Quality criteria for FE Modelling Element length 6 - 12 mm, Average 10 mm. Warpage < 15 degrees. Quad angle between 40 - 140 degrees. Tria Angle between 20 to 120 degrees. Percentage of tria. elements < 5%.

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CAE
Integration of systems Creation of spotweld file, with and without rupture model for Body in White,Door assembly and bumper systems, etc. Integration of all systems using NULL shell elements and tied contact. Removing penetration between all systems upto 0.7 mm, used for contact initialization. Preparation of complete input deck for various calculations and load BC file, apart from various vehicle sub-system FE models. Calculations Full frontal impact as per US-NACP Overall dynamic deformation > 650 mm. Steering column displacement < 80 mm. 40% overlap offset frontal crash as per EURO-NCAP Firewall intrusion < 150 mm. A pillar displacement < 50 mm. Steering column displacement < 80 mm. Minimal deformation between B pillars and doors.

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CAE
Side impact as per EURO-NCAP, US-NACP, IIHS and SINCAP. Max. intrusion velocity of B pillar < 7 m/sec. Rear impact as per FMVSS Minimal deformation of fuel tank. Rear seat relative movement < 50 mm. Slow speed frontal impact as per FMVSS Contain damage within bumper system, no permanent deformation in any other system. Pre development activities for child and adult head impact calculations HIC value below 1000 in the bonnet middle region, less than 2000 near outer edges. Post- Processing Preparation of storyboards and reports for performed calculations . Compare the results for base model and modified model for set target of project. Discussion with design and development engineers for design and manufacturing Tools i. Pre-Processor (mesh generation) ii. Pre-Processor (Spot weld generation) III. Solver iv. Post Processor

- ANSA, HYPERMESH - FEMOD - PAMCRASH - ANIMATOR, PAMVIEW

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CAE
Strength and Fatigue Analysis of BIW Client: BMW AG, Germany
FE Modeling: Components: Body in White, Drive Line Assembly and Spot Welds using multi beam Sub modeling and mesh refinement at critical areas

Quality criteria for FE Modelling: Element length 6 - 12 mm, average 10 mm. Warpage < 15 degrees. Quad angle between 40 - 140 degrees. Tria angle between 20 to 120 degrees. Percentage of tria. elements < 5%. Circle around circle near holes with minimum 8 quad elements Neglect holes less than 6 mm.

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CAE
Analysis: Dynamic Analysis using Abaqus Explicit for vehicle passing over obstacles Luggage retention using Abaqus Explicit Fatigue Analysis using Falancs for:  Entire BIW.  Failure of Spot Welds Post- Processing Preparation of storyboards and power-point presentation reports for performed calculations Results compared between base model and modified model for set target Discussion with design and development engineers for design and manufacturing Tools i. Pre-Processor (mesh generation) ii. Pre-Processor (Multi beam Spot weld generation) iii. Solver iv. Post Processor

ANSA, Hypermesh ANSA, Medina Abaqus, Nastran, Falancs ANIMATOR, Abaqus Viewer, Hyperview

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CAE
FE Analyses of Intake Manifold Systems Client: Mann+Hummel GmbH, Germany
Software: Hypermesh, Abaqus FE Modeling: Combination of Shell and Hexahedral/ Tetrahedral elements Special meshing methods used for simulation of weld rim areas of plastic Intake Manifold Systems Meshing of plastic parts for Mould Flow Simulation Structural Analysis: Burst pressure calculation in view of non-linear properties Thermo-mechanical stress simulation in view of Exhaust Gas Recirculation (EGR) Frequency response simulation with Engine excitations, as dynamic load varies according to engine running speed (obtained from test data). Study of response of systems at critical locations such as connectors Optimization of parts as per FE Analyses Vibro-Acoustic Analyses Transient loads (in the form of internal pressure) applied Weak structural areas determined and stiffened in next phase of design

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CAE
CFD Analyses of Engine Assembly Client: Luxury Car Manufacturer , Germany
Software: Ansa, StarCD, Ensight CFD Meshing CFD grid generation for Flow Analysis CFD grid generation for Conjugate Heat Transfer (CHT) Analysis

Flow Simulation: Components: Cooling Circuit of an Engine which includes Cylinder Head, Crankcase, Water Jackets and Water Pumps Analysis: Pressure Drop Evaluation Effect of variation of pressure drop with different flow rates Optimization of pressure drop Optimization of geometries for uniform flow distribution (involving design of gasket profile) Model size: 3 million tetrahedral cells with critical grid connectivity at Gasket Connections

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CAE
Conjugate Heat Transfer (CHT) Components: Engine Assembly which includes Cylinder Head, Crankcase, Valves, Guides, Seating Rings, Spark Plug, Injector and Gasket Analysis: Engine assembly analysed for simultaneous effect of flow and heat transfer Inputs from 1D simulation (GT-Power) applied on CFD model in view of temperature and heat fluxes in critical areas Fortran sub routines used for application of material properties and nucleate boiling effect Model size: 6 million fully connected cells, with 15-18 different solid materials defined in the model

Results: Study of temperature distribution and matching of results with GT-Power / test results Optimization of design for uniform temperature distribution Mapping of temperature results on FE Mesh for structural simulation.

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CAE
CFD Analysis of Vacuum Amplificator of Automobile Client: Automobile Supplier, Germany
Software used: Fluent 6.1 / Gambit 2.1 Design of vacuum amplificator with a blow-by inlet, based on venturi principle Verification of hand calculations with 2D and 3D simulations of 3 models 3D incompressible turbulent flow Analysis to study flow behaviour in terms of velocity, pressure and mass flow Optimization of blow-by inlet position and amplificator geometry for given area ratios, pipe length, velocity and other parameters Further 3D CFD simulations were carried out to achieve optimised geometry having better flow characteristics meeting design constrains and objectives

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Domain Expertise

Automobiles & Auto Components Aerospace Press Tools Molds & Dies Machine Tools Cutting Tools Marine Oil and Gas

Please ask us for more information on industry specific capability

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OUR GOAL
To be your business partner and provide you with a seamless, design outsourcing service so that you can more profitably manage your business.

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Contact Us
TOOLTECH Software (I) Pvt. Ltd. Maa House, No. 6, Service Road, 1st Stage, Domlur Layout, Bangalore 560071, India Tel: +91-80-41256556 TOOLTECH Deutschland GmbH Schleiheimer Strae 375, 80935 Mnchen, Germany Tel: +49-89-35719100 Fax: +49-89-35719141

B2i TOOLTECH S.A.S. Parc d'Affaires SILIC, 1, rue Traversire, BP 20327, 94598 Rungis Cedex, France Tel: +33 (0) 1 41 73 08 20

Head Office TOOLTECH Software (I) Pvt. Ltd. 401 Beta 1, Gigaspace, Viman Nagar, Pune 411 014, India Tel: +91-20-30511200 / Fax: +91-20-30511201 Email: info@tooltechsoft.com www.tooltechsoft.com

TOOLTECHSOFT Sweden Box 184, Drakegatan 10, S-401 23 Gteborg, Sweden Tel . +46 (0)31 773 7163

TOOLTECH Europe Oy Bulevardi 2-4 A, 00120 Helsinki, Finland Tel: +358-9 6150 7560

TOOLTECH ROMANIA Sos. Borsului nr. 20 410605 Oradea Rumnien Tel: +40-728837788

TOOLTECH INC. 5351, Rusche Drive NW Comstock Park, MI, 49321 Tel: +1-616-780-5666

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