Browse Topic: CAD, CAM, and CAE

Items (3,027)
Engineering change (EC) is a complex, manual, and expert-driven topic. It has significant downstream effects on logistic operations and cost structures. The impact of logistics cost is a critical consideration for any profiting company or original equipment manufacturer (OEM). Evaluating the logistics cost impact of an EC is a time-consuming and tedious labor-intensive task. There are multiple steps taken by engineers before making an evaluation of the logistics cost of an EC, these include examining multiple sources, computer-aided design (CAD) drawings, PDF documents, PowerPoint files, and descriptions of the modification. Automation is further complicated by the wide variation of ECs across vehicle model, module group, and product type. To address this, we introduce the logistics impact screening application (LISA), an AI-based system designed to predict logistics cost impacts automatically. LISA pulls together both structured and unstructured data and uses a mix of techniques
Surampudi, TejasYadav, VishwasAnandan, TejasweeNamdev, Vanshika
The concept of “quality feel” in automotive interiors relates to how consumers perceive a product’s quality through touch and feel. While subjective, it’s crucial for satisfaction and differentiation and is defined by engineering requirements like displacement, especially for interior components. Assessing this early in development is vital. Traditionally, this evaluation happens virtually using Computer Aided Engineering (CAE) simulations, which measure displacement and stiffness. However, conventional simulation methods, like Finite Element Method (FEM), can be time-consuming to set up. This work presents two case studies where the evaluation of an interior panel’s quality feel, using structural numerical simulations combined with the Simulation Driven Design (SDD) method was performed. SDD is an iterative process where simulation results guide design modifications, optimizing the component until it meets quality criteria, which are based on simulated human touch and resulting
Cunegatto, Eduardo Henrique TaubeCisco, Lenon AudibertSilva, Matheus RodriguesThums, EsmaelQuinelato, LeandroAraújo, Tomás Victor Gonçalves Pereira
In response to increasing environmental awareness and the automotive industry's push for sustainability, the development of lightweight and robust components has become a key area of focus. This paper presents a multidisciplinary approach to the design and optimization of an aluminum parking brake lever, leveraging advanced structural optimization techniques to enhance performance while meeting stringent environmental standards. Traditional manufacturing processes for automotive components, such as stamping, often rely on steel due to its strength and ease of processing. However, the high density of steel can significantly impact the overall weight of the vehicle, leading to increased fuel consumption and emissions. In contrast, aluminum’s superior strength-to-weight ratio offers a promising alternative. This study employs Finite Element Analysis (FEA) to model the initial stress history of the lever, followed by the application of structural optimization tools to refine its geometry
Filho, William Manjud MalufCarriero, Emily AmaralRequena, Felipe Carlos GarciaScatolin, Felipe MandichMarini, Vinicius KasterAlves1, Marcelo Augusto LealFerreira, Wallace Gusmão
In the development of virtual prototyping for rail vehicles, industrial design plays a bridging role between art and engineering. In the present industrial design process, on account of problems such as too many types of software were used and difficulties in model conversion, the research proposes a collaborative design method for industrial design based on the 3DE platform, aiming to establish a unified “3D data mainline” to achieve continuous development of industrial design and engineering design. Taking a certain urban rail vehicle as an example, the industrial design procedure is analyzed, including demand input, rapid modeling, real-time rendering, curve modeling, etc. It is hoped that this method can reduce development costs, shorten the time cycle, and improve work efficiency in the development process of virtual prototyping for rail vehicles.
Ji, XiranHuang, ShuoWang, ChuweiSun, Bowen
For the diesel engines first designed & developed before 2000s, push-rod type valvetrains with mechanical valve lash adjustment were common. For one such legacy diesel engine, first developed for tractors and now applicated for on road vehicles, having push-rod valvetrain architecture & mechanical valve lash adjustment (Type-5 valvetrain system) with flat follower tappet, integrating HLAs for enhancing the NVH & serviceability presented certain challenges. This paper delves into the challenges faced in the design & development phase of HLA integration project on a four-cylinder diesel engine. For integration of HLA, first, the packaging evaluation of valvetrain assembly was done followed by oil flow assessment and necessary changes in the oil pump and circuit. Then, valve lift profile optimizations were done since the ramp rate & seating velocity requirements are different for valvetrains with mechanical lash and HLAs. Numerous iterations were performed for cam-profile design to
John, Shijino ShajiBagal, Pratik
Vibration testing is an essential component of automotive product development, ensuring that components such as engines, transmissions, and electronic systems perform reliably under various operating conditions. The adoption of electronics in the automotive industry, particularly during the 1950s and 1960s, marked a shift in vibration testing approaches, moving from primarily low-frequency tests to methods that could address high-frequency vibrations as well. This evolution highlights the need for effective vibration fixture designs that can simulate real-world conditions, enabling manufacturers to detect potential weaknesses before products are integrated into vehicles. A key aspect of vibration testing is the identification of resonant frequencies within components. The coupled mass-spring-damper system, for example, can exhibit multiple resonances characterized by a Bode Diagram, where the Q factor technique is utilized to assess damping levels. Accurate vibration analysis can be
Shinde, PramodkumarShah, Viren
This study focuses on the technology for establishing design criteria for the piston pin circlip (hereinafter referred to as "circlip"), which is a component that holds the engine piston pin. During the development of high-revving engines, failure of the piston sometimes becomes a problem, and the main factors are fatigue failure of the piston and falling of the piston pin. The falling of the piston pin is caused by the circlip disengaging from the groove by the inertial force due to the vertical motion of the piston. The circlip is compressed to the size of the piston circlip groove and assembled to the piston. Therefore, in order to prevent the circlip from falling out, it is necessary to compress it more and increase the reaction force acting on the groove. However, this measure raises concerns about the deterioration of the ease of assembly of the circlip. Therefore, it is necessary to establish evaluation criteria that prevent the circlip from disengaging and deterioration of its
Ishizuka, AtsushiWatanabe, Naoto
This numerical study investigates a spark-ignited, two-stroke engine employing uniflow scavenging, flathead cylinder head design, and an exhaust valve system to identify the optimal bore-to-stroke (B/S) ratio for maximizing brake efficiency at fixed displacement. A single-cylinder prototype engine was constructed, and its experimental data validated a 1D GT-SUITE simulation model. This validated model was then utilized to simulate a full-scale, 1.5-liter displacement, horizontally opposed four-cylinder engine with supercharger-assisted boosting, intended for small aircraft propulsion. The simulations explored a range of B/S ratios from undersquare (0.7) to oversquare (1.5), maintaining a consistent brake power output of 60 kW at 3000 rpm and lambda 0.9. Results showed that increasing the B/S ratio enhanced brake efficiency from 26.0% at B/S=0.7 to 27.0% at B/S=1.5, largely due to reduced frictional losses attributed to shorter stroke and lower piston speeds, decreased heat transfer
Zanchin, GuilhermeHausen, RobertoFagundez, Jean LuccaLanzanova, ThompsonMartins, Mario
Compressor is one of rotating component in AC system and function of the compressor is to increase the pressure of refrigerant and circulate the refrigerant across the system. Swash plate compressor is generally used in automotive AC application due to its light weight and compact size. Torque required to operate the compressor is very important and Compressor torque for specific capacity need to be evaluated based on simulation result. For this, simulation tools are effectively used. Modeling and simulation are the key enablers to improve the design and development process. They are extensively used throughout the development cycle. MBD based simulation is more commonly used which gives better understanding of the movement of kinematic part. Reaction forces from the result will help in providing information for the CAE analysis. Many parameters like reaction forces, torque and power varying with shaft angle of rotation is predicted using MBD and result is analyzed. Rigid and Flexible
Parayil, Paulson
Heat exchangers are critical components in various industrial applications, enabling efficient energy transfer between fluids. Chiller (Plate-type heat exchanger), with its compact design and high thermal performance, have gained significant attention in industries such as HVAC, power generation, and chemical processing. This study presents a comprehensive thermo-structural analysis of a chiller generated due to varying fluctuating temperatures and vehicle vibrations using Computer-Aided Engineering (CAE) tools. The analysis involves modeling the heat exchanger geometry, including the alternate chiller plates, to capture the complex geometries. Advanced simulation techniques such as Computer-Aided engineering (CAE) and Finite Element Analysis (FEA) are employed to investigate the thermal behavior under varying operating conditions, including flow rates, inlet temperatures, and pressure drops. Key parameters like pulsation pressure test, temperature distribution, dynamic stress analysis
Jaiswal, AnkitParayil, Paulson
Measurement plays a crucial role in the precise and accurate management of automotive subsystems to enhance efficiency and performance. Sensors are essential for achieving high levels of accuracy and precision in control applications. Rapid technical advancements have transformed the automobile industry in recent years, and a wide range of novel sensor devices are being released to the market to speed up the development of autonomous vehicle technology. Nonetheless, stricter regulations for reliable pressure sensors in automobiles have resulted from growing legal pressures from regulatory bodies. This work proposes and investigates a tribo electric nano sensor that is affected by a changing parameter of the separation distance between the device's primary electrode and dielectric layers. The system is being modeled using the COMSOL multiphysics of electrostatics and the tribo-electric effect. Open circuit electric potential and short circuit surface charge density are two of the
P, GeethaK, NeelimaSudarmani, RC, VenkataramananSatyam, SatyamNagarajan, Sudarson
CAE (Computer Aided Engineering) optimization plays a pivotal role in various industries to gain a competitive edge. CAE optimization is essential in several industries, such as automotive, aerospace and consumer electronics, etc., concentrating on enhancing component structural design. The process helps in addressing complex design challenges, including weight reduction, material usage efficiency and operational effectiveness. This paper presents applications for an integrated form shape, size and topology optimization approach of structural systems by using CAE tools. For the present study, CAD (Computer Aided Design) was prepared using CATIA V5 followed by meshing in Hyper-mesh 2022.3 version software. Optistruct was used as a solver tool. Modal analysis was performed to extract the natural frequencies of vibration and respective mode shapes. According to the results of the frequency response function study performed on the automobile air conditioning condenser, based on low-stress
Mehra, AkankshaParayil, Paulson
The work presents a micro-electromechanical system (MEMS) temperature sensor that has been designed using COMSOL Multiphysics 6.0 software for use in predicting the temperature of automotive parts. Due to its versatility, the shape of this design employs a meander, and this involves joule heating physics. It clearly shows the variation of resistance with temperature. For this design, Nitinol nano material is used because of the following advantages: Enhanced Shape Memory Effect, Superior Super elasticity, Increased Surface Area, Increased Surface Area, Improved Biocompatibility, Tunable Properties, Enhanced Mechanical Properties. Nitinol having high strength to weight ratio find its application in aerospace industry. This sensor works based on the principle of temperature dependence of resistance; that is, the resistance of the material increases or decreases based on temperature. It is observed that Nitinol has low von Mises stress, proving the safety nature of the material in
P, Geetha
In both Internal Combustion Engine Vehicles (ICEVs) and Electric Vehicles (EVs), the refrigerant charge is essential for efficient climate control and energy consumption. An accurate refrigerant charge allows the system to regulate cabin temperature effectively and optimizing energy use. In ICEVs, this prevents the wastage of engine power. In EVs, it preserves battery life by minimizing energy drain by the climate control systems. Undercharging or Overcharging has adverse effects on the Heat Ventilation Air-Conditioning (HVAC) systems and the energy usage associated with it. Undercharging leads to poor cabin cooling which reduces heat absorption by refrigerant whereas overcharging leads to higher energy consumption by compressor, and potential damage to components, which can lead to wear, leaks, and system failures. Hence it is crucial to use optimum refrigerant charge quantity in Mobile Air-Conditioning (MAC) system both in ICEVs and EVs. Previous work on refrigerant charge
Shah, GeetJaiswara, PrashantKulkarni, ShridharJaybhay, Sambhajivangala, Sai krishnaM, Chandru
The research object of this paper is the bogie traction rod of urban rail transit vehicles in China. In order to better analyze the structural strength of bogie traction rod, we use advanced computer aided design and analysis software. Modeling software we use Solid Works to build a 3D model of the bogie traction device, which helps us to understand its structure and working principle more intuitively. The simulation analysis software uses ANSYS to carry on the static analysis of the subway bogie traction device, and establishes the finite element model, through simulation and calculation to predict the various situations and problems that the traction device may encounter in the actual operation.
Yue, DanfeiLun, JianlongRuan, ChijianTang, SiminYang, Zekun
Reliable antenna performance is crucial for aircraft communication, navigation, and radar detection systems. However, an aircraft's structure can detune the antenna input impedance and obstruct radiation, creating a range of potential problems from a low-quality experience for passengers who increasingly expect connectivity while in the air, to violating legal requirements around strict compliance standards. Determining appropriate antenna placement during the design phase can reduce risk of costly problems arising during physical testing stages. Engineers traditionally use a variety of CAD and electromagnetic simulation tools to design and analyze antennas. The use of multiple software tools, combined with globally distributed aircraft development teams, can result in challenges related to sharing models, transferring data, and maintaining the associativity of design and simulation results. To address these challenges, aircraft OEMs and suppliers are implementing unified modeling and
The objective of this effort is to create a methodology to posture and position equipped manikins in Computer-Aided Design (CAD) software for ground vehicle workstation design. A collaborative effort is taking place to evaluate the current practices used to posture and position both physical and digital human representations. The goal of the group is to determine how best to utilize posture and position data to update positioning procedures. Data from the Seated Soldier Study and follow-on studies is being utilized to develop statistical models using multivariate analysis methods. Design is the first area of focus across the broader design-develop-evaluate process. The products to address this need are parametric CAD accommodation models with imbedded Digital Human Models (DHMs). Developing updated positioning procedures for each of the manikins will provide a traceable justification for positioning manikins based on Soldier data.
Huston II, FrankZielinski, GaleReed, Matthew
Selective Catalytic Reduction (SCR) is a key technology for reducing nitrogen oxides (NOx) emissions in diesel engines. In this process, a urea-water solution (UWS) is injected upstream of the catalyst to generate ammonia, which reacts with NOx to form nitrogen. However, liquid urea can adhere to system walls, undergoing secondary reactions that lead to the formation of solid deposits. These deposits must be minimized to ensure the long-term durability and efficiency of the system. Computer-Aided Engineering (CAE) simulations play a crucial role in optimizing SCR performance during the design phase. However, accurately predicting deposit formation requires detailed chemical modelling, which is computationally expensive and introduces uncertainties related to reaction mechanisms definition. To address this challenge, simplified CAE approaches are needed to assess deposit formation risks while maintaining computational efficiency. This study presents an improved Deposit Risk Index (DRI
Bianco, AndreaPrestifilippo, MattiaRobino, CristinaPetrafesa, GiovanniPostrioti, LucioBuitoni, Giacomo
The electric conversion of a large passenger vehicle was investigated, in which the internal combustion engine and associated components were replaced by electric powertrain components. As this will have an influence on the rollover safety performance of the vehicle, compliance to the requirements of UN ECE Regulation No.66 was assessed. The vehicle geometry was captured through physical inspection. The unladen kerb mass of the vehicle was experimentally determined as 10660 kg. This mass excludes the mass of occupants as the vehicle is not fitted with occupant restraints. The location of the center of gravity was estimated using a representative CAD model. The center of gravity is located at a distance of 3580 mm behind the front axle and at a height of 1195 mm above the ground. An implicit nonlinear finite element (FE) analysis was conducted to quantify the energy absorption capability of a rollover hoop. This value was calculated as 5.65 kJ for a single rollover hoop and 67.80 kJ for
Raats, Daniel JamesVenter, GerhardBredell, Johann
In the Brazilian market, the 6x2 configuration for commercial vehicles is widely used. These vehicles feature a driven rear axle and a non-driven axle. For the non-driven axle, it is common to use a lifter system that allows the axle to be lifted when the vehicle is running empty. This system provides benefits such as reduced fuel consumption, lower tire wear, and reduced toll costs when charges are based on the number of axles in contact with the ground. Given these advantages, the system has a high demand, making it mandatory to perform a durability test prior to its market implementation. This paper will present the validation methodology for the lifter system bracket. To achieve this, the following stages will be discussed: CAE, instrumentation, data acquisition, test bench concept, test execution and results.
Leme, Cristianoda Costa Rodrigues, GilsonFigueiredo, Guilherme Galvãode Souza Maria, Heitor CunhaPires, Luciano Rogério
This article presents a design of experiments (DOE) approach to analyze automobile engine coolant leakage from hose joints. The data includes force measurement at hose joints through physical validation and computer-aided engineering (CAE) simulation results. The proposed approach involves utilizing digital validation data, which simulates the entire experiment using CAE. The novelty of this approach lies in its reliance on digital validation data rather than conventional physical measurements, thus providing cost and time savings for the organization. In this study, the authors investigated the force at the coolant hose joint, which results in oil leakage as the response variable. Nine independent factors were evaluated in this experiment. The study concluded through the identification of critical parameters and opposed regression model to predict force at hose joints.
Koulage, Dasharath BaliramMondal, KanchanManerikar, Dattatray Shriniwas
This paper presents a coupled electromagnetic and thermal simulation of Permanently Excited Synchronous Machines (PMSM) in the context of virtual prototyping in a real-time Hardware-in-the-Loop (HiL) environment. Particularly in real-time simulations, thermal influences are often neglected due to the increased complexity of a coupled simulation. This results in inaccurate simulations and incomplete design optimizations. The objective of this contribution is to enable a precise and realistic real-time simulation that represents the electromagnetic as well as the thermal behavior. The electromagnetic simulation is executed used a Field-Programmable Gate Array (FPGA) and parameterized by Finite Element Analysis (FEA) results. The thermal model is based on a Lumped-Parameter-Thermal-Network (LPTN), which is based on physical laws, geometry parameters and material specifications. The simulation results are validated with testbench measurements to ensure the accuracy of the overall model. By
Jonczyk, FabianKara, OnurBergheim, YannickLee, Sung-YongStrop, MalteProchotta, FabianAndert, Jakob
The design, development, and optimization of modern suspension systems is a complex process that encompasses several different engineering domains and disciplines such as vehicle dynamics simulation, tire data analysis, 1D lap-time simulation, 3D CAD design and structural analysis including full 3D collision detection. Typically, overall vehicle design and suspension development are carried out in multiple iterative design loops by several human specialists from diverse engineering departments. Fully automating this iterative design process can minimize manual effort, eliminate routine tasks and human errors, and significantly reduce design time. This desired level of automation can be achieved through digital modeling, automated model generation, and simulation using graph-based design languages and an associated language compiler for translation and execution. Graph-based design languages ensure the digital consistency of data, the digital continuity of processes, and the digital
Borowski, JulianRudolph, Stephan
Engine and powertrain mounts are vital for isolating vibrations and reducing the transmission of Noise, Vibration, and Harshness (NVH) from the engine to the vehicle structure. Despite technological advancements, addressing NVH issues related to tribological factors continues to pose significant challenges in automotive engineering. This study aims to systematically identify and optimize design parameters of engine/powertrain mounts to minimize NVH levels using CAE tools and parametric optimization techniques in Abaqus and Isight, respectively. The purpose of this research is to investigate the correlation between various design parameters of powertrain mounts and their impact on NVH characteristics. Specific attention is focused on noises such as clunking, banging, or thumping that emerge from the engine bay under dynamic conditions like acceleration, braking, or turning. These sounds often occur as the engine moves excessively due to worn mounts, making unintended contact with other
Ganesan, KarthikeyanSeok, Sang Ho
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