Simulation Software & Services for Automotive

Automotive

Toyota Prius CFD Model - Large

ANSYS FEA and CFD engineering analysis software have been widely used in all automotive design applications.  To learn more about projects that have been done with ANSYS FEA and CFD software, please see information below on specific automotive components.

In addition to simulation software and services, SimuTech is an industry leader in strain gage & telemetry to the automotive industry.

 


SimuTech Consulting Projects in the Automotive Industry:

  • Squeeze fit analysis for soft gasket contact
  • Key lock cylinder frictional contact fatigue study
  • CFD analysis into vehicle duct venting performance
  • Strength and deflection verification of clutch/brake/accelerometer pedal assembly system
  • Large deflection simulation of polymeric seal performance comparing relative design performance under complete cycle of seal compression and pressure application
  • DC Clutch magnetostatic analysis
  • Transit bus sway bar structural optimization

Headlight Assembly Underhood Thermal Body in White
Thermal - Headlight Assembly Underhood Thermal Management Body in White

Aerodynamics

Automotive Systems

Acoustics

Airbag Inflators

Brakes & Wheels

Climate Control Systems

Electronics

FSI Simulations

Headlights & Lamp Housings

Underhood Thermal Management

Mechanics

Body in White

Chassis & Suspensions

Hyperelastic Seals

Fuel Cells

Battery Packs


Design Elements Challenges Simulation Benefits

Aerodynamics

  • Resolve pressure distribution around the vehicle
  • Minimize vehicle drag (to improve fuel economy)
  • Assess vehicle handling and stability (side forces, lift)
  • High-end turbulence models
  • Sophisticated and accurate numerics
  • Highly efficient transient solvers
  • Mesh-adapt-on-the-fly ability
  • Industry-leading parallel scalability

Acoustics

  • Noise propagation for external and internal flows
  • Qualify acoustic sources
  • Determine dominant frequencies and sound pressure level (SPL)
  • Understand effect of modifications to local geometric features on SPL and frequency
  • High-end turbulence models
  • Highly efficient transient solvers
  • Highly accurate numerics
  • Built-in acoustics-specific tools
  • Industry-fastest turn-around times

Airbag Inflators

  • Optimize inflator design from the aspect of gas flow delivery in the airbag
  • Gas flow data are input for crash simulations
  • Need detailed characterization of the gas flow inside and/or outside the inflator
  • Robust explicit solver able to deal with highly compressible, unsteady, flows and propagating pressure waves
  • Species transport model

Brakes & Wheels

  • Design brakes and wheels that are durable and can sustain variable loads
  • Predict stress and fatigue
  • Predict local temperature distributions and thermal loads
  • Optimize brake venting
  • Flow and structural solution from the same CAE vendor
  • Easy and seamless transfer of CFD and FEA data between applications

Climate Control System

  • Design HVAC system able to provide thermal comfort to passengers over a wide range of driving and ambient conditions
  • Deliver appropriate cabin airflow for clearing windshield and windows as required by safety regulations
  • Optimize performance of HVAC components
  • Hexcore technology for efficient meshing
  • Robust and accurate solver regardless of mesh type
  • Deicing and defogging models
  • Solar load model

Electronics

  • Design components capable of sustaining harsh operating environments
  • Proper thermal management is crucial for reliability and durability
  • Accelerated failure mechanism in materials
  • Packaging constraints
  • Vibrations
  •  
  • Variety of products targeted for electronics, from full-feature applications to highly application-focused and automated vertical tools
  • Easy and seamless transfer of flow and structural data between CFD and FEA

FSI Simulations

  • Capture the flow-induced structural deformations (one-way coupling)
  • Capture the alterations of the fluid flow due to structural deformations (two-way coupling)
  • Both 1-way and 2-way FSI simulations can be performed entirely within the ANSYS Workbench environment
  • A single environment with a consistent graphical user interface, making it easier to learn and use
  • Simulation process completely streamlined
  • Automated mesh morphing
  • Both CFD and FEA results can be simultaneously post-processed in the ANSYS CFX post-processor

Headlights & Lamp Housing

  • New polymer materials have lower thermal resilience than glass
  • Thermal stresses caused by absorption of emitted light
  • Condensation is visible in case of clear panes
  • Flow distribution needs to be optimized for proper ventilation
  • Complete solution: CFD and FEA
  • Choice of several radiation models
  • Condensation model
  • Material nonlinearity
  • Easy mapping of CFD data onto FEA

Underhood Thermal Management

  • Predict cooling system performance (e.g. air flow distribution in heat exchangers, top hose temperature, fan-off temperature‚Ķ)
  • Minimize simulation turnaround time while meeting accuracy targets
  • Preprocessing: Complexity of the geometry, number of parts (in hundreds), dirty CAD data‚Ķ
  • Powerful pre-processing tools (e.g. TGrid, ANSYS ICEM CFD)
  • Full suite of physical models (e.g. radiation, buoyancy, shell conduction, fan model, heat exchanger model)
  • Robust and accurate numerics
  • Fully parallelized calculations for fast turnaround
  • Fully coupled solution with major 1-D fluid system (e.g. Flowmaster) and engine simulation codes (e.g. GT-Power and WAVE)

Mechanics

  • Analyze the mechanisms of complex assemblies involving many parts
  • Determine forces experienced at the joints
  • Predict stresses in critical regions
  • Rapid modeling of mechanisms and optimizing the design
  • Automatic joint detection for complex assemblies
  • Quickly switch simulation from fully- rigid to flexible in the same environment

Body in White

  • NVH and point mobility analysis of full BIW structures
  • Accurately model spot welds
  • Crash simulation of structure
  • Feature rich surface meshing tools including variable thickness
  • Auto creation of spot welds from weld data
  • Ability to export the model from static to crash analysis

Chassis and Suspension

  • Full system model of a chassis or suspension
  • Connection of all the parts in the assembly
  • Meshing the entire assembly
  • Include joints and mechanism
  • Advance preprocessing tools allow for geometry cleanup, midsurfacing in a single environment
  • Automatic contact detection
  • Contact easily defined between sheets and solids

Hyperelastic Seals

  • Predict leakages and failure of seals
  • Highly non-linear material and load behavior
  • Complex physics involving self-contact
  • Ability to model non-linear materials
  • Easy to set up self-contact
  • Easy to model 2-D as well as 3-D solutions
  • Advanced diagnostic tools to help convergence

Fuel Cells

  • Channel design that optimizes distribution of oxygen (hydrogen) to the cathode (anode)
  • Water management
  • Thermal stresses and cooling plate design
    • Materials
    • High costs
  • Property variation
  • Space limitations
  • Probabilistic design in virtual prototypes
    • Design for Six Sigma
  • Minimize costly physical prototypes using analysis based on first principle physics (electrochemistry, fluid flow, heat and mass transfer, structural mechanics)

Battery Packs

  • Increase power capability, while avoiding hot spots that cause premature failure
  • Insure proper thermal management of the battery pack for performance and reliability
  • Battery pack performance impacted by performance of individual cells and modules
  • Capture heat transfer of the actual cell or module (case, terminal posts, connectors, interconnects, relief valves, seals, etc.)
  • Multiphysics modeling capabilities (electro/thermal, CFD, FEA) all in a single CAE package