Computer-aided Engineering Tools Research Articles

Integration of extended reality and CAE in the context of industry 4.0

ABSTRACT Simulation plays a major role in the development of new products and is considered one of the nine technological pillars of Industry 4.0. By encapsulating a plethora of digital tools, simulation has transitioned towards what is known as Computer Aided Engineering (CAE), which further enables engineers to validate the design and ensure product performance. The development of cutting-edge digital technologies, such as Extended Reality (XR), has also gained attention aiming at the facilitation of human-machine interface (HMI) and the creation of communication channels for improved remote collaboration. The contribution of this study lies in the design and development of a cloud-based framework for the integration of CAE tools with Mixed Reality (MR), specifically, Computational Fluid Dynamics (CFD), focusing on industrial refrigeration systems design and editing applications. Furthermore, the developed solution provides augmented 3D visualizations overlaid on the existing installations. The proposed framework supports the virtual co-existence of engineers during the design phase, thus enabling collaboration and mentoring between experienced and young engineers. Additionally, it can be realized as a Cloud platform, which supports the distribution of several services such as storage of CAD files, simulation results, and the XR application for the setup and visualization of simulation results.

Fostering Design for Sustainability through the Adoption of Computer-Aided Engineering Tools in the Development of Energy-Related Products

The main challenge to face in the development of energy-related products is represented by the adoption of effective design for sustainability strategies that encompasses the adoption of engineering design tools, knowledge collection, and reuse/sharing in technical departments. This present paper proposes an engineering design for sustainability methodology that assists engineers in developing energy-related products in compliance with ecodesign standards. The methodology uses virtual prototyping tools to assess energy consumption in compliance with energy labeling directives and analyze different use scenarios. The results obtained by numerical simulations (e.g., Finite Element Method—FEM, Computational Fluid Dynamics—CFD) are used to create specific design eco-knowledge in the field of energy-related products. Numerical results are linked with design configurations to understand the benefits introduced by engineering design choices. This knowledge is stored in a structured database with the aim of being reused when a new product is developed or improved/upgraded. The case study of an induction hob, belonging to the household appliance product family, is investigated to understand the potential and drawbacks of the presented approach in a real application. The results show that potential energy and environmental performance benefits are achieved (e.g., reduction of energy losses, achievement of A+ energy class, and overall life cycle environmental impact reduction). Additionally, a new set of ecodesign guidelines are defined for this product family and employed in developing new compliant products belonging to the same family.

An Enhanced Temperature Control Approach to Simulate Profile Extrusion.

Thermoplastic extrusion, a widely used method for processing thermoplastic materials, requires precise temperature control to ensure product quality. However, existing computer-aided engineering tools often oversimplify the temperature distribution calculations, leading to additional discrepancies between simulations and the actual processes. This study introduces a novel multi-region modeling approach to address this issue. By employing realistic temperature control conditions, the methodology overcomes the limitations of current numerical modeling tools. The key contributions include the development of a transient, incompressible, non-isothermal solver integrated into the OpenFOAM computational library and the implementation of a specialized boundary condition that emulates Proportional-Integral-Derivative (PID) control using real-time thermocouple measurements. The findings highlight temperature deviations at the flow channel walls and total pressure drop while demonstrating a smaller impact on velocity and flow uniformity at the outlet under steady-state conditions. This research substantially advances the understanding of thermal dynamics in extrusion processes, offering crucial insights for enhancing temperature control and laying the groundwork for more effective and precise operational strategies.

Modelling of hybrid biocomposites for automotive structural applications

The demand for environmentally friendly materials is at its peak, and government legislations have become stricter and no longer tolerate violations. With biocomposites emerging as structural components instead of being hidden as non-structural applications and interiors, the automotive and motorsport sector started considering them for structural body parts. Natural fibres abundance, commercial availability, renewability, low density, low cost, and high tensile strength make biocomposite materials excellent candidates for eco-friendly vehicles. Several studies reported the utilisation of biocomposites as high-performance components and structural applications. However, current computer-aided engineering and modelling tools are insufficient to explore the vast field of possibilities during biocomposite materials selection to accurately predict the components' behaviour and analyses. Therefore, this study focuses on creating a material model to predict the behaviour of biocomposite materials. Additionally, the model is numerically implemented to illustrate the deformation and bending stiffness capabilities of a motorsport monocoque chassis structure application. A micromechanics modelling combining rate-dependant constitutive laws and multi-site interactions of inclusions is developed for studying the nonlinear response of composite materials. To avoid numerical instabilities when increments of time become very small, a regulation procedure concerning the visco-plastic function is adopted in the computation of the consistent tangent modulus. Based on the Generalised Mori–Tanaka (GMT) scheme, the effective properties are obtained for the nonlinear composite. The accuracy of the model is evaluated and validated by comparison results from the open literature. Finally, the developed constitutive equations are implemented as a user-defined material UMAT in a Finite Element code, leading to an application on a bio-based composite for the bamboo/flax fibre-reinforced epoxy hybrid composite materials.

Optimization of a tetrahedron compliant spherical joint via computer-aided engineering tools

This article focuses on enhancing the range of motion (ROM) of the Tetra II joint, a spherical compliant joint consisting of three internally interconnected tetrahedron-shaped elements that achieve motion through elastic deformation. Despite its excellent precision, this specific design is constrained in terms of ROM due to internal contacts among the tetrahedral elements. To overcome this limitation, this study utilizes a computer-aided engineering (CAE) framework to optimize the configuration of the Tetra II joint and enhance its ROM. The resultant optimized joint, referred to as Tetra III, is subsequently compared to Tetra II in terms of both ROM and center shift. Finite element models (FEM) are employed to validate the optimization results and examine how various tetrahedron-shaped geometries impact the joint’s performance. The newly optimized joint exhibits a significantly higher ROM compared to the previous version, while maintaining excellent precision and overall smaller dimensions. Finally, to demonstrate its manufacturability, the Tetra III joint is produced using selective laser sintering (SLS) technology, with Duraform PA serving as the construction material. The successful fabrication serves as a demonstrative example of the improved design of the Tetra III joint.

Engineering design and the impact of digital technology from computer-aided engineering to industrial metaverses: A perspective

Digital technology for engineering design is evolving from computer-aided engineering tools via digital twins to industrial metaverses. These advances are resolving many of the challenges associated with implementing concurrent design and enabling larger design domains to be considered and designs to be developed, reviewed and demonstrated more rapidly and with a wider range of stakeholders. However, the new technology is also creating new challenges associated with confidence in digital representations and with methods of working with a rapidly evolving design. These challenges need to be addressed so that radical new designs of complex systems can be produced quickly to support society in addressing the evolving crisis of climate change.

Design, Analysis, and Optimization of Off-Highway Rear Dump Truck Chassis Frame Rail Profile Using Design Exploration and Finite Element Analysis Technique

<div>During mining material hauling, the chassis frame structure of rear dump trucks is subjected to fatigue loading due to uneven road conditions. This loading often leads to crack propagation in the frame rails, necessitating the determination of stresses in the critical zone during the design stage to ensure structural integrity. In this study, a computer-aided engineering (CAE) methodology is employed to size and select the rectangular profile cross section of the chassis frame rail. A detailed design investigation of the chassis frame is conducted to assess its load resistance, structural flexibility, and weld joint fatigue life under critical stresses arising from combined bending and torsion loads. The optimization process aims to determine the optimal rail size and material thickness, striking a balance between minimizing mass and maximizing structural reliability. By achieving this, the risk of major structural failures during the transportation of large payloads can be significantly reduced. To address the demand for extended structural life and reduced chassis frame weight, the frame rail cross section is optimized using a multi-objective genetic algorithm (MOGA) implemented within the ANSYS software package. This optimization process is facilitated by utilizing design exploration studies and finite element analysis (FEA) techniques to understand how stress affects the chassis frame of a vehicle when it is subjected to combined bending and torsion load case. To do this, the research study used a combination of analytical calculations, mathematical modeling, and design exploration studies.</div> <div>The research findings highlight the effectiveness of combining empirical approaches with modern CAE tools, enabling engineers to design and analyze complex structures with optimized sizes and weights suitable for off-highway mining applications.</div> <div>Through the utilization of this integrated approach, significant advancements can be made in enhancing the structural performance and efficiency of chassis frame structures in the demanding off-highway mining industry.</div>

Geometrical and mechanical analysis of polylactic acid and polyvinylidine fluoride scaffolds for bone tissue engineering

Utilising finite element analyses and experimental testing, this study investigates the influence of scaffold porosity on mechanical behaviour and evaluates the potential of polylactic acid (PLA) and polyvinylidine fluoride (PVDF) as bone substitute materials. Scaffold geometries were devised using design parameters adapted from extant literature and then generated using computer-aided engineering tools. Methodical variations in strand thickness were applied, maintaining other design criteria constant for robust analysis. Results, derived under varied loading conditions, suggest that scaffold mechanical properties are influenced significantly by geometry, strand diameter and porosity. Cubic scaffolds exhibited marked strength. Structures with reduced porosity demonstrated heightened mechanical characteristics, while facilitating bone cell proliferation. For a comparative context, PVDF scaffolds were benchmarked against human femur bone properties, revealing a mechanical behaviour alignment, particularly in their Young’s modulus.

Advance algorithm for two-dimensional fibrous-network generation

Abstract Fibrous networks are abundant in nature and commonly used in industry. However, their geometrical modelling is challenging due to their complex microstructure. In this study, a novel method, called fibre placement method (FPM), is developed. In contrast to the existing methods, the FPM has various advantages, such as a fully parametric definition of structure. Also, this method is superior in mimicking the stochastic microstructure of fibrous networks compared with other schemes. Various fibrous networks can be generated easily by employing a user-friendly graphical user interface. Also, the generated fibrous networks are compatible with analysis software such as computer-aided engineering tools. Finally, this algorithm characterizes various features of networks including uniformity, void area fraction, and average curliness.

Design and analysis of single and multi-layer pressure vessel

This article presents a comprehensive investigation on the design and evaluation of monoblock pressure vessels using computer-aided design (CAD) and computer-aided engineering (CAE) software. Pressure vessels, commonly known as sealed cylindrical shells, are engineered to withstand high internal pressure and enhance structural robustness. The vessels feature a multi-layered structure that incorporates inherent safety mechanisms. They find widespread applications in diverse industrial sectors, including automotive, aeronautics, nuclear power, and biotechnology. This study utilizes established materials such as Steel-s515-gr70, Aluminium Alloy (6061-t6), and Grey Cast Iron to design a pressure vessel configuration comprising multiple layers, which aims to reduce stress and improve the security and longevity of the vessel. The CREO (8.0) software is employed for accurate modeling and optimization of the vessel's geometry, while the ANSYS (2022 R1) software enables static structural analysis to assess its performance under various loading scenarios. By utilizing CAD and CAE tools, this research aims to advance the techniques for designing and analyzing pressure vessels. The combination of pre-existing materials and a complex layered design serves to mitigate stress and enhance the safety and efficiency of the pressure vessel. The findings of this study contribute to the overall understanding of pressure vessel design and analysis, with the ultimate goal of developing pressure vessels that are safer and more efficient in diverse industries.

The 3-D optimization of an axial mixer propeller through high fidelity simulations

Homogeneous mixing is an important process quality indicator in biogas fermenters for introducing fresh organic feed material to certain bacteria groups such as methanogenic bacteria for anaerobic digestion. Energy consumption for mixing processes is one of the highest operational costs in biogas plants. Thus, it is crucial to carefully consider the energy expenditure per generated thrust (the first performance metric of an axial mixer) for a biogas mixer, since biogas plants are considered as a net carbon zero energy plant. There are several different types of mixers. Axial mixers both high speed and low speed together with paddle mixers are most common among various types of mixers used in fermenter tanks. In this study it is planned to improve conventional axial biogas mixer efficiency using computer aided engineering tools for design and optimization. This goal will be achieved by using a parametric design strategy for blade geometry together with the open source CFD analysis suite OpenFOAM for measuring performance metrics (i.e. power, torque, and thrust). The most efficient design will be chosen from a set of design candidates residing inside a reasonably large parametric state space, via maximizing the thrust to power ratio.

Design and Characterization of a Test Bench For Interior Noise Investigations

The increasing demand for acoustic comfort in vehicles has popularized the vibroacoustic analysis using computer-aided engineering (CAE) tools and boosted the development of various noise control measures. Concerning the often-unknown reliability of a CAE tool and the high cost of testing control strategies in a real vehicle, this paper proposes a test bench called Noise-Box, for benchmarking the CAE tools and testing new control measures. The test bench is designed towards a simple plate-cavity system that is easy to model and analyze, so that any vibroacoustic test performed on it can be accurately reproduced by numerical models. Specifically, it is a concrete box with six rigid walls and an opening that can be covered by flexible or soundproofing panels. The complete design is elaborated, including the cavity's shape and dimensions, the panel's installation and the device's overall configuration. Moreover, the acoustic field provided by the test bench is characterized for the typical features that will guide the device's future applications, covering modal property, reverberation time (or sound absorption) and field diffuseness. This work could be informative and instructive not only for the presentation of the novel test bench but also for the utilized methodologies in its design and characterization.

Machine Learning based Approach for Brake Pad Pressure Distribution

Abstract: The Brake system in automobiles plays a vital role in customer safety. Brake pads are crucial components that experience huge pressure while slowing down the vehicle’s movement. Designing a brake pad requires sound knowledge of structural design, manufacturing ability, and material properties. Further, an optimized model is chosen based on the size of the brake pad and the brake power requirement. Brake pad pressure distribution is one of the main studies in designing automobile brake pads. Numerical solvers are used to validating the experimental results, which is a repetitive process for every new design under the study. Computer-aided engineering tools are costly and time-consuming for design iterations. The present paper provides a new approach for estimating brake pad pressure distribution using machine learning techniques. The accuracy of the machine learning models for various designs shows promising outcomes.

Electrified powertrain sizing for vehicle fleets of car makers considering total ownership costs and CO2 emission legislation scenarios

Developing effective computer-aided engineering (CAE) tools is currently a compelling need for fostering industrialization and widespread diffusion of electrified road vehicles. A CAE methodology is proposed in this paper for sizing electrified road vehicle powertrains at an overall car maker vehicle fleet level by considering different evaluation criteria involving retail price, compliance with current and future regulatory CO2 emission requirements, drivability, and real-world operative costs. A case study is performed on a group of different vehicle models embedding the same electrified powertrain, and different vehicle electrification levels are assessed. Plug-in hybrid electric vehicle (HEV) is identified as the most robust propulsion system architecture solution considering different sizing targets and 2030 oriented regulatory scenarios. This suggests that, from the perspective of a car maker, investing in research and development and in upgrade of current vehicle production facilities to propose highly electrified vehicles in the market can be a more strategic and successful approach than a conservative strategy which would restrain the economic investments and limit the overall electrification level of all vehicle models. The considerably higher retail price that users are required to pay when purchasing a fleet of plug-in HEVs may in fact be paid off and eventually reveal beneficial in a long term given the avoidance of paying a regulatory CO2 sanction and the consistent reduction in the monthly operative costs in terms of fuel and electricity. Vehicle designers can implement the presented CAE methodology for assessing electrified vehicle sizing options at the overall car maker level based on realistic use case scenarios and different potential CO2 emission regulation scenarios.

A Multi Domain Modeling Approach for the CFD Simulation of Multi-Stage Gearboxes

The application of Computer-Aided Engineering (CAE) tools in mechanical design has consistently increased over the last decades. The benefits introduced by virtual models in terms of time and cost reductions are the main drivers for their exploitation in industry as well as for research purposes in academia. In this regard, Computational Fluid Dynamics (CFD) can be exploited to study lubrication and efficiency of gears. However, the mesh handling complexities deriving from the boundary motion is still a concern for its application to multi-stage gearboxes. In this work, an innovative multi domain partitioning method for the simulation of a two-stage industrial speed reducer is presented. The implemented solution foresees the combination of two remeshing strategies, namely GRA (Global Remeshing Approach) and GRAMC (GRA with Mesh Clustering), and resulted in a computationally effective performance. The results were compared with experimental data obtained with measurements on the real system, providing a good agreement in the power losses prediction. Considering the complexity of obtaining such results experimentally, the proposed numerical algorithm can offer substantial benefits for an estimation of the transmissions’ efficiency in various operating conditions. The numerical model was built in the open-source environment OpenFOAM®.

Razvijanje recipročnog mehanizma za hitnu implementaciju mehaničkog plućnog ventilatora koristeći integrisanu CAD-MBD proceduru

Following the COVID-19 outbreak, the redesign of an emergency mechanical pulmonary ventilator that is cheap and easily portable became necessary in several contexts, such as emergency hotspots and environments with poor resources. To address this important issue, a general multibody approach is employed in this paper to develop a reciprocating mechanism suitable for retrofitting the existing manual mechanical ventilators through computer-aided engineering tools. By analyzing various basic articulated mechanisms typically found in engineering mechanics, a prototype is created and reproduced in a three-dimensional environment using SOLIDWORKS's CAD software. Subsequently, a high-fidelity mechanical model is developed starting from the CAD geometry and employing the SIMSCAPE MULTIBODY software, an extension of the MATLAB family of programs that can effectively and efficiently perform kinematic and dynamic simulations of the mechanism of interest. As discussed in the paper, by carrying out numerous numerical experiments, the virtual simulations predict several fundamental medical parameters, such as the airflow introduced into patients, the respiratory rate, and the respiratory ratio.

Influence of the fin to baffle distance on temperature, stress distribution and fatigue life of a cooled Exhaust Gas Recirculation system

Environmental concerns and the decline of Earth's natural resources are among the most prominent issues in today's society, leading to stringent policies regarding commercial vehicle emission products, such as nitrogen oxides (NOx) and carbon dioxide (CO2) emission levels. Aiming to reduce their environmental footprint, car manufacturers have chosen to integrate the Exhaust Gas recirculation (EGR) cooler technology into their vehicles decades ago, as this is a resourceful and effective technique for reducing NOx emissions. This technique is still applied in hybrid cars and is foreseen to be used in future moved vehicles, proving its contemporaneity, adequacy, and relevancy. Nevertheless, this technology requires that different factors be considered during the design phase, such as high gas temperatures, mechanical vibrations, and other loads, as these may affect overall performance and durability. Therefore, this study aims to assess the impact of varying the inner fińs length on the applied loads and how it may affect the EGR Cooler efficiency. To this end, Computer-Aided Engineering (CAE) tools using numerical methods, such as Finite Element Method (FEM) and Finite Volume Method (FVM), were applied. This investigation revealed that varying the inner fi length affects each of the applied loads differently, and increasing the length was shown to improve the heat transfer process of the EGR; however, it also increases the thermally induced stresses at the hottest region, diminishing the fatigue resistance of the component. The advantages and disadvantages of several configurations understudy were addressed in the work carried out.

Computationally efficient evaluation of fuel and electrical energy economy of plug-in hybrid electric vehicles with smooth driving constraints

Advanced computer-aided engineering tools are urgently needed to foster the development of electrified road vehicles that would enable abating fuel consumption and pollutant emissions of the transport sector. Concerning plug-in hybrid electric vehicles (HEVs), implementing an energy management strategy that can rapidly estimate near-optimal powertrain control trajectories while effectively dealing with broaded battery state-of-charge (SOC) window utilization and smooth HEV driving requirements still needs extensive development. To overcome the highlighted drawback, this paper introduces a formulation of the slope-weighted energy-based rapid control analysis (SERCA) algorithm which can rapidly identify near-optimal plug-in HEV control trajectories while complying with SOC boundaries and limiting the number of thermal engine activations and gear shifts. The HEV numerical model is introduced first, followed by formulating the optimal plug-in HEV control problem with smooth driving constraints and describing the dedicated SERCA based control approach. A performed case study demonstrates that SERCA can identify smooth driving constrained near-optimal HEV control trajectories for a 1.5 hours-long real-world driving mission within two minutes on a desktop computer, while a global optimal control approach such as dynamic programming (DP) is found to require more than 10 hours to perform the same task. On the other hand, compared with the global optimal reference provided by DP, the increase in estimated plug-in HEV operative cost in terms of fuel and electrical energy consumption associated to SERCA is always contained within few percentage points. The proposed methodology can accelerate HEV powertrain design and on-board supervisory controller development procedures.

Challenges Faced While Designing Body in White

Abstract: Construction of Body in White (BiW) revolves around plenty of challenges. Ranging from BiW fixtures to curbing weight of Body in White sheet metal design. This paper discusses about all the design aspects in BiW manufacturing in automobile and confronting challenges that occurs. At present, lots of existing theories are being applied and efforts to improve the same are being made. This paper provides a path on how components can be developed and make necessary improvements. CAE (Computer Aided Engineering) tools have been used for FEA (Finite Element Analysis) and also an example of stress analysis of automotive chassis is given. An outcome depending on behaviour of loads acting on frame is drawn. The importance of hollow tubes, tubes of different- cross sections to counter weight and ease the designing of BiW frame have been proposed. This paper also provides insight on safety parameters with current construction of tubular frame chassis. Other solutions such as hybrid tubes, foam padding and plastic trim have been pointed out in this paper. Keywords: CAE, FEA, manufacturing, loads, tubes, cycle-time, cross-section.

CFD simulations of gearboxes: implementation of a mesh clustering algorithm for efficient simulations of complex system\u2019s architectures

In the last decade, computer-aided engineering (CAE) tools have become a determinant factor in the analysis of engineering problems. In fact, they bring a clear reduction of time in the design phase of a new product thanks to parametrical studies based on virtual prototypes. The application of such tools to gearboxes allowed engineers to study the efficiency and lubrication inside transmissions. However, the difficulties of handling the computational domain are still a concern for complex system configurations. For this reason, the authors maintain that it is fundamental to introduce time efficient algorithms that enable the effective study of any kind of gear, e.g., helical and bevel configurations. In this work, a new mesh handling strategy specifically suited for this kind of studies is presented. The methodology is based on the Global Remeshing Approach with Mesh Clustering (GRAMC) process that drastically reduces the simulation time by minimizing the effort for updating the grids. This procedure was tested on spur, helical, and bevel gears, thus demonstrating the flexibility of the approach. The comparison with experimentally measured power losses highlighted the good accuracy of the strategy. The algorithm was implemented in the opensource software OpenFOAM®.