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CAE & Simulation

With our extensive expertise in the fields of CAE & Simulation, we can get your product concept ready for series production quickly and cost-effectively. Lists of ambitious product characteristics and increasingly tight development times make it necessary to use effective CAE tools and enlist the services of experienced specialists. Our Center of Competence's CAE & Simulation ensure maximum reliability in virtual development. Whether CAE-driven component development, weight optimisation or complex system analysis, you know when you come to us that you're in safe hands.

Our main areas of expertise: 

Passive safety

Development of passive safety' refers to the process of designing vehicles to minimise the consequences of accidents for passengers, victims outside of the vehicle and any other road users. A high level of passive safety is achieved by maximising energy consumption in the bodywork, synchronising restraint systems and designing the interior suitably. In this sense, passive safety is an overall function of the vehicle, and achieved through optimal device interaction.


Modelling

The key to a high-quality and meaningful analysis is an underlying finite element network. Our expertise encompasses the following tasks and spheres of activity.

Tasks:

  • Construction of models mainly in ANSA and Hypermesh, based on CAD data in any format
  • Construction of simple to complex mid-surface and solid models for Nastran, Abaqus, PamCrash, LsDyna, CFD, etc.
  • Variant generation by arrangement, sketches
  • Assembly and upgrading via RBEs, beams, restraints, forces, contacts, etc.
  • Validation of models for proof of concept
  • Development of derivatives through morphing (stretching/compressing components)
  • Methodological issues relating to special imaging

Spheres of activity:

  • Complete vehicles in automotive engineering : body shell, doors and flaps complete with joining technology
  • Interior components:   seating, dashboard, centre console, door panel, headliner, etc.
  • Exterior components: axle beam, engine, transmission, HV battery, exhaust systems, etc.
  • Buses and lorries
  • Motorcycles: frame, plastic add-on parts, engine components, suspension, etc.
  • Aerospace: fuselage sections, ventilation system, flap tracks, etc.
  • Ships: hull structure
  • Trains: locomotives

Stiffness and strength

To ensure structures are effective, any underlying requirements regarding stiffness and strength must be optimised at an early stage. We support your development process with our solid knowledge base and can apply this expertise to all standard development environments.

  • Calculation of linear static stiffness
  • Simulation of non-linear strength requirements
  • Optimisation of topology and wall thickness
  • Optimisation of layered constructions in composite structures
  • Joining concepts for mixed material construction

We support your development process in the following areas:

  • Drives and undercarriages
  • Bodywork and attached parts
  • Interiors and trims
  • Structural components for plants and machinery

Vibrations and acoustics

Drive comfort and acoustics are fast becoming major distinguishing features, causing demands to increase at the same time. We manage the simulative design and coordination process for your components and assemblies:

  • Simulation of dynamic stiffness
  • Modal and harmonic response analysis
  • Investigation of operational vibrations
  • Calculation of system sensitivities
  • Component optimisation
  • Oscillation system and mass damper adjustment

Fatigue strength and service life

The desire for weight reduction and efficient use of materials mean there are an increasing number of challenges faced when evaluating service life. We help you to optimise the fatigue strength and service life of structural components during the design process:

  • Load data calculations
  • Load data analysis
  • Load spectrum determination
  • Service life planning for undercarriage and drive components
  • Bodywork and attached part coordination
  • Load path optimisation

Multi-body simulations

We use multi-body simulations to help you solve any kinematic and dynamic problems and have many years of experience in the following sub-areas in particular, which includes integration of flexible chassis and variable control systems.

  • Vehicle dynamics and ride comfort
  • Power train simulation
  • Gearbox design
  • Load data calculation and analysis

Flow calculation and thermal simulation

The 'Flow calculation and thermal simulation' department's main task is to conduct thermal analysis of systems and components. We use 3D flow calculations (CFD) as well as 3D thermal conduction and radiation calculations to examine heat transfer in-depth. More complex overall systems such as circuitry and charge cycles in combustion engines are depicted using 0D and 1D models, which can then be linked to detailed 3D models of components and subsystems. Material transport processes (including chemical reactions) are also taken into consideration for engine combustion and after-treatment of exhaust gases, as is air conditioning (humidity). The simulation techniques used are generic and can be applied in other areas. A series of 'focal areas' have emerged with these, however, such as the calculation of component temperature in vehicles based on engine compartment flow, air conditioning of passenger compartments and comfort ratings, calculations for cooling systems and charge cycle processes, and cooling of electrical components such as control units, batteries, LEDs and headlights.


Software and development methods

We develop software that is fine-tuned for your needs and requirements:

  • Automation in the CAE and simulation environment
  • Individual pre-/post-processing and solving
  • Simulation data management
  • UMAT and VUMAT for Abaqus

Structural mechanics aerospace

Structural mechanics (aerospace) cover the broad spectrum that is component development in the aerospace sector, with services including structural investigation, dimensioning, manufacturing support, test definition, verification management and supervision of series production. Static calculations for strength, stiffness and stability aside, we also work in other areas, such as dynamic modal analysis, fatigue and kinematics. Also in use in our everyday routine are standard 'manual' HSB and ESDU-based methods, likewise the finite element method, which involve calculations for metal structures as well as monolithic or sandwich-design fibre composite structures. This work requires us not only to optimise the layers (direction and quantity), but also to analyse the 'laying registers' for overlap, indentation and grading on the individual layers.

As part of our long-term company strategy, we guarantee customers that our partnership will be reliable and stable, and that we will remain available and by their side for upgrades and repairs throughout the product life cycle. Well-trained and experienced specialists and a large selection of analysis and development tools enable us to respond to any problems our customers may experience and to work together to find a solution to these. With our customers from the aviation industry, for example, we use all the well-known analysis tools for that particular sector and adapt these for the project, or develop our own software solutions.

Doing so ensures we provide our customers with the right support and advice in areas such as:

  • Development of structural concepts
  • Creation of design principles (metal and fibre composite construction)
  • Development and construction of metal and fibre composite components
  • Weight optimisation for metal and fibre composite components
  • Generation of production data (specifically for fibre composite components)
  • On-site manufacturing support
  • System installation and integration (especially mechanical systems, all ATA chapters)
  • Development of interior components (galleys, lavatories, stowage compartments, VIP décor)
  • Construction and design of cabin elements (F2Fs, PSUs, class dividers, etc.)

Electromagnetic simulation

By using FE calculations (2D/3D) in both the time domain and the frequency domain, we help you to solve electromagnetic issues such as:

  • Design of electrical and magnetic components and systems
  • Electromagnetic field distribution in a wide range of materials and geometries
  • Development of forces and torques due to the electromagnetic field
  • Thermal behaviour of current-carrying elements (conductive heating)
  • Electromagnetic induction

In all of these areas, we can fall back on our design expertise in relation to electrical machinery, electromagnetic actuators and linked systems (electrical-thermal-mechanical).


System simulation

In this area, we use simulation tools such as Matlab Simulink, SimulationX, Dymola and GT Suite to analyse multiphysical correlations, and can help you with the following:

  • Power trains
  • Regulated undercarriages
  • Energy management
  • Air conditioning
  • Cooling systems
  • Charge cycles
  • Coupling and co-simulation
  • Model order reduction

Theseus-FE software

Theseus-FE simulation software, which we developed ourselves and sell commercially, uses the finite element method as its basis and is essentially made up of the following components:

  • a solver base for thermal simulations (heat conduction and radiation)
  • a thermophysiological model to predict thermal comfort (e.g. inside vehicles or in buildings)
  • a special module (oven) to predict bodywork temperatures in paint-drying ovens (including Abaqus user sub-routine for bodywork adhesives)
  • a special module (e-coating) to simulate the thickness of the coat of paint in a cataphoretic painting container
  • a powerful graphical user interface (GUI) for modelling and evaluation of results
  • coupling tools, e.g. for CFD software such as Star-CCM+ and OpenFOAM
  • a mapper to transmit results between different networks and result formats

THESEUS-FE is used primarily for customers in the automotive industry, but is also used by building physics and aerospace departments at universities and academic/scientific institutions.

For more information about THESEUS-FE, go to http://www.theseus-fe.com