Computer-aided engineering simulation

cae

Company’s advantagesPLM Ural Engineering center offers computer-aided engineering simulation services to enterprises where it is necessary to :

  • Reduce the number of prototypes and physical tests
  • Investigate more prospective product designs to choose the best one
  • Evaluate the existing technology
  • Define defects’ reasons and find the ways of its correction
  • Decrease metal consumption
  • Accelerate the development of a new technology

Modern CAE systems and deep knowledge help PLM Ural specialists to evaluate accurately on the base of a computer prototype the product behavior at real operating conditions.

The results:

  • Development cost reduction
  • Time-to-market acceleration
  • Product quality increase

Engineering simulation – manufacturing-dependent design performance evaluation

We have the technical capability to run coupled analysis of the following manufacturing processes:

  • stamping – welding;
  • forging – heat treatment;
  • casting- heat treatment, etc.

After manufacturing processes simulation strength, tightness analysis, accounting real product characteristics, can be performed.

This approach enables an engineer to evaluate real product performance and durability.

Strength analysis of the final product taking into account the casting defectsMetal temperature during cooling

Simulation expertise

Engineering simulation – evaluating design performance

  • under static loading with linear and nonlinear formulation;
  • taking into account multiple contacts between bodies;
  • taking into account large deformations of construction, nonlinear material models (plastic strains in metals, different models of elastomers, soils etc.) and nonlinear long-term processes – creep, irradiation-induced swelling

linear and nonlinear formulation, postbuckling behavior analysis.

  • critical crack length analysis;
  • debonding and delamination processes of adhesive bondings.
  • eigenvalues and eigenfrequencies;
  • sthrength analysis of constructions under vibrating loadings with predetermined random spectrum;
  • rotor dynamics analyses

based on high- and low-cycle analysis, calculation of fatigue crack damage accumulation during variable alternating loading and fatigue crack growth.

  • impact;
  • perforation;
  • bearing failure;
  • fracture;
  • detonation;
  • earthquake.
  • aircraft and automotive aerodynamics;
  • HVAC;
  • gas dynamics of burners, furnaces and combustion chambers including chemical reactions;
  • turbomachinery throughflow (turbines, compressors, pumps, fans);
  • flows in separation equipment;
  • hydraulics of valves and pipelines.

All types of heat transfer analysis (thermal conductivity, natural and forced convection, radiation and phase change effects). Thermal analysis of electronic and electromechanical devices, various machines and equipment.

Electromagnetic analysis of sensors, electromagnets, actuators, electric machines (any type of motors and generators), transformer technology (current limiting reactor and arc-suppression coils, current and voltage transformers). Evaluation of insulators dielectric strength, development of control schemes.

  • scanner antenna optimization including antenna array;
  • analysis of passive planar and volumetric VHF devices (fi lters, power dividers, couplers, coupled cavities...);
  • signal integrity analysis, estimation of electromagnetic compatibility;
  • calculation of scattering cross-section.
  • aeroelasticity and flutter;
  • thermal stress analysis;
  • Joule heating and eddy current thermal losses;
  • induction heating, electromagnetic mixing of alloys;
  • analysis of magnetic flowmetersvibration analysis of electric machines.
  • product vibroacoustic analysis using spectral methods;
  • simulation of layers and volumes of porous absorbing material, nonreflective boundaries, dispersion, deterministic and random loads;
  • analyzing designs for acoustic modes determination, sound pressure levels indoors and outdoors, losses in exhaust system muffler, structural stresses and strains due to acoustic loads.

Determining design or operation conditions, which yield the best value of objective function (device efficiency, wing lift, mass, design life, etc.)

Topology optimization allows for shape variation decoupled from original CAD model, which significantly extends the optimization domain. As the result, the procedure may yield bionic design.

Engineering simulation – virtual manufacturing

  • simulation of processes of hot and cold, volumed and sheet metal stamping, rolling, drawing, forging, rolling wheels and rings and other processes;
  • analysis of strains fields, stresses, thinning / thickening of the metal;
  • determination of energy-power parameters of tools and plotting these parameters on the various arguments;
  • evaluation of products quality from the forming limit diagram FLD;
  • identification of production defects - cracks, breaks, bumps, wrinkles, shrinkage cavity;
  • determination of the springback level in detail after removing it from a die;
  • automatic die compensation after springback
  • Simulation of extrusion process for any matrix die type and complexity;
  • reconstruction of matrix die prototype from a flat drawing;
  • blank contour and trimming lines optimization for stamping;
  • optimization of pressure supply schedules for superplastic forming.
  • thermal fields analysis;
  • hardness analysis;
  • austenitic grain size analysis;
  • stress strain state analysis;
  • yield stress analysis;
  • hot and cold cracking analysis.
  • simulation of any casting process;
  • macro and micro shrinkage porosity;
  • gas porosity;
  • shrinkage pipes;
  • hot spots;
  • hot and cold cracks;
  • residual stresses and deformations;
  • fatigue limit;
  • misran and cold shuts;
  • oxides and inclusions;
  • grain structure;
  • segregation;
  • mechanical properties;
  • finite part's dimensions.
  • thermal and mechanical stress strain fields analysis under heating and cooling in different medias;
  • hardness analysis;
  • austenitic grain size analysis;
  • stress strain state analysis;
  • distortion analysis;
  • yield stress analysis;
  • hot and cold cracking analysis.
  • simulation of the process production of composite materials;
  • master preparation and selection of the type and quantity of fibers and layers of weave, draperies;
  • automatic calculation of equivalent mechanical properties of the materials developed in the program;
  • accounting for the heterogeneity of the structure and properties of the anisotropy.
  • thermoforming operations;
  • explosion forming;
  • diaphragm forming;
  • stretching forming;
  • molding including the use of the elastic punch;
  • models for plastic materials, fabrics and reinforced polymers;
  • multilayer composites;
  • prediction of defects: wrinkles, corrugations, gaps;
  • distortion warp fibers analysis.
  • RTM - injection of the binder in the closed mold;
  • vacuum RTM;
  • VARI - vacuum infusion;
  • prediction of impregnation defects: incomplete impregnation of resin due to solidification, porosity, formation of nodules and others;
  • modeling for the changes in the permeability of distortion after fiber preform on stage automatic selection of the optimal feed rate of the binder to minimize the formation of defects;
  • tools for validation processes impregnation and determination of the best combination binder and reinforced foundations.
  • study materials after production bases of operations, and impregnation of the preform;
  • integrated solution for loads, check the quality of products;
  • carrying out static and dynamic tests of the obtained materials to check their properties and performance.