Design Verification by Simulation

Design verification and validation (V&V) using computer simulation enhances the designer’s capabilities. ProSIM uses a variety of simulation procedures (including commercially available tools, open source software, and in-house developed routines / macros) for V&V of different applications.

For design V&V, ProSIM capabilities include analysis of coupled phenomena, multi-physics simulations and multi-scale modelling.


Stress

ProSIM has the ability to carry out linear and non-linear stress analysis including static and dynamic loads. Using expertise ProSIM can suggest on design changes, scale up or scale down / optimisation/ VA / VE.

ProSIM has the abilities to predict residual stress (for example in welding, casting etc) due to thermal gradients or due to mechanical working (shot peening/ hole expansion). Capabilities include experimental correlation using a variety of measurement techniques such as X-Ray diffraction, Ultra-sound, hole drilling etc.

FEM analysis is used validation of stress in operating / loading conditions to predict the stress (and strain) distribution, propensity of plastic deformation, factor of safety, and verify the allowable stress limits. More often the resultant stress has to be determined considering the thermal state of the system.

Flow and Thermal

ProSIM has capabilities in computational fluid dynamics and thermal analysis, and in fluid-structure interaction. Our experience spans subsonic/ supersonic and hypersonic flows; multi-phase flows, compressible flow and mixed flow domains.

Often, in engineering systems, flow – thermal-mechanical performance are linked to each other. ProSIM has worked on such analysis of a variety of systems including inlet/ exhaust manifolds, pumps, compressors, blowers/ fans, electronic systems, furnaces, jet deflectors, cooling pipe circuits, data centre thermal flow management, military shelters, and so on, vessels, slurry distributors and so on.

Noise, Vibration and Harshness (NVH) / Acoustics

Noise level control has become a key component of product performance. codes and standards mandate certain allowable limits of noise emission for different category of products. ProSIM has expertise in noise analysis (NVH) of a variety of systems including alternators, motors, reactors, transformers, engines, gear box, brakes, and so on. Here again a combination of FEM and/or MBD system simulation is invoked.

Vibration and dynamics

ProSIM expertise in vibration and dynamic analysis includes using FEM (finite element method) based or MBD (multi-body dynamics) / MBS (Multi-body simulation) platforms. ProSIM capabilities include time domain and frequency domain analysis.

  • Natural Frequency analysis and mode shape extraction
  • Forced Vibration analysis
    1. Harmonic Analysis
    2. Random Vibration Analysis
    3. Response Spectrum analysis
    4. Full transient dynamics analysis
    5. Shock/ bump / sine
  • Torsional vibrations
  • Order Analysis
  • Rotor dynamics

ProSIM has worked on vibration analysis including vibration induced fatigue of automotive systems, aerospace systems, power plant systems, engines, drive trains, and so on.

Impact / Crash / Drop test

ProSIM has high capability to carry out explicit dynamic analysis for assessment of impact / crash/ drop test.

We have carried out several projects such as:

  • Frontal impact of SUV
  • Side impact of passenger car
  • Crush analysis of aluminium foam bumper
  • Missile impact on tanks
  • Failure analysis of concrete structures under missile impact
  • Drop test of enhanced fatigue meter
  • Drop test of mobile MRI scanner unit

Electro-magnetics

Today, there is an increased usage of electro-mechanical systems in many industrial sectors. Automation, sensors, drivers, energy conversion devices, induction heating devices, and so on need more robust electro-magnetic analysis.

Using science based multi-physics simulations, coupled electro-magnetic-thermal-structural analysis of electro-magnetic systems is carried out at ProSIM to determine:

  • Electrical current flux density distribution
  • IR / Stray/iron/ copper losses
  • Temperature rise due to losses and distribution
  • Magnetic flux distribution (including in the air regions)
  • Magnetic losses
  • Mechanical forces
  • Noise and vibration of electrical machinery
  • Electro-magnetic noise

Multi-body Dynamics

ProSIM expertise in vibration and dynamic analysis includes using FEM (finite element method) based or MBD (multi-body dynamics) / MBS (Multi-body simulation) platforms. ProSIM capabilities include time domain and frequency domain analysis.

  • Natural Frequency analysis and mode shape extraction
  • Forced Vibration analysis
    -Harmonic Analysis
    -Random Vibration Analysis
    -Response Spectrum analysis
    -Full transient dynamics analysis
    -Shock/ bump / sine

  • Torsional vibrations
  • Order Analysis
  • Rotor dynamics
    ProSIM has worked on vibration analysis including vibration induced fatigue of automotive systems, aerospace systems, power plant systems, engines, drive trains, and so on.

Scale-up/ Scale-down

Simulation assists to evaluate the alternative scenarios of operating conditions, load conditions of a proposed or working design. This can be used for temporary or regular usage in scaled-up/ scaled-down conditions. For example, questions such as below can be answered quantitatively using simulation

  • Can an existing pump design deliver more discharge? If so what happens to the efficiency?
  • Can a turbine, after its service life be still used with lower plant load factor? For how long? What will be its reliability?

Warranty Assessment

Warranty claims by users, for OEMs are expensive and will damaging for OEMs. Using computer simulations realistic estimates of durability and reliability dof products for various operating and loading conditions can be assessed. Probabilistic variations of loading factors and material properties are incorporated in the simulation based studies. Virtual endurance testing can be carried out giving appropriate factors of safety. All this will lead to more realistic warranty claim estimation.

ProSIM assists customers to determine the number of hours (or kilometres or cycles and so on) of safe and reliable working. ProSIM also assists to determine the decline in the reliability with increase of load or decrease of material strengths based on the factor of safety chosen.