Engineering Design

At ProSIM, we carry out

  • Conceptual Design
  • Basic Design
  • Engineering design.

We take up performance requirements and specifications from our customers and develop the design in a collaborative and consultative manner.

Once the conceptual part of design is cleared, we do the basic design calculations as per industry practice and carry out detailed engineering design for rigorous validation exercise.



TOOL SKILLS

ProSIM team members have expertise to use several CAD/CAM/CAE/Simulation (CAx) tools. The collective team expertise at ProSIM is augmented by the experience of ProSIM team members in their previous organizations, or while working onsite at customer places. This expertise is further accentuated by the design and analysis process orientation at ProSIM.

At ProSIM, we have the ability to look at the particular problem of our customers, and suggest optimum software tool to be used for that particular application. We can use the licenses provided by customers, or rent/ lease the licenses depending on the customer specific needs or use our licences available.

  • CAD
    – CATIA, UG – NX, Pro-E, Inventor
  • CAE
    – HYPERMESH, FEMAP, ICEMCFD, PATRAN
  • FEM
    – ANSYS, NASTRAN, ABAQUS, LS DYNA, LUSAS, NISA
  • MBD
    – SIMPACK, ADAMS
  • Electro Mechanical System
    – JMAG ,
  • Topology Optimization
    – Optistruct, Tosca
  • Parametric Optimisation
    – iSight, HEEDS, in-house routines, Matlab
  • Fatigue & Durability
    – FeSAFE, In-house models
  • Crack Propagation & Damage Tolerance (Fracture)
    – ZENCRACK
  • Materials and Damage modelling
    – ZEBULON, Z-MAT, ABAQUS
  • Casting Simulation
    – ADSTEFAN, Magma,
  • Forging and Metal Forming
    – Abaqus, DEFORM, Hyperform, Zebulon
  • Use and Customisation of Open Source software platforms.
    – Expertise includes usage of open source software tools (for CAE /FEM /MBD /CFD /EMAG /Optimisation etc.
    – Development of interfaces between open source tools and commercial tools

(PS: ProSIM may have exposure to additional software tools, including usage of open source platforms, in addition to those mentioned here. For any such requirement contact ProSIM).

 

DEVELOPMENT OF PLUG-Ins

We create unique plug-ins for simulation software. For example, we have developed plug-ins / Macros for:

  • Verification of designs for seismic evaluation of nuclear components/ systems (Class I, II, III, and IV) as per ASME codes (Section 3) NB/NC/ND/NF in ANSYS and ABAQUS
  • Verification of various types of damages as per RCCM-R codes
  • Verification of design of cranes for CE certification
  • For simulation of powder compaction process and predicting the elastic spring back
  • A scripted interface to generate 3D CAD model of air core reactor, and input to JMAG software for electro-magnetic and noise analysis for certification as per // …. Standard//
  • Our engineers understand your company’s unique requirements and help by customizing the software available according to their specific application needs. Our engineering focus has built solutions tailored to realize customer’s business goals of creating innovative products at a reduced cost and within shorter time frames.
  • Plug-ins are also developed for open source software tools for customer specific applications.

 

CUSTOMISATION OF CAX SOFTWARE

ProSIM has expertise in customisation of CAX software using scripting, macros, APIs. For example, we have customized

  • ABAQUS software for design, FEM analysis, verification as per ASME Pressure Vessel codes, and report generation. By this, the effort for an analyst to qualify the design is reduced from about 30 to 40 man days of effort to about 5 to 7 days.
  • We have assisted a reputed automotive wheel maker to streamline the design by generating the parametric models and design automation scripts. Using this, our customer can generate new designs in a matter of hours (compared to weeks of effort earlier)
  • We customise the open source software for customer specific application and provide training on the usage of customised software tools.

Virtual Product Development

ProSIM has significant experience in realising product development using simulation techniques using collaborative platforms and principles of Virtual product development (VPD). VPD enables use of resources (people, hardware and software assets, expertise) situated across geographies to innovate faster and realise better products/ processes.

Only with successful deployment of VPD processes, can a company launch new and innovative products in market place. There is a tremendous pressure on companies to design / deliver and introduce new products quickly, and at low cost. New concepts are flooding market much faster. New ideas, new materials, new processes, are emerging fast and enhancing user experience.

Using VPD, one can run through all the stages of product development life cycle (PDLC) digitally on the computer, without resorting to the realization of physical prototype. Without invoking principles of simulation based virtual product development (VPD), virtual prototyping and virtual testing, new products cannot be developed and deployed in market today efficiently.

Entire process of design, validation, optimization, manufacturing, tooling, and layout be conceptualized on the screens of computer first. The final (or near final) design option can be taken up for physical prototyping and testing. Applying digital engineering, designer can explore the design space more exhaustively. Designer can:

  • Create more innovative concepts and engineer more accurate digital prototypes
  • Perform simulations on digital prototypes to optimize designs
  • Streamline documentation, data management, and collaboration
  • Develop compelling, realistic visualizations to experience products before they’re real

Today, benefits of VPD process are well known and documented. By invoking the principles of VPD, it is possible to reduce the time of development by an order of 20 to 50% or more, and cost by 30 to 40%.

Collaborative platforms provide further advantage of sharing the design and development work at multiple centres spread across countries / time zones.

Click here, for more details of VPD driven product development process

Legacy Design Transformation

Design drawings (typically 2D CAD drafting) were traditionally, used mainly for production planning and assembly in earlier days. Today, all modern and progressive enterprises have 3D CAD models (created in CATIA/ Pro-E/UG-Nx/ Inventor/ Solidworks/ Solid Edge etc). Some of the legacy design drawings are being converted to latest releases of 3D CAD platforms. These 3D CAD models have use in multiple stages of product development life cycle as below. At each stage of PDLC, the design becomes interactive, and design details can be changed easily in the 3D CAD model.

  • Digital Mock up (DMU)
  • Finite element analysis (FEA/ FEM)
  • Computational Fluid dynamics (CFD)
  • Multi-body dynamics simulation (MBD /MBS)
  • Virtual reality (VR)
  • Technical Product Documentation (TPD)
  • Rapid Proto Typing (RPT)
  • Numerical control / Robotic control (NC/ RC)
  • Geometric Dimensioning and Tolerance (GD&T)

ProSIM is assisting customers to transform the legacy design documents to current 3D models and assist developing parametric designs that can be re-used with ease. ProSIM is also assisting customers with customisation of these designs by scripting

Technical Expertise

ProSIM has inter-disciplinary and multi-physics expertise spanning the following areas.

  • Design, GD&T, FMEA
  • CAE (meshing or FE / CFD model building)
  • Finite Element Analysis, including
    1. Non-linear (material, contact, large strain)
    2. Vibration, transient dynamics, shock,
    3. Impact / Crash
    4. Coupled thermo-mechanical
    5. NVH / Accoustics
  • Computational fluid dynamics (including coupled thermal-structural-flow studies, mixed flow, hypersonic flow etc)
  • Electro-magnetic (including coupled electro-magnetic -thermal -structural) covering wire harness, EMC, EMI, SIL, HIL etc.
  • Fatigue, fracture and durability, creep-fatigue interaction
  • Wear analysis
  • Remaining life assessment and extension
  • Multi-disciplinary optimization (including parametric, size, shape, topology and structural optimization)
  • Design of experiments (DoE) and sensitivity analysis.
  • Multi-body Dynamics simulation including railway dynamics, vehicle dynamics, flexible body dynamics, SIL/ HIL, linking control systems (Matlab/Simulink)
  • Materials (constitutive modelling, visco-plastic and visco-elastic materials, temperature dependent, strain & strain rate dependent, creep and fatigue damage modelling, composite materials, honey comb structures, titanium (Ti) /Nickel (Ni) alloys, Copper, magnesium, aluminium and other non-ferrous alloys, steel alloys including high strength steels, cast iron, rubber, plastic)
  • Manufacturing Process Simulation
    1. casting,
    2. Sheet metal forming,
    3. Forging
    4. welding,
    5. powder compaction,
    6. sintering
    7. Heat treatment and annealing

Platform Expertise

ProSIM platform expertise can be viewed from 3 different perspectives

  • Tool Skills
  • Development of customised plug-ins
  • Customisation of software