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Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
TOOLTECH SOFTWARE TOOLTECH SOFTWARE
(India) Pvt. Ltd.(India) Pvt. Ltd.
Corporate PresentationCorporate Presentation
Certified to ISO 9001:2000Certified to ISO 9001:2000
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
• Concurrent design solutions in a wide spectrum of domain areas
– Automotive, General Engineering, Aerospace, Marine & Tooling, Oil and Gas
• Clear competencies in Knowledge Management
• European Focus: in depth understanding of cultural & business practices
• Flexible business model:
– functionality of a local company & offshore cost advantage
TOOLTOOLTECHTECH GROUPGROUP
TOOLTOOLTECHTECH GROUPGROUP
Introduction
Among 1st few Asian companies to be selected as a Tier 1, Offshore Strategic Design partner by BMW AG
Among 1st few Asian companies to be selected as a Tier 1, Offshore Strategic Design partner by BMW AG
Similar long term Partnerships with
Atlas Copco, Mann+ Hummel
Similar long term Partnerships with
Atlas Copco, Mann+ Hummel
Chosen by Aker Yards Finland, to set
up a dedicated facility for 100+ people in
India
Chosen by Aker Yards Finland, to set
up a dedicated facility for 100+ people in
India
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
TOOLTOOLTECHTECH GROUP GROUPCORPORATE PROFILECORPORATE PROFILE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Group Structure
Göteborg, Sweden
Helsinki, Finland
Michigan, U.S.A
Project Management
Norway
Denmark
Turku
Employee Strength
Last Year: 150
Current Year: 270 Tooltech Deutschland GmbH, Munich (Automotive)
HO: Pune, India (Auto &
General Engineering)
Design Centers
Bangalore, India (Aerospace)
B2i – Tooltech S.A.S.Paris, France
Tooltech Romania
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Locations
•
•
•
•
•
• •
Germany
India
U.S.A.
Sweden
Finland
France
Tooltech Inc.
(USA) Michigan
B2i-Tooltech
S.A.S. (France)
Paris
Tooltechsoft (Sweden) Göteborg
Tooltech Deutschland
GmbH(Germany)
Munich
Tooltech Europe Oy (Finland) HelsinkiTurku
Tooltech Software
(India)Pune / HQ
Tooltech SoftwareBangalore
Romania•
Tooltech Romania
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Economics of Outsourcing
Processing costs in Europe, North America excluding remote services
Processing costs with remote services
Processing cost differential
Additional management, telecom,etc. expenditure of Client
40–50%100%
60–70%
30-40%
** Source: McKinsey analysis 2002
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Corporate Rationale - India: The ITES Outsourcing Capital of the World
Size of circle corresponds to number of knowledge workers
Source: McKinsey analysis 2002
Infrastructure
Country risks/
Govt. incentives
Time zone
attractiveness
High
Low People Attractiveness
Loc
atio
n at
trac
tive
nes
s
High
India
Philippines
China
Mexico
Singapore
Ireland
Russia
Australia
Quality of work
Capabilities
Cost factor
Language
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Head Office Location
Pune: India’s foremost Engineering Hub
AutomotiveAutomotive
Daimler Chrysler, FIAT, Tata Motors (Trucks, MUV’s and cars), BAJAJ AUTO (Two-
wheelers), JOHN DEERE (Farm), PIAGGIO, EXIDE, FICOSA, JOHNSON
CONTROLS, TOYO, ZF STEERING…
Consumer Consumer GoodsGoods PHILIPS, WHIRLPOOL, SHARP…
GeneralGeneralEngineering Engineering
ATLAS COPCO, COMAU, CUMMINS, KRUPP, SANDVIK, SECO…
Forgings, Castings & Forgings, Castings & ChemicalsChemicals
25 Engineering Colleges25 Engineering CollegesMajor Defense, Electronic,Major Defense, Electronic,
Computing & Vehicle Computing & Vehicle Development Research labsDevelopment Research labs
World Class Telecommunication & InfrastructureWorld Class Telecommunication & Infrastructure
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Clients
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Management
• J.K Khanna, ChairmanWell established and highly reputed Chartered Accountant and Financial Consultant based in Bombay, India.
• Atul Khanna, Director and Chief PromoterSuccessful entrepreneur having promoted various businesses involving international collaboration with Germany, the USA and Sweden. New project in Bioinformatics.
• Mr. Vivek Annaswamy, President and Chief MentorMr. Annaswamy was previously the Head of the Passenger Car business of Tata Motors and spearheaded its famed turnaround. He has also consulted on the Board of Hyundai Motors India.
• Dr. Klaus Faust, Director and Managing Director, Tooltech Deutschland GmbHFormer Senior Executive in the German auto industry. Now heads a family concern, Lodenfrey GmbH, based in Munich.
• G Dentler, DirectorRecently retired as a Director with a German engineering company. Expertise in technology transfer.
Board of DirectorsBoard of DirectorsBoard of DirectorsBoard of Directors
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Key Personnel
• S. Manivasagam - Head, Engineering
Graduate in Mechanical Engineering, Post Graduate in Engineering Design and Doctorate in
Mechanical Engineering with 17 years of experience in CAE and New Product Development
of auto components and air conditioner compressors.
• V. Ravindra - Manager Operations
Graduate in Mechanical Engineering with 15 years experience in automobile industry
and project management.
• Pradeep George – Manager CAD
Graduate in Mechanical Engineering with 8 years experience in automotive and hydraulic
components.
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Key Personnel
• Harald Reukauf - Head CAE, Tooltech Deutschland GmbH
Master in Mechanical Engineering from Karlsruhe University, Germany with 10 years of experience in CAE
• N.B. Srinivas – Head, Oil & Gas
• Murali Veeravalli – Senior Project Manager CAE, BMW/Automotive, Tooltech Software (India) Private Limited
BE and M.Tech in Mechanical Engineering with more than 13 years of focused CAE experience
• S. Gunaseelan – Manager CAE, Tooltech Software (India) Private Limited
ME in Engineering Design and BE in Mechanical Engineering with 9 years of experience in Research and Development mainly in Pumps industry
B.E. in Civil Engineering over 23 years of rich experience in Oil and Gas industry of which 22 years was in Oil and Natural Gas Corporation Limited (ONGC) in India
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
• Anil Talwani - Country Manager Finland
Graduate in Mechanical Engineering with 12 years of Marketing experience in sectors
including industrial, heavy engineering, OE, hydraulic components and material handling
both in India and Germany.
• Abhay Jahirabadkar - Country Manager Sweden Graduate in Production Engineering with 9 years experience in design and development
of assembly fixtures, off high way equipments, industrial gear boxes and machine
tool components.
• Kurt Isaksson – Senior Advisor, Sweden
Former president of SAAB Rosemount AB, well known for his views on globalization in the Swedish industry
• B. V. Patil - Country Manager USA
Diploma in Tool and Die Making with 10 years experience in mold, Tool Design and Manufacturing.
Key Personnel
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Activities
CADCADCADCAD
Concurrent Engineering
Concept Design
Product Development
Tool Design
Mechanism Design
Raster to Vector Conversion
Reverse Engineering
Software Customization
Software Porting
Steady State & Transient Thermal Analysis
FE Model Creation & Assembly
Linear Static Analysis
Non – linear Analysis
Dynamic Analysis
Modal Analysis
NVH Analysis
Fatigue Analysis
Crash Analysis
CFD Analysis
CAECAECAECAE CAMCAMCAMCAM
NC Tool Path Generation for 2.5 – 5 Axis
Post Processor Development
for 2.5 – 5 Axis
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
CAD Skill Sets
Software CapabilitiesSoftware Capabilities
DASSAULT SYSTEMESDASSAULT SYSTEMES CATIA V4 CATIA V5
DASSAULT SYSTEMESDASSAULT SYSTEMES Solidworks
PTCPTC ProEngineer
UGSUGS Unigraphics SolidEdge I-DEAS
AutodeskAutodesk AUTOCAD MDT Inventor
AvevaAveva Tribon AdobeAdobe
Illustrator
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Software CapabilitiesSoftware Capabilities
Pre/Post-ProcessorPre/Post-Processor
Hypermesh Ansa I-DEAS Patran FEMOD ANSYS Animator
SolversSolvers
Abaqus LS-Dyna Ansys Nastran Pamcrash
CFDCFD
Pre- Processor: Gambit
Solver & Post-Processing: Fluent T-Grid
Capabilities CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Concurrent Engineering Project Methodology
Assignment of a dedicated team
Assimilation of Client’s industry + product expertise
Replication of Client engineering methods and Quality Standards
Secure FTP sites for file transfer and online collaboration.
Effective Client Communication through:• Teleconferencing
• Collaborative net meetings & brain -storming sessions
• Email and PowerPoint graphics• Regular onsite visits / onsite collaboration
Effective Client Communication through:• Teleconferencing
• Collaborative net meetings & brain -storming sessions
• Email and PowerPoint graphics• Regular onsite visits / onsite collaboration
Onsite Project Coordinator for seamless outsourcing project integration
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Interaction Example
Will there be any change on the flange accordingly?
**mmAs per the
model **mm
New ** data Old data
At the new manifold should be the same flange than in the old one. Make a smooth transition from the cross-sectional area of the flange to the cross-sectional area of the new runners (inbetween the first ** mm)
The outer dia of the rotary valve hole has to be ***. We can’t maintain this dimension (**) because of its intersection with the Plenum. Hence the outer dia is kept **. The inner dia is **mm.
The outer diameter of the rotary valve should be **mm
We have changed this radius form 50mm to 49.9mm. Will this be OK? This change is made to avoid modeling problems during surface merge.
That´s OK!
The radius is changed to **mm from **mm to accommodate tulip radius of **mm with **mm wall thickness. Will this slight change in Plenum volume OK?
Yes, that´s OK!
From TT
From MH
From MH
From MH
From MH
From TT
From TT
From TT
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
The OutcomeThe Outcome
A seamless extension of the Client’s design
office without the additional manpower
and infrastructure investment.
A seamless extension of the Client’s design
office without the additional manpower
and infrastructure investment.
Client retains control
Client retains control
Concurrent Engineering Project Methodology
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Common Project Management Information System (PMIS) for all CAD & CAE Projects
- Common portfolio templates and checklists used for new project
- When required, Client templates and checklists used
- Detailed Project and Resource Plan
- Input Data Verification
- Project Requirement Specification
Phase I - Project Initiation:
- Periodic project monitoring and status reports
- Client approval for each deliverable and gateway
- Outgoing data routed through QC team, using Client-approved checklists
- Change Requests recorded / Corrective actions initiated
Phase II - Project Execution:
- All deliverables pertaining to identified milestones / gateways submitted through FTP sites,
- Encryption of all data files before submission / Passwords given through different media
Phase III - Project Delivery:
Figure 1: Sample PMIS folder
Project Management
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Tooltech Competitive Advantages
Due to non disclosure agreements we are not permitted to disclose all client names and details
• Engineering our core competence; not an annex to software development
• Small, nimble and quick reacting organisational structure
• Capital Adequacy :
– Regular investment in people, hardware, software & systems to support necessary ramp ups
• Proven concurrent engineering approach: buddy system, effective & simple
collaboration methods
• Experience in setting up & ramping up dedicated teams for diversified Clients
- Team sizes: 2-5 members / 5-10 members / 10+ members
• Project facilitation through local offices in the market that we operate in.
• European focus:
- In depth understanding of work, cultural & business practices
Atlas Copco Mann+Hummel BMW AG
Aker Yards Finland Autoliv B.V. & Co. KG
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
CASE STUDIESCASE STUDIES
In accordance with Non – disclosure and Confidentiality agreements, certain Client names & confidential project information are omitted.
All names, information & diagrams that follow, are mentioned withprior permission of the concerned Client.
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
• Tooltech has been chosen by Aker Yards Finland, one of the
world’s largest shipyards, to set up a Dedicated Facility
• Ramp up: 100+ people in 1 year .
• Hulls
• Superstructures
• Engine Rooms
• Machine Drawings
• Current team size: 20 people
• Facility & Manpower Ramp Up Ahead of Schedule
Dedicated India Engineering FacilityClient: Aker Yards, Finland
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Current Projects include:
• Detail Design & Production Drawings of Hull in a Ro Ro Vessel
• Software: Tribon & AutoCAD
Input :
• Classification Drawings of Hull in DWG formats
• Available drawings in Kronodoc
• Project Specifications
Scope:
• Generation of 3D Model of Hull in Tribon
• Approval/Checking of basic hull structure, mainly position & scantlings
• Detail Design/Modeling of Hull in Tribon
• Approval/checking of production drawings
• Nesting and part list generation
Output:
• Production drawings
• Nesting and part list generation
CAD
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Design & Manufacture of a VIP Military Helicopter Interior Client: Indian Government Defense Aeronautical Agency
• Awarded “first of its kind” full programme contract for the design & manufacture of a
“World Class” VIP Helicopter Interior.
• To be certified to FAR Part 25
• Concept Design, Development, Cabin Noise Reduction, Weight Optimisation
• Original design to be led by Tooltech & German Aircraft Interior Specialist.
• Manufacture (panels, sound insulation, carpets, etc) outsourced to a Bangalore based
Aero Structures Company
• Project management & full programme responsibility with Tooltech
• Software used: Catia V5
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Software used: ProEngineer
• Creation of a 3D solid Model
• Definition of runner length & profile
• Definition of runner cross section considering section area
• Definition of Plenum considering volume
• Resolve issues of Tooling & Plastic Welding
• Supply of 2D manufacturing drawings
We partner with Mann+Hummel GmbH, Germany
to design Air Intake Plastic Manifold Assemblies
CAD
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
We partner with BMW AG for the Design of
Various Interior & Exterior Components
• Engine shields• Underbody covers • Floor covers• Fender covers• Sunroof systems
• Bumper covers• Air guides
• Sound isolation systems
• Heat isolation systems
Software Used:
CATIA V4 & V5
CAD
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Design of Fabricated Structures Client: Atlas Copco, Sweden
d. Rock Drill Boomers
b. Handling Systems
Tooltech has experience in the design of fabricated structures for:
a. Mining Equipment
c. Earth Moving Equipment
Design, Assembly and Detailing of fabricated base structures
for mining equipment
Models of the fabricated structures highlighting weld joints
CAD
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Master Model creation of Plywood Manufacturing Machine Components
Client: Machine Manufacturer, Finland
Software used: ProEngineer
• Master Model creation of the following components of a Plywood Manufacturing Machine
• Vacuum Belt Conveyor • Vacuum Feeder • Arch Conveyor
• Crossing Station • Alignment Conveyor• Out Feed Conveyor
Scope
• Creation of 3D models and 2D drawings for different versions of a Veneer feeder mechanism.
• Creation of a master model to incorporate different versions of the feeder
a. This master model can be retrieved by the client from a database.
b. Client design requirements can be fed into the master model.
c. New designs would be available with a time reduction of upto 75%
CAD
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Design of Reduction Gear BoxClient: Marine Equipment Manufacturer, Norway
Software used: Inventor 10, MathCAD
Input:
• Technical Specifications such as Torque, RPM and Space Availability
Scope:
• Designing of 2 stage reduction gear box of 1:60 ratio using helical gears.
• MathCAD calculations for AGMA certification.
• Creation of 3D models & 2D manufacturing drawings with required
technical details.
Output:
• 3D model of all parts used in Gear Box
• 2D manufacturing drawing with technical specifications
• Calculations in MathCAD for certification
CAD
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
CAE
• Software: Hypermesh, Abaqus, FEMFAT
• FE Modeling:• Crankcase, Bed Plate, Cylinder Head Bolts, Valve Seats • Hexa elements with critical requirements such as:
• No. of elements over Cylinder Bores• Mesh pattern around Crankcase Bearing and Cylinder Head Bolt Holes• Diameters of Bolts for precise pre-tension loads
• Mapped meshing (second-order Tetra elements) on contact regions of seat and bolts. • Model size : approx. 1 million DOF
• Analysis:
• Multi-step and Non-Linear Analysis (consisting of assembly loads, firing pressure
and thermal loads) using Abaqus Standard
• 2-3 load cycles analysed. At the end, FE model unloaded in a specific order
• Results imported in FEMFAT for evaluation of low cycle and high cycle fatigue
using Haigh´s theory for uni-axial and multi- axial loads.
• Analysis cycle repeated to achieve desired results.
Fatigue Analysis of Engine AssemblyClient: Diesel Engine Manufacturer, Finland
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Software used: ABAQUS, ABAQUS/CAE, Hypermesh
• FE Modeling of symmetric sector using 2nd order brick elements
• Static Analysis
• “*TIE” Contact between casing and bolts
• Gas pressure, vane loads
• Extraction of severe temperature fields from Transient Analysis
• Multiple thermal loads
• Modal Analysis
• Hot and cold conditions – hot state temperature field as preload
• Temperature-dependent properties
• Campbell diagram plots
Static & Buckling Analysis of a Turbine CasingClient: Aero Engine Manufacturer, Germany
CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
• Elastic Buckling Analysis
• Bending and twisting loads, hot state temperature field as
preload
• Results in the form of Interaction diagrams
• Plastic Buckling Analysis
• Riks Method of Analysis
• Load Vs. Displacement plots for pre and post buckling range
Plot of DeformationPlot of Plastic Strain for
Plastic Buckling Analysis
Plot of Buckling Mode
Shape for Twisting LoadPlot of Stresses
CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Crash SimulationClient: BMW AG, Germany
• FE Modeling of following vehicle sub systems
• Body in White
• Drive line assembly (except front and rear axis assembly)
• Front and rear bumper assembly.
• Door assembly (excluding interiors)
• Bonnet and front panel assembly.
• Quality criteria for FE Modelling
• Element length 6 - 12 mm, Average 10 mm.
• Warpage < 15 degrees.
• Quad angle between 40 - 140 degrees.
• Tria Angle between 20 to 120 degrees.
• Percentage of tria. elements < 5%.
CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Integration of systems
• Creation of spotweld file, with and without rupture model for Body in White,Door
assembly and bumper systems, etc.
• Integration of all systems using NULL shell elements and tied contact.
• Removing penetration between all systems upto 0.7 mm, used for contact initialization.
• Preparation of complete input deck for various calculations and load BC file, apart
from various vehicle sub-system FE models.
Calculations
• Full frontal impact as per US-NACP
• Overall dynamic deformation > 650 mm.
• Steering column displacement < 80 mm.
• 40% overlap offset frontal crash as per EURO-NCAP
• Firewall intrusion < 150 mm.
• A pillar displacement < 50 mm.
• Steering column displacement < 80 mm.
• Minimal deformation between B pillars and doors.
CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
• Side impact as per EURO-NCAP, US-NACP, IIHS and SINCAP. • Max. intrusion velocity of B pillar < 7 m/sec.
• Rear impact as per FMVSS• Minimal deformation of fuel tank.• Rear seat relative movement < 50 mm.
• Slow speed frontal impact as per FMVSS • Contain damage within bumper system, no permanent deformation in any other system.
• Pre development activities for child and adult head impact calculations• HIC value below 1000 in the bonnet middle region, less than 2000 near outer edges.
Post- Processing• Preparation of storyboards and reports for performed calculations .• Compare the results for base model and modified model for set target of project.• Discussion with design and development engineers for design and manufacturing
Toolsi. Pre-Processor (mesh generation) - ANSA, HYPERMESHii. Pre-Processor (Spot weld generation) - FEMODIII. Solver - PAMCRASH iv. Post Processor - ANIMATOR, PAMVIEW
CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Strength and Fatigue Analysis of BIW Client: BMW AG, Germany
• FE Modeling:
• Components: Body in White, Drive Line Assembly and Spot Welds using
multi beam
• Sub modeling and mesh refinement at critical areas
• Quality criteria for FE Modelling:
• Element length 6 - 12 mm, average 10 mm.
• Warpage < 15 degrees.
• Quad angle between 40 - 140 degrees.
• Tria angle between 20 to 120 degrees.
• Percentage of tria. elements < 5%.
• Circle around circle near holes with minimum 8 quad elements
• Neglect holes less than 6 mm.
CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
• Analysis:
• Dynamic Analysis using Abaqus Explicit for vehicle passing over obstacles
• Luggage retention using Abaqus Explicit
• Fatigue Analysis using Falancs for: Entire BIW. Failure of Spot Welds
• Post- Processing
• Preparation of storyboards and power-point presentation reports for performed calculations
• Results compared between base model and modified model for set target
• Discussion with design and development engineers for design and manufacturing
• Tools
i. Pre-Processor (mesh generation) - ANSA, Hypermesh
ii. Pre-Processor (Multi beam Spot weld generation) - ANSA, Medina
iii. Solver - Abaqus, Nastran, Falancs
iv. Post Processor - ANIMATOR, Abaqus Viewer,
Hyperview
CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
FE Analyses of Intake Manifold SystemsClient: Mann+Hummel GmbH, Germany
• Software: Hypermesh, Abaqus
• FE Modeling:
• Combination of Shell and Hexahedral/ Tetrahedral elements
• Special meshing methods used for simulation of weld rim areas of plastic Intake
Manifold Systems
• Meshing of plastic parts for Mould Flow Simulation
• Structural Analysis:
• Burst pressure calculation in view of non-linear properties
• Thermo-mechanical stress simulation in view of Exhaust Gas Recirculation (EGR)
• Frequency response simulation with Engine excitations, as dynamic load varies
according to engine running speed (obtained from test data).
• Study of response of systems at critical locations such as connectors
• Optimization of parts as per FE Analyses
• Vibro-Acoustic Analyses
• Transient loads (in the form of internal pressure) applied
• Weak structural areas determined and stiffened in next phase of design
CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
CFD Analyses of Engine AssemblyClient: Luxury Car Manufacturer , Germany
• Software: Ansa, StarCD, Ensight
• CFD Meshing
• CFD – grid generation for Flow Analysis
• CFD – grid generation for Conjugate Heat Transfer (CHT) Analysis
• Flow Simulation:
• Components: Cooling Circuit of an Engine which includes Cylinder Head, Crankcase,
Water Jackets and Water Pumps
Analysis:
• Pressure Drop Evaluation
• Effect of variation of pressure drop with different flow rates
• Optimization of pressure drop
• Optimization of geometries for uniform flow distribution (involving design of gasket profile)
• Model size: 3 million tetrahedral cells with critical grid connectivity at Gasket Connections
CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
• Conjugate Heat Transfer (CHT)
• Components: Engine Assembly which includes Cylinder Head, Crankcase, Valves,
Guides, Seating Rings, Spark Plug, Injector and Gasket
Analysis:
• Engine assembly analysed for simultaneous effect of flow and heat transfer
• Inputs from 1D simulation (GT-Power) applied on CFD model in view of temperature and heat fluxes in critical areas
• Fortran sub routines used for application of material properties and nucleate boiling effect
• Model size: 6 million fully connected cells, with 15-18 different solid materials defined in the model
Results:
• Study of temperature distribution and matching of results with GT-Power / test results
• Optimization of design for uniform temperature distribution
• Mapping of temperature results on FE Mesh for structural simulation.
CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Software used: Fluent 6.1 / Gambit 2.1
• Design of vacuum amplificator with a blow-by inlet, based on
venturi principle
• Verification of hand calculations with 2D and 3D simulations of 3 models
• 3D incompressible turbulent flow Analysis to study flow behaviour in
terms of velocity, pressure and mass flow
• Optimization of blow-by inlet position and amplificator geometry for
given area ratios, pipe length, velocity and other parameters
• Further 3D CFD simulations were carried out to achieve optimised
geometry having better flow characteristics meeting design constrains
and objectives
CFD Analysis of Vacuum Amplificator of AutomobileClient: Automobile Supplier, Germany
CAE
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Domain Expertise
Automobiles & Auto ComponentsAerospacePress Tools
Molds & DiesMachine Tools Cutting Tools
Marine Oil and Gas
Automobiles & Auto ComponentsAerospacePress Tools
Molds & DiesMachine Tools Cutting Tools
Marine Oil and Gas
Please ask us for more information on industry specific capabilityPlease ask us for more information on industry specific capability
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
OUR GOALOUR GOAL OUR GOALOUR GOAL
To be your business
partner and provide
you with a seamless,
design outsourcing
service…
To be your business
partner and provide
you with a seamless,
design outsourcing
service…
…so that you can more profitably
manage your
business.
…so that you can more profitably
manage your
business.
Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE
Contact Us
TOOLTECH Software (I) Pvt. Ltd. Maa House, No. 6, Service Road,
1st Stage, Domlur Layout,Bangalore – 560071, India
Tel: +91-80-41256556
TOOLTECHSOFT Sweden Box 184, Drakegatan 10,
S-401 23 Göteborg, SwedenTel . +46 (0)31 773 7163
TOOLTECH Deutschland GmbHSchleißheimer Straße 375,80935 München, Germany
Tel: +49-89-35719100Fax: +49-89-35719141
TOOLTECH INC.5351, Rusche Drive NW
Comstock Park, MI, 49321Tel: +1-616-780-5666
Head OfficeTOOLTECH Software (I) Pvt. Ltd.
401 Beta 1, Gigaspace,Viman Nagar, Pune 411 014, India
Tel: +91-20-30511200 / Fax: +91-20-30511201
Email: [email protected] www.tooltechsoft.com
TOOLTECH Europe Oy Bulevardi 2-4 A,
00120 Helsinki, Finland Tel: +358-9 6150 7560
B2i – TOOLTECH S.A.S.Parc d'Affaires SILIC,
1, rue Traversière, BP 20327, 94598 Rungis Cedex, France
Tel: +33 (0) 1 41 73 08 20
TOOLTECH ROMANIASos. Borsului nr. 20
410605 OradeaRumänien
Tel: +40-728837788