Corporate Presentation

45
Your Partners in Concurrent Engineering – CAD, CAM, CAE Your Partners in Concurrent Engineering – CAD, CAM, CAE TOOLTECH SOFTWARE TOOLTECH SOFTWARE (India) Pvt. Ltd. (India) Pvt. Ltd. Corporate Presentation Corporate Presentation Certified to ISO Certified to ISO 9001:2000 9001:2000

Transcript of Corporate Presentation

Page 1: Corporate Presentation

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

Page 2: Corporate Presentation

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

Page 3: Corporate Presentation

Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE

TOOLTOOLTECHTECH GROUP GROUPCORPORATE PROFILECORPORATE PROFILE

Page 4: Corporate Presentation

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

Page 5: Corporate Presentation

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

Page 6: Corporate Presentation

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

Page 7: Corporate Presentation

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

Page 8: Corporate Presentation

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

Page 9: Corporate Presentation

Your Partners in Concurrent Engineering – CAD, CAM, CAEYour Partners in Concurrent Engineering – CAD, CAM, CAE

Clients

Page 10: Corporate Presentation

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

Page 11: Corporate Presentation

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.

Page 12: Corporate Presentation

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

Page 13: Corporate Presentation

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

Page 14: Corporate Presentation

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

Page 15: Corporate Presentation

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

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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

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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

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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

Page 19: Corporate Presentation

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

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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

Page 21: Corporate Presentation

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

Page 22: Corporate Presentation

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.

Page 23: Corporate Presentation

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

Page 24: Corporate Presentation

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

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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

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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

Page 27: Corporate Presentation

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

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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

Page 29: Corporate Presentation

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

Page 30: Corporate Presentation

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

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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

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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

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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

Page 34: Corporate Presentation

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

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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

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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

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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

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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

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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

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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

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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

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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

Page 43: Corporate Presentation

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

Page 44: Corporate Presentation

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.

Page 45: Corporate Presentation

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