Automotive Engineering

Automotive Engineering Artificial Intelligence Analysis FEA|CFD & AI Integration

We focus on strategic use of CAE to Optimise Designs, investigate and resolve problems, and minimise time and cost to market. Advanced geartrain modelling and analysis software packages, provides the foundation of concept and definitive design for all driveline and transmission projects that we undertake.

Powertrain component development involves the design and optimization of various components such as engines, transmissions, and axles. FEA and CFD-based simulation can be used to evaluate the structural integrity, fluid dynamics, and thermal performance of these components, allowing engineers to optimize designs and improve performance.

NVH is another important consideration in automotive engineering. By using FEA-based simulation and analysis tools, engineers can evaluate the vibration and noise levels of various components, helping to identify and resolve potential issues before physical prototypes are built.

Combustion and thermal simulation are also critical areas in the design of automotive components. By using CFD-based simulation tools, engineers can model and analyze the behavior of combustion processes and thermal systems, allowing them to optimize designs for efficiency and performance.

Automotive Engineering, Integrated FEA|CFD with Artificial Intelligence

Crash Test and Crashworthiness

Crash testing and crashworthiness are critical aspects of automotive safety engineering. Crash testing involves deliberately crashing a vehicle under controlled conditions in order to evaluate its safety performance in the event of a collision. Crashworthiness, on the other hand, refers to the ability of a vehicle to protect its occupants in the event of a crash.

LS-DYNA is a widely used finite element analysis software that is commonly used in the automotive industry for crashworthiness simulation. LS-DYNA offers a variety of tools for simulating different types of crashes, including frontal, side, and rear impacts.

During a crash, LS-DYNA can model the behavior of different materials, such as high-strength steel or composites, under impact. This includes modeling the deformation and failure of individual components and the overall vehicle structure.

LS-DYNA can also be used to evaluate the performance of different safety features, such as airbags and seat belts, and optimize their design for improved crashworthiness. This can involve modeling the behavior of airbags during deployment or evaluating the effectiveness of different types of seat belts.

In addition, LS-DYNA can be used to simulate different crash scenarios, including vehicle-to-vehicle and vehicle-to-barrier collisions, and evaluate the performance of the vehicle under these conditions. This can help us to identify potential areas of weakness in a vehicle's design and test different design modifications to improve crashworthiness.

Generative Design + CFD: Topology-Optimized Fluid Dynamics

Combine genetic algorithms with RANS/LES simulations to auto-generate weight-optimized turbomachinery blades, heat sinks, and microfluidic devices.

Crash Test and Crashworthiness, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence

Advanced Engineering Solutions

Flow, Combustion and Emission

CFD simulation is a powerful tool in the automotive industry for predicting and analyzing flow, combustion, and emission characteristics of internal combustion engines (ICEs). It allows engineers to optimize the design of engines and their components, as well as develop strategies for reducing emissions and improving fuel efficiency.

One of the key advantages of CFD simulation is its ability to predict the behavior of fluid flow inside the engine, which is essential for understanding the combustion process. This includes modeling the fuel injection process, air-fuel mixing, and combustion chemistry. CFD can also be used to analyze the performance of different engine components, such as intake and exhaust systems, and optimize their design for improved flow and combustion characteristics.

In addition to improving engine performance, CFD simulation can also be used to reduce emissions and improve fuel efficiency. By accurately modeling the combustion process, engineers can optimize the air-fuel ratio and fuel injection timing to minimize emissions while still meeting performance requirements. CFD can also be used to analyze the thermal management of the engine, including the cooling system and exhaust gas recirculation, to improve fuel efficiency and reduce emissions.

To further enhance the accuracy of CFD simulations, 1D-3D coupling can be used to integrate 1D system models with 3D CFD simulations. This allows for more accurate predictions of flow and combustion characteristics, as well as the thermal behavior of the engine.

Cognitive FEA: Machine Learning-Predictive Structural Integrity

Deploy graph neural networks (GNNs) to forecast nonlinear material deformation, crack propagation, and fatigue failure. Train AI on legacy FEA datasets for ISO-certified validation of aerospace composites, additive manufacturing defects, and seismic-resistant infrastructure.

Flow, Combustion and Emission, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence

Advanced Engineering Solutions

Injection Nozzle Development

To develop and optimize injection nozzles, a combination of advanced CFD tools such as Ansys Fluent, Siemens Star-ccm+ and AVL Fire is typically used. This includes a one-dimensional model of the entire fuel injection system, from the fuel tank to the injector, as well as a 3D CFD solver to focus on the fluid flow inside the injection nozzle itself.

The one-dimensional model is used to simulate the behavior of the fuel system as a whole, including the fuel pump, fuel lines, and pressure regulator. This allows engineers to optimize the overall performance of the system, ensuring that the fuel pressure and flow rate are optimized for the specific engine and operating conditions.

The 3D CFD solver is then used to simulate the fluid flow inside the injection nozzle itself. This includes modeling the injection process, fuel spray pattern, and combustion characteristics. By optimizing the design of the injection nozzle using CFD simulations, engineers can improve fuel atomization, reduce emissions, and optimize engine performance.

Our cutting-edge Artificial Intelligence & Machine Learning integrated development solutions combine technical excellence with business insight to deliver exceptional digital experiences.

We leverage modern frameworks with CFD & FEA solvers and cloud infrastructure to build applications that scale seamlessly with your industrial needs.

Injection Nozzle Development, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence

Advanced Engineering Solutions

NVH & Acoustics for Powertrain

The development of fuel-efficient internal combustion engines in response to global demand for more eco-friendly vehicles has had an impact on the noise, vibration, and harshness (NVH) and acoustic behavior of vehicles. As automotive OEMs and suppliers work to improve fuel economy and reduce emissions, they must also address the NVH and acoustic challenges that arise as a result.

NVH and acoustic simulation plays a critical role in the design and development of powertrains in the automotive industry. By using advanced simulation tools, engineers can identify and address potential NVH issues early in the design process, reducing the need for costly physical prototypes and testing.

One key challenge in powertrain NVH and acoustic simulation is the need to balance conflicting objectives. For example, reducing engine noise may require adding additional sound-absorbing materials, which can increase the weight and complexity of the engine. Alternatively, reducing engine vibration may require changes to the engine mounts or the use of additional damping materials, which can also increase weight and complexity.

Multiphysics AI: Simulate Fluids, Structures, & Electromagnetics

Model EV motor cooling, MEMS sensors, and satellite thermal-vibration coupling. Use pytorch/TensorFlow-integrated solvers to automate boundary conditions and predict multiphysics failures in mission-critical systems.

NVH & Acoustics for Powertrain, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence

Advanced Engineering Solutions

Powertrain Engineering

Powertrain engineering encompasses a wide range of technologies and processes, from diesel engines to electric drives, from alternative fuels to control, from transmissions to batteries. Powertrain engineers work with advanced software tools and simulation techniques to optimize powertrain performance and efficiency, reduce emissions, and improve reliability.

Some of the key areas of focus in powertrain engineering include:
1- Engine design and optimization: Powertrain engineers design and develop engines that are efficient, reliable, and meet regulatory requirements. This includes optimizing engine performance, reducing emissions, and improving fuel economy.
2- Transmission design and optimization: Powertrain engineers design and develop transmissions that are efficient, reliable, and provide optimal performance for a given vehicle.
3- Hybrid and electric drivetrain development: Powertrain engineers work on developing hybrid and electric drivetrains that provide optimal performance while also meeting regulatory requirements for emissions and fuel economy.
4- Control systems development: Powertrain engineers design and develop control systems that optimize powertrain performance and efficiency while also meeting safety and regulatory requirements.

AI-Driven Simulations for Smarter Engineering.

Leverage Artificial Intelligence to optimize CFD, FEA, and multiphysics simulations. Automate workflows, reduce errors, and accelerate innovation. Transform your engineering processes with AI-powered insights.

Powertrain Engineering, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence

Advanced Engineering Solutions

Quenching: Virtual Heat Treatment Optimization

FEA simulations can predict local temperature gradients, the overall cooling history, and the resulting material properties after quenching. This information can be used to optimize the quenching parameters, such as cooling rate, quenching medium, and immersion time, to achieve the desired material properties while minimizing the risk of distortion or cracking.

To accurately simulate the quenching process, it is important to consider the effects of material properties, such as thermal conductivity and heat capacity, as well as the geometry and initial temperature of the component. The simulation should also account for the interaction between the component and the quenching medium, including convective and evaporative cooling effects.

Solve Complex Problems with Multiphysics Simulation.

Combine forces, heat, fluids, and more in a single multiphysics simulation platform. Drive innovation across aerospace, automotive, and energy sectors. Experience the power of integrated engineering solutions.

Quenching: Virtual Heat Treatment Optimization, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence

Advanced Engineering Solutions

Strength and Durability Analysis

The strength analysis involves evaluating the structural integrity of components and systems, using techniques such as finite element analysis (FEA), to predict the stresses and deformations in the structure. This information is used to determine the safe working stresses and deformation limits for the component, ensuring that it can perform its intended function without failure.

Durability analysis involves evaluating the component's ability to withstand cyclic loading and fatigue, using techniques such as fatigue life calculations and material testing. The analysis takes into account factors such as load frequency, amplitude, and duration, as well as the material properties, manufacturing processes, and assembly stresses.

In modern automotive engineering, the analysis is not limited to just fatigue life calculations. The output from the analysis can include safe working stresses, warranty claim curves, and the effects of high temperatures, manufacturing processes, and assembly stresses. This information is critical for optimizing the design and ensuring that the component meets the performance and durability requirements of the application.

Revolutionize Fluid Dynamics with CFD Simulation.

Optimize fluid flow, heat transfer, and turbulence with advanced CFD simulation tools. Enhance engineering designs for aerospace, automotive, and energy industries. Experience precision and efficiency in fluid dynamics analysis.

Strength and Durability Analysis, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence

Advanced Engineering Solutions

Thermal & Energy Management

Finite element and CFD simulation tools can be used to model and analyze the thermal behavior of various components such as engines, batteries, and power electronics.

These simulations can help to identify potential hot spots and optimize cooling systems to ensure components operate within safe temperature limits. They can also be used to investigate energy recovery and thermal management strategies such as waste heat recovery, exhaust gas recirculation, and active cooling systems.

By optimizing powertrain energy management strategies, automotive engineers can improve fuel economy, reduce pollutant emissions, and ultimately enhance vehicle performance.

Engineering Reliability, One Simulation at a Time.

Finite Element Anlaysis(FEA) and Computational Fluid Dynamics(CFD) ensures your designs are built to last. From automotive to aerospace, analyze structural integrity with precision. Trust in reliable solutions. Whether predicting pressure drop, thermal shock, stress, strain, or deformation, FEA & CFD delivers the insights you need to innovate with confidence. Build products that perform under pressure.

Thermal & Energy Management, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence

Advanced Engineering Solutions

Turbocharging Simulation

To achieve the desired level of engine performance and reduce pollutant formation, turbocharging simulation is an essential part of the design process. Turbocharging simulation involves using advanced computational fluid dynamics (CFD) tools to model the flow of air through the turbocharger and engine intake system. The simulation predicts the pressure and temperature distribution, velocity profiles, and other important parameters that affect the performance of the turbocharger.

The simulation also helps to optimize the turbocharger system design to achieve the desired performance characteristics. For example, the simulation can help to determine the best turbocharger size, blade geometry, and compressor wheel design. It can also help to optimize the air intake and exhaust systems to maximize the efficiency of the turbocharger.

In addition to improving engine performance, turbocharging simulation also plays a crucial role in ensuring component durability and minimizing NVH (noise, vibration, and harshness). By predicting the stresses and thermal loads on the turbocharger components, engineers can optimize the design to improve component life and reduce the risk of failure.

Artificial Intelligence & Machine Learning Powers the Future of Simulation.

Transform your simulations with AI-driven insights. Automate workflows, reduce time-to-market, and unlock new possibilities. Embrace the future of engineering. From CFD to FEA, AI enhances every aspect of simulation, delivering faster, more accurate results. Experience the next generation of intelligent engineering solutions.

Turbocharging Simulation, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence

Advanced Engineering Solutions