Simulation instead of Iteration

A quicker solution with the help of CAE

Simulation instead of Iteration

Faster to the goal: Simulation instead of Iteration

Vibration Simulation

Modal Simulation of a Turbocharger Cladding-Deformation-Tension

Temperature Analysis

Temperature distribution on Insulation Assembly of an Agriculture Machine

The development of new products takes time. Don’t spin in circles when you design, construct and implement test phases! Our simulation service will help you avoid pitfalls in the development process.

Using Computer Aided Engineering (CAE) lets you evaluate ideas long before production of prototypes. Simulation can accelerate the path to production-ready status and increase cost-effectiveness.

What are Simulations?
Simulations allow concepts and designs to be assessed in detail during the early stages of a project, possibly meaning that just one prototype needs to be manufactured, and that following successful testing and validation, immediate approval for production can be given.

Create a Finite Element-Model
Simply put a simulation is done using the following steps:
| Import the geometry of a component
| Create a FEA (Finite Element Analysis) – Model with physical properties such as wall thickness, cross-sections, mass, stiffness etc.
| Apply the loads and other boundary conditions such as forces, temperatures, accelerations.
| Solve the model
| Evaluation and analysis of the results including deformation, strain, temperature etc.

What are the possible applications?  
Simulations can be used in various ways in product development and can give advanced information on the suitability of the final component.
We’ll use two examples to show you how.

Optimize Dynamic Behavior
Example: Vibration Simulation
Using a modal analysis, it is possible to predict the vibration behavior of a virtual component. This enables us to establish the most suitable design prior to manufacturing of a prototype.
A modal analysis could be for example how the vibrations of the engine influence our insulation cladding. The closer the excitation frequency of the engine gets to a natural frequency of our insulation cladding, resonance is more likely to occur. In case of resonance, the mechanical demands due to vibrations are particularly strong and can lead to cracking in the insulation.
As part of a project to design turbocharger cladding, we used modal analysis to identify the critical natural frequencies, and were able to subsequently reduce critical frequencies to an absolute minimum using optimized design steps.
In the technical article “Numerical Simulation of Large Metallic Insulation Assemblies in the Off-Highway Market“, case studies will show you how to get your products ready for serial production faster and more cost-efficiently. Download 

No Thermal Hot Spots
Example: Temperature Analysis
Thermal Analysis makes it possible to simulate the thermal characteristics of the components in question, meaning early recognition and improvement to possible hot spots in the design.
Thermal analysis can clarify important questions upfront such as, are the surface temperatures of insulated components below the ignition temperature of potential leaked fuels or other combustible fluids?
During a project in the agriculture machinery sector a thermal analysis enabled us to make a meaningful prediction of possible hotspots which were above the ignition temperature of fuel oil (>220 °C / 428°F) and organic cereal dusts (ca. >250 °C / 482°F)
Afterwards a CFD-analysis with consideration of the conjugate heat transfer was performed to thermally validate the overall concept.

The Benefits for you
| Time and Cost savings in the development process meaning a faster, cost-effective path to a production-ready product
| Real simultaneous engineering

If you would like to learn more about how simulations with Thermamax could improve and accelerate your Product Development, please contact our expert:

Phone: +49 621 322 35 474