CAE Simulation Expert-Ansys|Fluent|LS-DYNA|Abaqus-AI CAE simulations

Example

Import CAD assembly, remove tiny fillets/bolts not important for structural load paths, heal bad faces, create mid-surfaces for thin-walled components, and generate watertight solids for CFD.

Scenario

A transmission housing with many small chamfers and bolt threads — defeature to reduce mesh count while preserving stiffness-critical geometry; produce shell midsurface for thin-wall stiffeners used in crash simulations to cut element count by 60% without losing global structural response.

Example

Generate hexa-dominant mesh for a gearbox housing, boundary-layer prism mesh for turbine blades, and fine-tetra mesh around welds; run quality checks for skew, aspect ratio, Jacobian and refine automatically.

Scenario

Compressible flow over an airfoil: create multi-zone structured O-grid around the airfoil to capture boundary layer, plus prism layers to resolve near-wall gradients for accurate lift prediction; run y+ checks and adapt mesh to meet solver requirements.

Example

Define temperature-dependent plasticity for high-temperature creep of nickel superalloy, hyperelastic rubber model (Ogden/Mooney-Rivlin) for seals, and strain-rate dependent Johnson–Cook model for metal under impact.

Scenario

Crash simulation: assign Johnson–Cook parameters to the vehicle bumper and structural members to predict deformation and fracture at high strain rates; include explicit damage initiation and element erosion to capture tear-through.

Example

Use Abaqus/Standard for slow, highly nonlinear static load (large plastic deformation, contact), LS-DYNA explicit for fast transient impact, and Ansys Fluent with RANS for steady external aerodynamics and LES for high-fidelity unsteady vortex shedding.

Scenario

Designing a bicycle helmet: run an LS-DYNA explicit transient impact for headform deceleration; use Abaqus implicit to evaluate static liner compression under repeated loading for comfort and durability; use Fluent to simulate ventilation airflow through vents for thermal comfort.

Example

Two-way fluid–structure interaction between blood flow and arterial wall using Fluent for flow and Abaqus for structure via co-simulation; conjugate heat transfer for engine cooling using Fluent coupled to Ansys Mechanical.

Scenario

Turbocharger housing: simulate hot gas flow inside turbine and conjugate heat transfer into the housing to predict thermal gradients and creep; couple thermal load into structural solver to assess thermal fatigue life of mounting points.

Example

Use LS-DYNA to model vehicle crash, blast/fragmentation, and drop tests with contact, large deformation, and material failure. Include contact stiffness tuning, mass scaling considerations, and time-step management.

Scenario

Automotive frontal crash: simulate occupant kinematics, airbag deployment, and seatbelt loads with full-vehicle finite element model to evaluate occupant injury metrics (HIC, chest deflection) and iterate on energy-absorbing structures.

Example

Use Fluent to run turbulent combustion with chemical kinetics for an internal combustion engine, multiphase VOF for sloshing in tanks, and particle tracking/DEM coupling for sprays or particulate transport.

Scenario

Rocket engine injector development: perform reacting flow simulation to predict combustion stability, heat flux to walls, and injector spray atomization; optimize injector geometry to reduce hotspots while maintaining desired thrust.

Example

Compare modal frequencies from modal analysis to experimental modal test; run mesh convergence studies, sensitivity to material parameters, and Monte Carlo sampling of manufacturing tolerances to produce confidence intervals on performance metrics.

Scenario

Aerospace bracket qualification: validate FE model stiffness against test modal frequencies; quantify the effect of manufacturing variation in hole positions on fatigue life using stochastic sampling and present probabilistic margins to certification authority.

Example

Use design of experiments to sample geometry and material space, build surrogate models (response surfaces), apply topology optimization to minimize mass subject to stiffness constraints, and run gradient-based optimizers for fine-tuning.

Scenario

Lightweighting a suspension component: perform topology optimization to remove low-stress material, convert the result into manufacturable geometry, validate with detailed FEA under service loads, and iterate to meet fatigue life and manufacturing constraints.

Example

Parallel solver runs across hundreds of cores for large explicit crash models, automated batch parametric sweeps using Python/Ansys ACT/Abaqus scripting, and job orchestration on cloud/HPC for continuous integration of simulation.

Scenario

A tier-1 supplier runs nightly automated durability sweeps across dozens of loadcases and material variants; failures are flagged and the design team receives a prioritized list of issues before the next design review.

Example

Generate contour plots, time-history traces, eigenmodes, and create standardized PDF/HTML reports; expose model inputs/outputs to PLM systems and create reduced-order models for digital twin deployment in operations.

Scenario

Wind turbine blade test: produce fatigue damage maps and export a reduced-order model for the SCADA system to predict remaining useful life in operation using sensor inputs.