The Virtual Prototyping Magazine Lighter is Better How Virtual Prototyping Helps Smaller Companies Develop Lighter and Greener Products
special report
SL Rasch Relies on Virtual Performance Solution to Achieve Architectural Excellence Register: www.esi-group.com/CompositesSeminar2015 Contents Editorial
04 special report Lighter is Better: How Virtual Prototyping Helps Smaller Companies Develop Lighter and Greener Products Fouad El-Khaldi Industry Strategy & Innovation 09 customer success General Manager, Casting Simulation Helps Honda Cut Die Design Trials ESI Group Significantly Mitsubishi Hitachi Power Systems Europe Increases its Competitiveness with IC.IDO SL Rasch Relies on Virtual Performance Solution to Achieve Architectural Excellence Many small and medium enterprises (SMEs) today are unaware AEROCAMPUS Aquitaine Adopts IC.IDO to Offer of the value Virtual Prototyping software can bring to their Virtual Reality to its Trainees University of Ulster Relies on PAM-STAMP to Develop business. Common perception may be that the technology Innovative Manufacturing Processes for an Aeronautic is too complex or too expensive and, thus, accessible only Part to larger organizations. This is a misconception today: the Inegi Uses ProCAST to Manufacture Hip Prostheses technical and financial barriers preventing small companies Cost Effectively from switching to numerical modeling are disappearing (page4). Comil Ônibus Reduces Distortion by 75% Using Weld Planner Simulation Software Technology is part of our daily lives and simulation is everywhere – from childhood games to models of our planet 16 corporate success Earth, our weather and our economies. Today, graduating Saving Lives with Virtual Prototyping engineers enter the workforce equipped to develop computer 18 product success models using simulation software. Employers can build Visual-Environment 10.0 Delivers Key Improvements on this expertise and subsequently assure that engineers for Computational Fluid Dynamics and maintenance operators alike are trained in the latest Introducing the New IC.IDO 10 technologies and enjoy successful and rewarding careers. In this edition of ESI Talk we report (on page 12) such an 20 corporate evolution at Aerocampus Aquitaine, Europe’s largest training Looking Back on ESI Global Forum 2014 center for aeronautic maintenance. Students are trained in ESI Wins a Prize Recognizing its Growth Over the Past the latest aircraft maintenance procedures using Virtual Reality 3 Years installations to visualize and interact with virtual engines and 22 events other aircraft equipment. Computer hardware and the IT Save the Date! infrastructure necessary to conduct such simulations are increasingly affordable, while “software on demand” and Cloud 23 financial Computing make even the most advanced simulation tools Sales for the 3rd Quarter of 2014 accessible. Nomination of Two Independent Directors Using simulation software to build models and virtual prototypes is proving to be cost and time-effective in esi talk is issued bi-annually by ESI Group All PAM - and SYS - product names as well as comparison with conventional methods, and helps companies Executive Editor: Amy de Rouvray other products belonging to ESI’s portfolio, Editor-in-Chief: Celine Gallerne including OpenFOAM® are tradenames or get new products “right first time”. Design errors detected [email protected] trademarks of ESI Group, unless specifically ESI Group Marketing mentioned. All other trademarks are the early in the development cycle can save companies costly Parc d’Affaires SILIC property of their respective owners. 99, rue des Solets - BP 80112 All text and images included in the articles are 94513 Rungis Cedex - FRANCE iterations (representing millions of Euros). Read our Special the copyright of the companies presenting their Tel: +33 (0) 1 41 73 58 00 applications and simulation tasks. Fax: +33 (0) 1 46 87 72 02 Report (p 4-6), on how smaller companies are using virtual www.esi-group.com [email protected] Photo credits: Expliseat, Euros, Acoudesign, Design: Herbatnik Studio Honda of America, Mitsubishi Hitachi Power prototyping to design and manufacture highly innovative parts ISSN 12105-1739 Systems, SL Rasch, Aerocampus Aquitaine, Print: Groupe Dupli-Print University of Ulster, Inegi, Comil, Renault, and components with minimum initial investment and in the 2 Rue Descartes ZI Sezac - 95330 Domont Audi AG. Dépôt légal: Janvier 2015 G.OM.15.23A shortest amount of time.
issue 45 : winter 2014 3 special report Lighter is Better How Virtual Prototyping Helps Smaller Companies Develop Lighter and Greener Products
Pressure to reduce weight has been guiding innovations must be carefully investigated to avoid design errors and in the mobility sector for decades. Today lightweight costly surprises. manufacturing is crucial to reduce fuel consumption, But product testing has a cost – a cost that can prevent CO , and greenhouse gas emissions. Beyond automotive 2 smaller businesses from entering the game. This is where and aerospace, other sectors such as electronics or ESI comes into the equation: by proposing reliable Virtual architecture are also exploring the use of lightweight Prototyping software and services. Enabling engineers materials to achieve greater efficiency, save costs or to get their products right the first time, ESI relieves simply make ground-breaking designs possible. small and medium enterprises (SMEs) from the high initial investment formerly required to test and certify a Whatever the industry, lighter alternatives are product. constantly being made available – benefiting from ultra-high strength steel, aluminum, and composite ESI’s simulation solutions empower smaller businesses to materials, to name a few options. These innovative develop the right simulation and optimization strategies lightweight materials need to be thoroughly evaluated and thereby develop, certify and launch their new to avoid product failure, gain certifications required for products faster – and secure revenue earlier. commercialization, guarantee product usability, comfort We feature in this article several compelling examples of and durability. The manufacture of lightweight parts, their companies who, despite a troubled economic climate, physical properties, performance and usage in different managed to get ahead of their game and deliver truly environments under normal or accidental conditions fantastic innovations, thanks to Virtual Prototyping.
4 special report
Expliseat releases the world’s lightest aircraft seat
French company Expliseat used ESI’s Virtual Seat Solution to develop the revolutionary Titanium Seat, the lightest seat ever certified by both the European Aviation Safety Agency (EASA) and the American Federal Aviation Administration (FAA).
”Virtual Seat Solution has helped us reduce drastically the development time usually required to design an innovative product, and has allowed us to increase the business value of our company in record time!” Dr. Vincent Tejedor, Chief Technical Officer of Expliseat
Thanks to Virtual Seat Solution, Expliseat was able to develop fully virtual seat prototypes; easily conducting many iterations without the need to build numerous (and costly) real prototypes. The company was also able to develop and test newly patented technologies that are used to absorb the shocks felt by aircraft passengers inflight, and thereby increase their comfort.
Available for Airbus 320 and Boeing 737 aircraft, the new Titanium Seat weighs only 4 kilograms, a 50 percent weight saving compared with today’s lightest models (8 to 10 kilograms). It fulfills the many requirements of an economy class seat: light weight, sleek design, excellent ergonomics, ease of personalization, safety, and From top to bottom: Expliseat Titanium Seat: real seat, real prototype and virtual prototype. durability. The super-lightweight seat respects all EU and US safety standards and is now approved for flight on EUROS manufactures its first ever board any airline in the world. The seat allows airlines to benefit from an estimated 3 to 5 percent fuel saving – 80-meter long composite rotor blade a considerable gain for our environment and representing To achieve lightweight wind blades, the wind industry $ 300,000 to $ 500,000 savings per aircraft per year. generally favors composite materials – a choice hard to The contribution of numerical simulation is best reconcile with increasing length requirements. expressed in the words: German company EUROS manufactures its long composite rotor blades by Vacuum Assisted Resin ”Virtual Prototyping is a proven industrial approach to Infusion (VARI). Recently, the company needed to develop pre-certify the manufacturing process and performance a specific process to enable the manufacturing of an of an innovative product, such as our Titanium seat. 80-meter long wind turbine rotor blade, the biggest they Our experience working with ESI’s Virtual Seat Solution had ever made. confirms the efficiency of this solution in speeding up innovation.” Usually, this would have required several infusion trials. Dr. Vincent Tejedor, The costs of each trial are high and increase quickly with Chief Technical Officer of Expliseat blade length and design complexity, as does the process development time.
issue 45 : winter 2014 5 special report
In view of the challenges, EUROS decided to introduce To undertake the complex vibro-acoustic analysis simulation as a means to better understand the VARI needed, Acoudesign chose VA One; software from ESI process and its influencing parameters. The wind blade that uniquely covers low, mid, and high frequencies. manufacturer chose PAM-RTM, ESI’s software dedicated Using VA One, Acoudesign developed a 3D Finite Element to the infusion process of large composite parts, to model of the acoustic panel to demonstrate the efficiency replicate and support their physical tests (RTM for Resin of both its air layer and its elastic suspensions. VA One Transfer Molding). Thanks to PAM-RTM, their engineering also enabled Acoudesign to optimize the performance/ team determined the best injection strategy; one that weight ratio of the panel’s light multilayer structure. minimized risks, optimized the quality of the wind blade, reduced manufacturing time, and assured process repeatability. ”Noise and vibration are one of the main problems in the aerospace industry as a wide range of frequencies Benefiting from the use of PAM-RTM, EUROS successfully are involved. The results obtained with VA One to design built their first 81.6-meter long, 32.8 tons, offshore blade a high performance acoustic panel for noise reduction and reached all their goals. in the new generation X4 helicopter cabin have been very satisfying. VA One allowed us to meet quickly our predefined objectives thus significantly reducing the ”Thanks to PAM-RTM, we can develop several infusion cost of the project.” strategies in a short time for the manufacturing of different types of onshore and offshore wind turbine Dr Jean-Philippe THOMÉ, rotor blades.” Owner, Acoudesign
Dipl. Ing. Mathias Marois, Head of Production Technology Department, EUROS Germany
The internal noise field in a helicopter cabin depends on external noise sources, noise transmission, as well as the internal reverberation in the cabin’s volume.
Benefits to SMEs
Small and mid-sized companies (SMEs) across industries Acoudesign develops an acoustic panel continue to obtain measurable gains from leveraging to reduce noise inside helicopters ESI’s Virtual Prototyping solutions in their product development process. Benefits include cost reduction as French company Acoudesign specializes in optimizing they reduce or even eliminate physical trials as well as acoustics for interior designs in the building and mobility time savings and accelerated development processes. industries. PEGASE competitiveness cluster selected Importantly, companies are able to investigate design Acoudesign to join a research program for the new alternatives easily and respond to new challenges generation Airbus X4 helicopter. with agility. Virtual Prototyping empowers SMEs to Acoudesign’s role in the project was to develop a light, produce innovative, state-of-the-art products, parts or stiff and thin acoustic panel to be used in noise reduction components that meet design objectives. Just like larger in the helicopter cabin. The requirements were to provide corporations, SMEs are able to shorten the pre-industrial both insulation and high absorption performances, while phase of new products – and to do so with minimum meeting aerospace standards. initial investment.
6 interview
3 Questions for…
Christian Matzen Head of Virtual Reality at ESI
Christian Matzen gives us a strategic overview of the business value of immersive Virtual Reality across multiple industries
Why does Virtual Reality represent the future for process. The challenge for them is to perform collaborative the manufacturing industry? and immersive design reviews, to evaluate and optimize assembly and disassembly sequences, to verify resources Increased technical complexities, elongated and dynamic and tooling for both manufacture and maintenance, to supply chains, growing shortage of experienced workforce, support documentation and workflow animation/ training. and relentless time and budgetary pressures lead to a The ability to detect contact and obstruction during assembly complex environment that challenges the culture and and maintenance procedures, to evaluate instantaneously traditional means by which companies make decisions. flexible components, pipes and cables is critical for them. Rapid evolution in the capabilities and complexity of design tools and the steady push for digital design – where What do the manufacturers concretely do with ESI’s physical products do not exist until most of the design has Virtual Reality solution IC.IDO? been completed – are so many reasons to turn to Virtual With IC.IDO, manufacturers of complex products are able Reality. It is also the best possible technlology to eliminate to clearly identify and resolve issues in real-time. They communication barriers, especially for participants outside use Virtual Reality to present and communicate products the engineering community. virtually. IC.IDO allows for fast, reliable and convenient decisions throughout the whole product development What do manufacturers (aerospace, automotive, process. The solution streamlines workflows, reduces errors, energy, etc.) need in the area of Virtual Reality? and minimizes overlooked issues that evolve into costly In the 2000s, Manufacturers started to believe in the power downstream problems. IC.IDO allows them to make early, of immersive VR as a unique tool to intuitively experience effective and reliable decisions, with a lasting positive impact innovative products in their environments. What they need on both revenue and cost. is a powerful and robust solution combining high-end visualization and real-time simulation of product behavior in its actual size, to allow product operation very close to reality. for more information They need a solution that is made for engineers, usable on www.esi-group.com/icido a daily basis as a cornerstone of the product development
issue 45 : winter 2014 7 special report
Join our Webinars Every week one new topic on challenges of the vibro-acoustic world
8 Register: www.esi-group.com/webinars automotive | customer success
Casting Simulation Helps Honda Cut Die Design Trials Significantly
Honda of America uses ESI’s ProCAST to evaluate the initial die design and try out alternatives before building any physical prototype
“Engineers at our parent company in Japan by requiring refurbishment of the die in have long used simulation to evaluate between runs. ”We have found ProCAST predictions prototypes before they even think of With the help of ProCAST, Honda EGA to be very accurate. Simulation building a trial die,” said James Kreitzer, successfully understood the root cause provides far more information than Engineering Coordinator for Honda of of the die erosion and found a solution is obtained during testing, such as America Manufacturing. “They were able to fix it. the flow velocity and temperature at to successfully bring parts into production every point in the mold throughout in considerably less time than we were able the filling and cooling process. The to accomplish here. So we started looking resulting visualization of the casting at various options to simulate the casting process helps engineers understand process.” the causes of defects and evaluate the performance of modified tooling Honda of America Manufacturing Anna designs without having to actually Engine Plant (Honda EGA) produces produce tooling. aluminum die castings, such as engine As a result, we have been able to blocks and cylinder heads. Before substantially reduce the number of implementing simulation, due to the die tries and compress the entire complexity of the dies, even experienced product development process by casting engineers rarely were able to several months.” produce a die design that resulted in quality parts on the first try. The time- James Kreitzer, consuming build and test process, which Engineering Coordinator for was required to complete the design, Honda of America Manufacturing involved multiple die trials at a cost of nearly $50,000 per try.
To address this issue, Honda chose ESI’s About Honda of America casting simulation software, ProCAST to The Anna Engine Plant, established in evaluate the initial die design and try out 1985, is Honda’s first U.S. engine plant alternative solutions before building or and largest auto engine facility in the testing any hardware. The simulations world producing four-cylinder and six- typically show flow and solidification cylinder automotive engines for North related problems such as gas and American-built Honda and Acura autos shrinkage porosity. Engineers can then Erosion location and metal front meeting location in as well as drivetrain components. Honda modify the virtual model to correct these real die tries and in ProCAST. recently invested $180 million in the plant issues. As a result of virtual prototyping use, to expand its capabilities in aluminum die Recently die erosion on an industrial Honda of America has lowered the casting and engine parts production. grade C18150 copper permanent mold average number of die tries and reduced for the ferrous castings production line the die development process by months. created a major problem. In addition to Their products are ready to be delivered for more information www.esi-group.com/casting increasing scrap rate and downtime to fix to customers sooner and cost less to www.honda.com the die, this eventually increased the cost develop.
issue 45 : winter 2014 9 customer success | energy & power
Mitsubishi Hitachi Power Systems Europe Increases its Competitiveness with IC.IDO
Turning to Virtual Reality has helped MHPSE decrease time-to- market and prevent engineering errors
The global energy sector today faces an collaboration: intuitive interaction with Virtual Reality consultants, MHPSE went unprecedented number of challenges plant and equipment that bridges the gap one step further in making Virtual Reality related to tough competition coming between different engineering domains, even more accessible. They put in place from emerging countries. In this context, generations, languages and cultures. automated processes that significantly Mitsubishi Hitachi Power Systems Europe optimize data preparation and upload “Using IC.IDO allowed us to detect numerous (MHPSE), designer and constructor of time. Preparation for a full power station failures in our power station 3D mock-ups, fossil-fired power plants and related key review can now be completed in only before it was too late to halt the construction components, decided in 2006 to look for 1 hour; a dramatic improvement over the process. By identifying these kinds of critical a new tool that would address their main 8 hours required before mistakes, Mitsubishi Hitachi Power Systems challenges: Europe has avoided significant time loss, • Convincing potential customers of and the costly penalties we would have paid. the value of their solutions by using The ROI of IC.IDO is indisputable. ESI helped innovative differentiators during the Hitachi not only detect errors but actually ”Although we have come a long way bidding phase; prevent them,” explains Christoph Kastl, since we implemented IC.IDO, we are Head of technical IT at Mitsubishi Hitachi • Reducing the cost of engineering absolutely sure that the perspectives Power Systems Europe. errors (sometimes with associated of Virtual Reality for our industry penalties of millions of Euros), and In order to truly integrate Virtual Reality are still infinite. Nevertheless, we eliminating project delays related to late in their engineering process, MHPSE can today claim that we have met error detection or last minute design decided to invest in a dedicated room our initial objectives. Virtual Reality adjustments; equipped with IC.IDO and a Large-Scale contributes to developing a more 3D visualization powerwall. • Shortening the engineering cycle time, innovative and efficient image of while improving collaborative decision- Since this investment, MHPSE has Mitsubishi Hitachi Power Systems making with subcontractors. exploited the benefits of 3D immersive Europe; a great advantage in the visualization broadly in their business. Replacing the usual solid models and Their engineering department, face of competition.” 2D screenshots, MHPSE deployed ESI’s contractors and sub-contractors can Christoph Kastl, Virtual Reality solution IC.IDO to visualize now perform highly efficient, real-time and fully experience their 3D prototypes Head of technical IT at Mitsubishi engineering reviews with very little data in a highly immersive environment. Hitachi Power Systems Europe preparation and in a short amount of They now benefit from the interactivity time. features that allow users to move around actual size virtual prototypes in real time, Encouraged by the high level of and to identify potential design errors, acceptance of Virtual Reality in the About Mitsubishi Hitachi and inconsistencies. IC.IDO enables true company, and with the help of ESI’s Power Systems Europe
MHPSE GmbH, a subsidiary of globally operating Mitsubishi Hitachi Power Systems Ltd., designs and constructs fossil-fired power plants and supplies key components such as utility steam generators, environmental engineering equipment, turbines and pulverizers.
for more information www.esi-group.com/icido www.emea.mhps.com With IC.IDO, examining Virtual Prototypes is both realistic and intuitive.
10 construction | customer success
SL Rasch Relies on Virtual Performance Solution to Achieve Architectural Excellence
SL Rasch collaborated with ESI to virtually build and test different types of lightweight structures for architectural projects in the holy sites of Mecca and Medina
In 2005, SL Rasch GmbH, a German Rasch conducted initial studies using architecture firm that specializes in wind tunnel tests on reduced scale rigid buildings and lightweight structures, took models. However, these models could ”With the know-how of ESI experts on complex projects in Medina and Mecca, not predict the flexible behavior of the and the capabilities built into ESI’s Saudi-Arabia; destinations for millions structures under wind load. advanced CAE software solutions, of pilgrims every year. They addressed Consequentially, Dr. Rasch, CEO of designing our innovative structural the design of 250 giant, hydraulically SL Rasch, and his longtime friend Dr. systems became possible.” powered umbrellas, each fifteen Eberhard Haug, a co-founder of ESI meters high, and providing 26m x 26m Group, began collaborating to apply cover over the Medina Haram Piazza. Dr. Mahmoud Bodo Rasch, simulation methods to address the design For Mecca, SL Rasch designed the Mecca Founder and owner challenge of the structures. Royal Hotel Clock, an architectural work- of SL RASCH GmbH of-art situated at the top of the 600m SL Rasch virtually built and tested different tower, just a few steps away from the types of minimal energy lightweight Grand Mosque. structures for the foldable umbrellas by relying on Virtual Performance Using simulation, SL Rasch was able to The flexible shading umbrellas and the Solution (VPS), ESI’s software to assess test different versions of the design of huge elastic wing-like clock hands on the all domains of product performance. the umbrellas and the clock and achieve top of the clock tower presented very For structural analysis of turbulent wind optimal results while addressing all specific challenges. With the objective load on such lightweight structures, the of creating wind-resistant designs, SL applicable safety requirements. The team used Fluid-Structure Interaction studies helped SL Rasch save time, energy, (FSI) simulations, coupling Computational and considerable cost while making solid Fluid Dynamics (CFD) and Computational Structural Dynamics (CSD). ESI’s expertise decisions on how to construct these in the simulation of airbag folding for massive structures. the automotive industry proved to be invaluable as they were able to use Virtual Performance Solution to simulate the About SL Rasch folding and stowing of the umbrellas in their narrow containers. SL Rasch specializes in Special Buildings and Lightweight Structures; integrating The Mecca tower, which is a high architecture and engineering. strength steel structural skeleton clad with lightweight ornamented carbon- The company brings together an Umbrellas at the mosque. epoxy sandwich panels, had to be interdisciplinary team of professionals, aerodynamically stable under high wind composed of architects, structural, velocities and pressures. The project team mechanical and aeronautical engineers, performed structural analyses of the physicists and computer specialists topmost 200 meters of the tower using together with in-house departments for wind tunnel analysis and CFD, which also project management, graphic design and provided detailed evaluation of the wind pressures on smaller structures. model making.
for more information www.esi-group.com/VPS www.esi-group.com/engineeringservices (1) Mecca clock; 2D surface mesh of the clock hands and (2) clock hand velocities, studied using Fluid-Structure www.sl-rasch.com Interaction method.
issue 45 : winter 2014 11 customer success | areonautics
AEROCAMPUS Aquitaine Adopts IC.IDO to Offer Virtual Reality to its Trainees
The Virtual Reality room opens new perspectives for professional training, providing an immersive experience, greater interactivity, and team collaboration
Major manufacturing companies in the aerospace, ground transportation, and industrial machinery sectors use IC.IDO to perform design reviews, evaluate and optimize assembly and disassembly sequences, verify resources and tooling and support documentation and workflow training.
Created in 2011 in Bordeaux, France AEROCAMPUS Aquitaine is Europe’s leading aircraft maintenance training center, serving the biggest aeronautic manufacturers in the region. AEROCAMPUS has recently implemented a Virtual Reality powerwall running IC.IDO, ESI’s Virtual Reality solution, allowing trainees to experiment with aeronautic maintenance operations in an ultra- realistic immersive environment. With real-scale and real-time interactions, they can work collaboratively and connect to Virtual Reality systems located at other sites. For example, pupils located About Aerocampus in Toulouse may now connect virtually ”Virtual Reality is a fantastic AEROCAMPUS Aquitaine, the former with their fellow trainees in the new technology providing the most military aeronautical engineering AEROCAMPUS Virtual Reality room in interactive teaching experience training center in Lastrene (Gironde), is Bordeaux. possible. Not only does this a technological center of international importance, entirely devoted to train Using Virtual Prototypes, rather new technology make learning aircraft maintenance technicians as than traditional real prototypes, the fun, IC.IDO also enables the well as diverse professions linked to the AEROCAMPUS Cluster ensures that experimentation of real- aeronautical industry. equipment data is current and takes into life physics and the realistic account the slightest change in aircraft rehearsal of maintenance parts or maintenance processes. procedures, without having to provide costly aircraft parts.” “Virtual Reality is ideal to keep up with the latest training data as it offers a greater Jérome Verschave, reactivity with respect to frequent changes in Managing Director, aeronautic parts or processes,” comments for more information AEROCAMPUS Aquitaine www.esi-group.com/icido Jérome Verschave, Managing Director, www.aerocampus-aquitaine.com AEROCAMPUS Aquitaine.
12 aeronautics | customer success
University of Ulster Relies on PAM-STAMP to Develop Innovative Manufacturing Processes for an Aeronautic Part
Reducing drag on an aircraft engine nacelle leading edge by developing a process able to manufacture it in one piece
The increasing pressure on the aerospace and hydroforming. Here, technical industry to reduce its environmental requirements inherent to optimum part impact has rekindled the interest design resulted in many challenges on ”PAM-STAMP is an incredibly flexible in laminar flow technologies, which the production side. In particular the virtual try-out software for sheet me- essentially ensure that airflow remains increased draw depth in axial direction tal forming simulation that enables laminar until it naturally detaches from increases the risk of wrinkles, potentially the rapid development of innovative the surface of an aircraft, thus reducing results in excessive thinning, requires forming solutions at minimal cost.” turbulence and drag. Assuring laminar multi-stage heat treatments, and can flow necessitates reduced geometric often create unwanted grain growth. tolerances, reduced surface waviness Dr Alan Leacock, Early on in its research, AMFOR Group (linked to manufacturing and assembly), Reader in Advanced Metal realized that traditional forming and the elimination of cross-flow joints. Forming, University of Ulster techniques would not be sufficient to The Advanced Metal Forming Research deliver a robust manufacturing process. Group (AMFOR Group), based at the AMFOR Group then decided to use PAM- University of Ulster in the United Kingdom, STAMP from the initial conception of the has been developing an innovative process to test multiple ways of making The virtual development of the process process to manufacture an aircraft engine this component. It was from this initial took less than four months, resulting in a nacelle leading edge (also called ‘lipskin’) modeling work that the process was patented process. in one piece, preserving laminar flow and derived. Following a series of production trials, significantly reducing aircraft drag. The freedom to define unusual / non- the production cycle was adapted to Lipskins are generally manufactured standard boundary conditions in PAM- eliminate the need for inter-stage heat using aluminum alloys or stainless steel. STAMP was an essential element to treatments that are common in many Common manufacturing processes evaluate this process virtually. Through lipskin production processes used today. include deep-drawing, spinning a series of virtual trials, AMFOR Group The AMFOR Group is presently seeking optimized the blank profile, conic taper, to commercialize the new production tool motions and forces required. These process through partnerships with values were then used to guide the design aerospace manufacturers. and development of a tailored forming system for the production of a prototype lipskin. About the AMFOR Group of the University of Ulster
The AMFOR Group has over 17 years’ a b experience and is dedicated to the development of high value manufacturing processes for the sheet metal forming
c d industry and particularly in the pragmatic application of science for the solution of industrial forming problems.
e for more information www.esi-group.com/PAM-STAMP www.amfor.ulster.ac.uk An engine nacelle lipskin part. The key forming process steps.
issue 45 : winter 2014 13 customer success | medical
Inegi Uses ProCAST to Manufacture Hip Prostheses Cost Effectively
Improving the patient’s comfort and safety while reducing costs of manufacturing
Hip prosthesis (Image courtesy of http://orthoinfo.aaos.org)
A hip prosthesis is a highly customized variables, including the gating system Inegi set up different sets of simulations product, tailored to the exact morphology that controls the flow into the mould, to determine the most adapted gating of a patient. Although modern medical are adjusted. Such iteration is costly and design. The castings produced by the imagery enables the construction of an time consuming when relying on physical finally accepted process were free from accurate 3D model of the patient, the prototyping and inspection, as production any centerline shrinkage and the surface design and manufacturing of prostheses engineers have to re-create the metallic finish was also improved. Based on these to high specification levels is still very dies for the wax pattern for each design successes, Inegi now uses ProCAST to widely based on a trial and error change. simulate all their casting processes . approach, which is both expensive and Inegi turned to virtual manufacturing time-consuming. as a means to develop processes that About Inegi Faced with the challenge of developing eliminated the casting defects that can high quality prostheses, Inegi, a non-profit accelerate fatigue failure and reduce the Founded in 1986, Inegi is an interface organization in Portugal which provides lifetime of a prosthesis. They conducted Institution between University and R&D support to various industries, turned several virtual trials using ESI’s ProCAST Industry, oriented to the activities of to simulation software to develop a cost- to obtain greater insight into the filling Research and Development, Innovation effective medical implant manufacturing sequence and temperature gradients at and Technology Transfer. Being a non- technology. Investment casting was various sections in the casting and shell. profit private association recognized as selected as the most appropriate process To support these studies Inegi obtained being of public utility. Inegi is currently as it is the best adapted to manufacturing from ProCAST’s thermodynamic database considered an active agent playing a products with unique features and the high temperature properties of significant role in the development of requiring exceptional precision. Inegi the specific Ti6Al4V alloy used for the the Portuguese industry, and in the selected ESI’s casting simulation software prostheses. transformation of its competitive model. ProCAST to identify the most efficient investment casting process suitable for custom-built prosthesis. ”Scientific methods can always save us time and cost. ProCAST is justthat Investment casting requires the tool helping foundry men find the right solutions. For the investment casting development of metallic dies that are used to produce the wax pattern which process, ProCAST can generate different layers of shells and with wrapping forms the geometry of the shell required outside. This helps predict the temperature field more precisely.” for the casting process. Casting of complex parts, such as hip prosthesis, can Nannan Song, result in defects, including the occurrence Senior Researcher, of center-line shrinkage porosity, bad Advanced Foundry and Rapid for more information surface finish & residual stresses. www.esi-group.com/casting Eliminating these defects typically Prototyping Technologies, Inegi www.inegi.pt requires several trials in which process
14 ground transportation | customer success
Comil Ônibus Reduces Distortion by 75% Using Weld Planner Simulation Software
Allowing them to meet tolerance requirements on a bus door frame cost effectively
and costly, trial-and-error prevented a Based on this first success, Comil started structured corrective approach to design to implement a standard methodology improvement, as Comil could only rely that integrates the use of Weld Planner, on experience to modify the welding enabling them to reach their targets for sequence and clamping positions. cost, quality and time.
Comil thus turned to ESI simulation “Weld Planner brings great benefit in software Weld Planner to meet the quality dimensional distortion control of welded specifications, deal with distortions, out of structures, allowing the study of different we- design tolerances, and cut development lding sequences. Results are fast and highly time and cost. accurate, ensuring significant technological First, Comil ran a benchmark to test improvement for our company, and and demonstrate – with success – the consequently reducing costs previously correlation of numerical results against spent on prototypes and materials that physical tests. Comil then launched its were just scrapped when they didn’t meet first project integrating CAE simulations specifications“, comments Thiago Sotilli, into its welding process development Corporate Engineering, Comil. workflow, allowing them to compare the numerical results with existing physical tests.
After obtaining satisfactory results from the simulations, Comil fully integrated Weld Planner in its workflow. The maximum distortion was reduced to 4.7 mm: a 75% reduction compared to Comil’s Versatile vehicle and its door frame. Local deformation of the welding assembly: before the 18.9 mm before simulation integration. use of Weld Planner (left) and after the use of Weld Planner (right). Comil Ônibus S.A. is a major bus As a result, they were able to trim the welded bus door structure without any manufacturer in Brazil, selling its vehicles About Comil Ônibus in more than 30 countries. One particular compensation or rework. bus design incorporated a door with Comil Ônibus S.A. is a major bus an inner structure made of steel, a manufacturer in Brazil and present on the streets and roads of more than configuration meant to meet the ABNT ”Simulating the steel welding NBR 7008 standard. These inner door 30 countries. It has a complete line of sequence using Weld Planner panels then had to be assembled and vehicles that includes coach, urban, micro, welded by Gas Metal Arc Welding (GMAW). software significantly reduced and special buses produced through manufacturing cost and time. careful market research. The company The prototyping department in charge The simulation results allowed believes that the joining of competencies, of developing the welding process first talents, experiences, and knowledge performed physical tests and used trial- us to control the dimensions of result in a quality product, and ensure the and-error to simulate the welding device critical parts and avoid rework satisfaction of passengers, drivers, and and welding sequence. Unfortunately, in our assembly line.” fleet owners. physical tests consistently revealed excessive welding distortion (up to 20mm) André Luis Petry, and consequently led to a rejection Engineering Supervisor, for more information of the bus’ front door inner structure www.esi-group.com/welding-assembly Comil on the basis of inadequate quality. www.comilonibus.com.br In addition to being time-consuming
issue 45 : winter 2014 15 corporate success
Saving Lives with Virtual Prototyping
Summing up the contribution of simulation to increased road safety over the past 30 years
The risk of death and injury in the event of a road Automotive companies rely on numerical simulation to accident has been importantly reduced in recent years predict with accuracy the impact occurring between the thanks to progress made in both active and passive occupant and a fully deployed airbag. This so – called safety measures. “In-Position Airbag Deployment Simulation” has become a standard virtual test for at least the last ten years. Virtual Prototyping is widely used by the industry to Car manufacturers use this information to evaluate the predict the results of crash tests – as defined in the new effectiveness of the airbag restraint function. car assessment programs including Euro NCAP or US NCAP – which are conducted to assure compliance with Automotive manufacturers also use numerical simulation regulations and satisfactory customer ratings. Virtual to reduce fatalities and even maximize protection in Prototyping reduces, and can even eliminate, testing cases where the impact with the occupant occurs before of real (hardware) prototypes. Importantly, early and the airbag is fully deployed. For these complex “Out-Of- effective Virtual Prototyping can be used to avoid the Position” situations, the deployment kinematics of the surprises in the late stages of a vehicle development airbag and local associated pressures play a major role program which can take substantial amounts of time and and require precise gas flow modeling. In order to model money to correct. these phenomena, ESI introduced in the 2000’s advanced simulation techniques that incorporated Fluid Structure In regards to passive safety, airbags have been a Interaction (FSI) in its Virtual Airbag Solution. Today, FSI standard safety component in cars since the 1990’s. techniques are also used for side airbags, like curtain Their main function is to mitigate the abrupt deceleration airbags or knee airbags. experienced during a crash, and to prevent occupants from impacting the car’s components; including the instrument panel and steering wheel. Today, most vehicles feature not only frontal airbags but also passenger airbags and even side or curtain airbags.
Out-Of-Position: The airbag comes in contact with the occupant at the very beginning of its deployment.
In addition to FSI, ESI’s Virtual Airbag Solution takes into account the manufacturing of the airbag and thereby increases the precision of the Virtual Prototype. This involves the precise modeling of the membrane material, which deeply influences the volume and the pressure of the airbag. Modeling the folding procedure is also very important – which is why ESI’s Virtual Airbag Solution enables manufacturers to precisely simulate the different folding operations of the airbag and its placement in its In-Position Deployment: The occupant comes in contact with the fully deployed airbag. casing.
16 corporate success
This set of advanced functionalities, unique on the market, has earned the trust of the world’s most renowned carmakers, including Audi.
Dr. Erich Blümcke, Vehicle Safety Simulation Engineer, AUDI AG, comments on the incredible advances of simulation, with regards to occupant safety:
“Four or five years ago, I had high discrepancies between physical testing and my simulation results. Nowadays, I am in a very good range: I can do specific simulations in order to validate my models and then really make decisions on how to design the airbags. ESI helps Audi The passenger airbag folding process using ESI’s Virtual Airbag Solution. design accurate airbag folding pattern in good timing.” Towards active safety
After decades of research to improve crash- worthiness and passenger safety, car manufacturers are now looking Today, Virtual Airbag Solution helps clients in the at active safety measures: they are not only trying to automotive sector: mitigate the consequences of a car crash, they are also • Reduce airbag development cost and time trying to prevent the collision from happening in the first • Decrease the number of physical tests performed place! There again, Virtual Prototyping lends a helping • Optimize the development process hand. For example, virtually simulating the behavior of • Improve procedure and interactions between high-frequency RADAR captors (77GHz) has helped car departments manufacturers develop innovative collision detection • Accelerate airbag model construction time systems. Active safety is today an important topic, on Drivers around the world have access to safer cars, at which ESI teams are already working with some of the a lower price, and in less time! world’s biggest OEMs.
for more information www.esi-group.com/VPS Virtual electromagnetic testing of active safety systems, such as blind spot assistance.
issue 45 : winter 2014 17 product news
Visual-Environment 10.0 Delivers Key Improvements for Computational Fluid Dynamics
Offering a dedicated user environment for open source code OpenFOAM®
Visual-Environment 10.0 is an open simulation platform that enables the management of Virtual Prototyping processes efficiently in a single environment.
Designed to support the most demanding CAE requirements, With this latest release, Visual-Environment 10.0 platform now Visual-Environment is a comprehensive simulation platform supports additional formats generated by third-party CAD tools, enabling faster decision-making across multiple domains. such as ACIS, Solid Edge, Inventor and SolidWorks, allowing users to import files without the need for time-consuming The latest version, Visual-Environment 10.0, includes several conversions. major enhancements:
• It delivers a very intuitive interface for all CFD engineers, allowing them to accelerate the preparation of most common ”Working hand-in-hand with ESI, AMD is able to provide CFD calculations, including airflow for external aerodynamics, Visual-Environment 10.0 users with a certified driver, internal airflow for underhood and climate control, and delivering robust and feature-rich graphical support to investigation of flow around rotating bodies manage virtual prototypes and large-scale engineering • It provides users of the well-known open source CFD modules simulation models, as required for every day Finite Element of OpenFOAM® with the first compatible industrial grade analysis and for Computational Fluid Dynamics.” platform, enabling seamless CAD import, easy model set-up,
pre- and post-processing, macro-capabilities and customization Antoine Reymond, • It gives design engineers access to quick answers for various Strategic Alliances Manager design options. Once a CFD engineer has defined an analysis AMD process, fellow design engineers can benefit from automated meshing, set-up and processing, enabling them to obtain CFD for more information models in a third of the time, with no supervision and with www.esi-group.com/Visual-Environment minimum training.
18 corporate
Introducing the New IC.IDO 10
ESI takes Virtual Reality to the next level with workflow efficiency and high fidelity rendering for industrial applications
Industrial manufacturers of large or complex products Also part of this release, the new module IDO.Process allows for continually seek innovative ways to increase productivity efficient, interactive and collaborative planning and validation and reduce potential design issues. Immersive Virtual Reality of assembly processes. In combination with IC.IDO’s immersive solution IC.IDO empowers their teams to collaboratively experience, IDO.Process addresses the demand of industrial explore and resolve design challenges throughout product engineers and service managers for an agile and robust planning engineering, manufacturing and aftersales. The latest release, and validation environment of their respective processes. IC.IDO 10, elevates the fidelity of decision-making and delivers Recently, automotive manufacturer Renault implemented IC.IDO an unprecedented immersive experience. to speed up the quality and efficiency of their design processes. IC.IDO 10 features the new module IDO.Illuminate, providing ultra-realistic lighting conditions, so that users may experience their product “as good as real”, long before a physical prototype is available. For the first time, users of IC.IDO 10 are able ”We’re excited about this latest release and expect a lot to experience their future product under realistic lighting from IC.IDO 10 in terms of physics simulation for flexible conditions, without sacrificing performance or interactivity. and kinematic chains, manikin manipulation, data flow They can create complex 3D environments in which to immerse and workflow organization. Our objective, with the help their product, appreciate the visual appearance, experience of IC.IDO, is to increase the quality and efficiency of our operating conditions more realistically, and better assess the assembly validations, and to decrease our development manufacturability or serviceability of a product. For example, times.” with IDO.Illuminate an automotive company can assess if lighting conditions on the assembly line are sufficient in order to ensure safe and efficient operations by workers. Renaud Deligny, Specialist for 3D Engineering for Product and Process Design at Renault
Industry has adopted IC.IDO to perform collaborative and immersive design reviews, to evaluate and optimize assembly and disassembly sequences, to verify resources and tooling for manufacture and maintenance, and more.
Leading companies benefit from IC.IDO. Customers amongst the automotive manufacturers include Chrysler, Daimler, Fiat, Ford, Honda, Hyundai, JLR, and Volkswagen. In the aerospace sector, customers include Airbus, Boeing, and Lockheed Martin. Machinery and tooling manufacturers such as AP&T, Bausch & Stroebel, Gabler, Herrenknecht, MTU and Oerlikon Neumag Virtual Reality solution IC.IDO improves the efficiency of engineering design processes at Renault. use IC.IDO; as do Caterpillar, John Deere and Bombardier in the commercial vehicles and transportation sector; and the prominent energy companies Siemens and Hitachi. It is important to note that IC.IDO 10 optimizes rendering performance during runtime so users can benefit from the best possible balance between visual quality and real-time interactivity. Not only does the new module IDO.Illuminate bring increased productivity, it also delivers a compelling experience for more information for presentations to the end customer by showing the impact of www.esi-group.com/icido lighting conditions on usability or perceived quality.
issue 45 : winter 2014 19 corporate
Looking Back on ESI Global Forum 2014
Last May in Paris, France, ESI Group held its third ESI Global Forum, an international conference dedicated to Virtual Product Engineering
To fulfill the needs of ESI’s growing vibro-acoustics user community, four vibro-acoustics workshops ran in parallel to the aforementioned industry presentations. These workshops focused on Powertrain Exhaust and Intake, Wind Noise, Cabin Noise, and Low Frequency Interior Acoustics.
The event, tailored to CAE experts and decision-makers, In addition, ESI organized jointly with customer and gathered some 300 attendees from around the globe. partner AP&T a micro-seminar on the Virtual Prototyping ESI customers and simulation engineers from various of the hot forming manufacturing process. Here they industry sectors shared their expertise, challenges and demonstrated and visualized the full engineering workflow achievements. Held every 2 years, ESI Global Forum – all the way from original customer request through to brings together industry leaders to help them implement a production solution, with material cost estimation, die best practices and get the best return on their investment face design, stamping feasibility assessment, and cooling in Virtual Product Engineering: from increased product channel validation – in Virtual Reality. performance to cost reduction and reduced time to market. Also taking place in parallel to ESI Global Forum, a round table discussion dedicated to Virtual Reality offered an opportunity for ESI clients to come together and debate A few words from attendees… the future of this technology and its deployment at an industrial level. ”Excellent work!“ As in past years, the ESI Fair brought together ESI partners. “Very useful event.” These included hardware and software suppliers who took the opportunity to offer exciting and cutting-edge demos, “Good to meet ESI people face to face and discuss and display how their latest solutions bring benefits in developments.” productivity and performance. “The organization was excellent!“ ESI would like to thank all speakers, sponsors and “Thank you for giving us a great opportunity.” participants, who made this international event a success!
“I look forward to participating again.”
Following the opening of the forum by Alain de Rouvray, the co-founder and CEO of ESI Group who shared his strategic vision for Virtual Product Engineering, exceptional keynotes were delivered in the extended plenary session by some of ESI’s leading customers: Renault, Airbus Defense & Space, AREVA, Nissan Motor, and Volkswagen.
The event then split into 3 parallel sessions dedicated to Ground Transportation, Energy & Power, and Aerospace & Defense. Specific challenges and best practices in these The ESI Global Forum fair featured Haption, a provider of haptic devices for Virtual three industries were addressed. Reality.
20 corporate
ESI Wins a Prize Recognizing its Growth Over the Past 3 Years
The “Grand Prix des Entreprises de Croissance” is awarded to French companies that have achieved outstanding growth in the previous three years.
Vincent Chaillou, Chief Operating Officer, and Laurent Bastian, Chief Financial Officer, ESI Group
Last July, ESI Group won the prize “Grand Prix des Entreprises de Croissance,” awarded to French companies ”This award is a valuable testimony to the excellence that have achieved outstanding growth in the past three shown by ESI Group teams worldwide over more than 40 years. With its increasingly innovative virtual years. The committee selected ESI in the “Software and prototyping solutions, the Group has made a global IT Services” category for companies with a turnover of name for itself due to its vitality and technological between €100 million and €1 billion in the period 2010- expertise, through which it has helped secure the long- 2013; when ESI Group’s turnover rose on average by term industrial leadership of its customers. The award 13.2% a year. also recognizes the Group’s ambition to usher in the ICT based fourth industrial revolution, fostering a more In addition to the growth requirement, the award was efficient economy through disruptive productivity based on a thorough examination of six criteria that gains and a more engaged social responsibility. Given the quality of the candidates and the discerning demonstrate the excellence of ESI Group over the selection process, being chosen for the first edition of long term, namely: sustainability and profitability, job this brand new award is not only an honor for the creation, corporate social responsibility, leadership and Group, but it also sends out a strong signal that spurs collaborative management, innovation, and development on our indomitable quest for excellence.” and growth potential. Alain de Rouvray, Chairman and Chief Executive Officer of ESI Group
for more information www.grandprix-entreprisesdecroissance.fr
issue 45 : winter 2014 21 events
Save the Date!
Mechanical Performance (fatigue, Composites Virtual Prototyping Stuttgart, Jan 27-28, 2015 strength, crash), Manufacturing effects, Expert Seminar Germany Multi-Scale technologies
Marine Special Interest Group Seminar showcasing latest developments in the Mumbai, Jan 27-28, 2015 Vibro-Acoustics Marine SIG Asia 2015 field of Vibro-Acoustics related to the India Marine Industry
"Gießtechnik im Motorenbau 2015" Casting technology in engine Magdeburg, Feb 10-11, 2015 - Potential capacity for the next construction 2015 Germany generation of power engines
The major global composites event Paris, Mar 10-12, 2015 JEC Europe 2015 in the world France
Nuremberg, Mar 16-19, 2015 DAGA 2015 41st annual conference for acoustics Germany
To develop and evolve methodologies Pass By Noise Special Interest Nuremberg, Mar 20, 2015 capable of performing PBN simulation in Group (SIG) Germany a virtual environment.
17th International Exhibition of Virtual Laval, Apr 8-12, 2015 Laval Virtual 2015 Technologies and Uses France
May 31- Jun 05 One-week course to improve knowledge Les Diablerets, Solidification Course 2015 2015 in the field of solidification Switzerland
6th International Conference on Rome, Jun 15-17, 2015 Marine 2015 Computational Methods in Marine Italy Engineering
Bringing together the world’s industry International Paris Air Show Paris, Jun 15-21, 2015 leaders in Aerospace, around the latest (Le Bourget) France technological innovations
Duesseldorf, Jun 16-20, 2015 GIFA 2015 13th International Foundry Trade Fair Germany
Forum for leading industry professionals to SAE 2015 Noise and Vibration Grand Rapids, MI, Jun 22-25, 2015 share the latest technologies surrounding NVH United States Conference and sound quality
Bamberg, Oct 7-8, 2015 ESI DACH Forum 2015 Expert platform for Virtual Prototyping Germany
The forum brings together users sharing Tokyo, Nov 19-20, 2015 ESI Japan Forum 2015 (PUCA) their expertise, best practices, challenges Japan and successes.
for more information www.esi-group.com/events
22 financial
Sales for the 3rd Quarter Nomination of Two of 2014 Independent Directors
Alain de Rouvray, ESI Group’s Chairman and CEO, comments: “Third-quarter sales continue the trend observed during the first half. The Licenses activity showed further strong demand for our innovative solutions, while the Services reflect the refocus in favor of high value added projects. We are anticipating an amplification of the seasonal nature of sales in the fourth quarter due to the repositioning of some License contracts, and the improvement in Services during Véronique Rajani this period. Encouraged by the commercial momentum Jacq Ramanathan of the Licenses, ESI Group maintains its expectations of growth and improvement of profitability over the full year.” The Board of Directors of ESI Group, on the recommendation of the Compensation, Nomination and Governance Committee, elected two new independent directors – Ms Véronique Jacq and Licenses: robust business Ms Rajani Ramanathan – at the Annual General Meeting held on The Licenses business reported sales of €42.5 million, stable in 24 July 2014. The Board now consists of 8 members. real terms and up 2.2% at constant exchange rates compared with the same period last year. This growth, as mentioned in Véronique Jacq is a graduate of the Ecole des Mines de Paris and regard to the first half, was mitigated by the repositioning of of the Corps des Mines. She began her career with the French major contracts in the fourth quarter. At constant exchange Nuclear Safety Authority and has gained a sound knowledge of rates, and adjusted for the repositioning of these contracts, the technology firms through various management positions that installed base grew. The rate of recurrent business remained she held. In 2012, she took over as head of digital investment high at 78.7%, compared with 78.5% in same period last year. New Business activity totaled €9.8 million at current exchange at CDC Enterprises and currently performs the same role in the rates, representing 26.2% of Licenses sales, compared with digital investment division of Bpifrance. 25.4% in the same period last year. Rajani Ramanathan gained experience running her own companies in India and holding leadership positions in both Services: further consolidation of business small and large organizations in the US. She has spent the last Services sales totaled €19.5 million in real terms, a decline of 14 years at Salesforce.com, a company she joined in 2000 when 7.0% at constant exchange rates. This was attributable to the it was only a start-up. Most recently she was COO (EVP) of the continued refocus of the business; an impact which is expected Technologies & Products division. In 2014, she was awarded the to lessen by the end of the year. YWCA TWIN (Tribute to Women and Industry) Award, considered one of Silicon Valley’s most prestigious awards, honoring women Geographic mix: strong business in Europe who exemplify leadership excellence in executive-level positions. The geographic breakdown of sales over the first nine months reflected a shift in favor of Europe, driven primarily by the Licenses business. This region accounted for 42.9% of total revenues, compared with 40.8% in the same period last year. The trend in Asia (39.1% vs. 39.7%) was mainly attributable to the unfavorable impact of exchange rates and adverse business situation. The reduction of business volumes in the Americas, which accounted for 18.0% of sales compared with 19.5% in the same period last year, resulted from the refocus of the Services for more information business. This masked the strength of the Licenses activity in this www.esi-group.com/investors region during the first nine months.
issue 45 : winter 2014 23 Headquarters Subsidiaries Agents and Distributors
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