Automotive Engineering: Crash Test, Seat Design, Powertrain Component Development, NVH, Combustion, Thermal Simulation, Welding, Casting & Forming Technologies
FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization
Simulation and analysis of complex systems is at the heart of the design process and is key to achieving truly optimised components in Automotive Engineering. We focus on strategic use of CAE to Optimise Designs, investigate and resolve problems, and minimise time and cost to market. Advanced Crash Test Simulation, Seat Design, Powertrain Component Development, NVH, Combustion, Thermal Simulation, Welding, Casting and Forming Technologies, Geartrain modelling and analysis software packages, provides the foundation of concept and definitive design for all driveline and transmission projects that we undertake.
Simulation Based Design of Powertrain Systems
Enteknograte engineering team use advanced CAE software with special features for mixing the best of both FEA tools and CFD solvers: CFD codes such as Ansys Fluent, Siemens StarCCM+ for Combustion and flows simulation and FEA based Codes such as ABAQUS, AVL Excite, LS-Dyna and the industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life to calculate fatigue life of Welding, Composite, Vibration, Crack growth, Thermo-mechanical fatigue and MSC Actran and ESI VA One for Acoustics simulations. With combination of deep knowledge and experience in sophisticated FEA and CFD based design tools, Enteknograte engineers can solve any problem with any level of complexity in Automotive Engineering.
Finite Element Simulation of Crash Test and Crashworthiness with LS-Dyna, Abaqus and PAM-CRASH
Enteknograte engineers simulate the crash safety with innovative CAE and virtual prototyping available in the non-linear structural codes: LS-DYNA, PAM-CRASH, RADIOSS and ABAQUS. We offer advanced FEA modeling consultancy services. We are experienced with automotive crash safety and consumer crash test protocols such as (frontal impact), (side impact), IIHS and EuroNCAP. Our engineers have Tier1 backgrounds in FEM (Finite Element Method) and are fluent in the codes: LS-DYNA, PAM-CRASH, RADIOSS and ABAQUS.
This research is responsible for developing and upgrading test procedures for evaluating motor vehicle safety. Crashworthiness research encompasses new and improved vehicle design, safety countermeasures and equipment to enhance occupant safety.
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NVH based Design and Considerations
The challenge for the NVH specialists is to support the concept and design development process by reliable recommendations just-in-time prior concept or design freeze. Enteknograte’s specialists particularly use advanced methodologies for NVH simulation and optimization:
- FEA based Powertrain
- Structural Optimization
- Optimization of Engine Dynamics based on MBD ( Multi-Body Dynamics Simulation)
- Concurrent optimization of combustion efficiency with NVH considerations
- Vehicle Interior Noise Simulation based on measurement and CAE
- Vehicle Exterior Noise Simulation with couple use of CFD and FEA solvers
- Objective Analysis of Sound Quality
NVH & Acoustics for Powertrain
In addition, new energy management systems such as cylinder deactivation systems and start-stop systems can cause new transient NVH phenomena. These new complex NVH issues need to be addressed on top of the typical engine-related NVH topics, such as engine radiation, gearbox rattle, whine, judder, clunk, fuel slosh, intake and exhaust noise, and auxiliary noises.
Read more... Finite Element and CFD for Powertrain Engineering
From diesel engines to electric drives, from alternative fuels to control, from transmissions to batteries, we have been working to design and optimize new challenging process to obtain new standards criteria and even more than it. Unique synergies with Enteknograte experience and combination of Advanced Simulation Technologies enable the development of highly creative, mature and application-specific solutions to enable our customers to meet their future market challenges.
Read more... Flow, Combustion and Emission
With 1D-3D coupling, we deliver a solution dedicated to solving specific tasks related to Internal Combustion Engine (ICE) development, such as matching performance requirements, lowering fuel consumption, emissions, CO2 and optimizing the engines thermal management.
1D-3D coupling are the industry’s first choice when reliable results are needed for engine thermodynamics and combustion/emissions development. The intelligent integration of these two software tools facilitates solutions for complex tasks early in the development phase and provides unparalleled accuracy during the detailed design phase by global CAE leaders.
Read more... Thermal & Energy Management
The overall complexity of the powertrain has significantly increased with the need to understand the detailed interaction of the individual sub-systems across a range of attributes. Improving fuel economy while reducing pollutant emissions implies deep engineering investigation to optimize powertrain energy management strategies, and ultimately how it impacts vehicle performance.
Read more... Strength and Durability Analysis
By combination of best in class CAE package, Enteknograte propose best solution for strength and durability analysis with various modeling depth levels ensuring accuracy according to stage in the development process.
The solution comprises the whole analysis workflow from dynamic analysis of subsystems and entire powertrains up to stress and fatigue strength evaluation of powertrain components, Outstanding models of lubricated contacts (slider bearings, piston and piston rings) facilitate detailed investigations of the contact behavior, including the prediction of friction and wear.
Read more... Turbocharging Simulation
Turbocharging allows automakers to reduce engine size and emissions while continuing to deliver the power and performance consumers demand. To improve overall engine performance, reduce pollutant formation, optimize NVH and ensure component durability, Enteknograte combine advanced simulation tools offer exactly what is needed to design advanced pressure charging systems.
Read more... Injection Nozzle Development
This simulation capabilities enable virtual design of: Reduce cavitation and avoid erosion in injection nozzles Achieve higher engine-out performance and lower engine-out emissions Performance Counts. In an early engine design stage, fuel injection details, such as needle lift and inlet pressure level, are not known. Thus, a virtual prototyping environment, consisting of 1D and 3D fuel injection simulations is extremely valuable.
Read more... Simulation for Quenching: Virtual Heat Treatment Optimization
Quenching is used in the production of cast or otherwise-produced metal components. In particular, immersion or direct quenching processes are widely adopted procedures in the automotive and aerospace industries to minimize the formation of undesirable thermal and transformational gradients, which may lead to increased distortion and cracking. The proposed method for simulation must accurately predict real-time quenching effects, local temperature gradients and the overall cooling history of complex quenched components.
Read more... Real-World Simulation services in Automotive Engineering, Powertrain Component Development, NVH, Combustion, Thermal Simulation, Crash Test Simulation, Seat Design, Welding & Forming Finite Element based Technologies
CFD Simulation of Reacting Flows and Combustion
Knowledge of the underlying combustion chemistry and physics enables designers of gas turbines, boilers and internal combustion engines to increase energy efficiency and fuel flexibility, while reducing emissions. Combustion System couples multiphysics simulations incorporating accurate physical models with an advanced chemistry solver to provide a complete end-to-end combustion chemistry simulation capability to optimize products that involve reacting flow.
Read more... Fuel Injectors and Spray CFD Simulation
CFD software such as MSC Cradle, AVL Fire, Siemens Star-ccm+, Ansys Fluent and Converge is well equipped to simulate fuel injectors and spray processes including liquid atomization, drop breakup, collision and coalescence, turbulent dispersion, spray cavitation, drop-wall interaction, and drop evaporation.
Read more... CFD Simulation of Engine Exhaust Aftertreatment
Aftertreatment systems are a critical component to ensure emissions from engines and power generation equipment comply with environmental standards. CFD (computational fluid dynamics) simulations can be used as part of a rapid prototyping process to design systems that reduce NOx, CO, and particulate matter emissions with minimal efficiency and maintenance costs. Two of the main challenges in aftertreatment system design are maximizing the uniformity of flows upstream of catalysts and eliminating areas at risk for urea deposition.
Read more... 1D/3D Coupled Simulation and Co-Simulation: Detailed Chemistry & Multiphase Flow Modeling with 1D Modeling
Enteknograte engineering team use advantage of CFD solver’s detailed chemistry, multiphase flow modeling, and other powerful features in coupling and co-simulation of CFD (Siemens Star-ccm+, AVL Fire, Ansys Fluent, Converge), 1D systems softwares (Matlab simulink, GT-Suite, Ricardo Wave allowing 1D/3D-coupled analyses to be performed effortlessly) and FEA software (Abaqus, Ansys, Nastran) for engine cylinder coupling, exhaust aftertreatment coupling, and fluid-structure interaction coupling simulation.
Read more... Full Vehicle MultiBody Dynamics Simulation: Car Ride, Driveline, Engine and Tire MBD
With MultiBody Dynamic Simulation, you can perform various analyses on the vehicle to test the design of the different subsystems and see how they influence the overall vehicle dynamics. This includes both on- and off-road vehicles such as cars, trucks, motorcycles, buses, and land machinery. Typical full vehicle analysis includes handling, ride, driveline, comfort, and NVH. Automotive models are also used for Realtime applications (HiL, SiL, and MiL). We can also examine the influence of component modifications, including changes in spring rates, damper rates, bushing rates, and anti-roll bar rates, on the vehicle dynamics.
Read more... Multibody Dynamics & NVH (Noise, vibration, and harshness)
Noise, vibration, and harshness (NVH) are critical factors in the performance of many mechanical designs but designing for optimum NVH can be difficult. While strength and durability limits are being pushed further and further, requirements for noise reduction are becoming more stringent. In addition, focus is increasingly being placed on transmission and powertrain noise because other sources could be reduced meanwhile.
Read more... FEA Based Simulation of Rubber Matrix Composite: Tires, anti-vibration systems, seals or hoses
Tires, anti-vibration systems, seals or hoses are rubber based components which turn into high-tech systems as soon as their material properties are tuned by embedded inclusions. A simple tire unfolds its performance due to influences from various scales. On the microscopic scale carbon black or mica particles are filled into the rubber matrix to compound materials with specific properties. On the belt edge a sophisticated weave of embedded steel fibers controls the footprint of the tire.
Read more... NVH & Acoustics for Hybrid & Electric Vehicles
In NVH Engineering and simulation of Hybrid/Electric Vehicles, the noise from tire, wind or auxiliaries, which consequently become increasingly audible due to the removal of the broadband engine masking sound, should be studied. New noise sources like tonal sounds emerge from the electro-mechanical drive systems and often have, despite their low overall noise levels, a high annoyance rating. Engine/exhaust sounds are often used to contribute to the “character” of the vehicle leads to an open question how to realize an appealing brand sound with EV.
Read more... Noise, Vibration & Harshness – NVH for Electric Motors
To optimize for NVH, our engineers use the forces from the EM analysis to perform advanced vibro-acoustic simulations. The forces are mapped to evaluate the structural dynamics response of the motor.
Modal and harmonic stress coupling responses are important for simulating the NVH of an electric motor and for proper vibro-acoustic design of electric vehicles (EVs). The harmonic analyses generate absolute magnitudes of vibrations and waterfall diagrams to get a complete picture of the motor’s acoustic profile.
Read more... Electric Motors Cooling
Coupled Electromagnetic Solver with Finite Element & CFD Based Multiphysics simulation
Our FEA and CFD based multiphysics simulation design provides electronics cooling simulation products for chip, package and board thermal analysis as well as thermo-mechanical stress analysis. Multiphysics simulation tools help our customers to enhance reliability of the entire electronic system by managing excessive heat that can otherwise lead to increasing leakage and electromigration failure. Electric motors cooling becomes critical as we want to move to higher power, high-efficiency equipment.
Read more... FEA Based Composite Material Design and Optimization
Fatigue, Fracture, Impact, Crash, Acoustics and Vibration with Abaqus, Ansys, COMSOL and LS-DYNA
Finite Element Method and in general view, Simulation Driven Design is an efficient tool for development and simulation of Composite material models of Polymer Matrix Composites, Metal Matrix Composites, Ceramic Matrix Composites, Nanocomposite, Rubber and Elastomer Composites, woven Composite, honeycomb cores, reinforced concrete, soil, bones ,Discontinuous Fiber, UD Composit and various other heterogeneous materials.
Read more... Passenger’s Thermal and Acoustic Comfort
The passenger’s thermal and acoustic comfort is an essential design-criterion for the air-conditioning and customization of a cabin. In industry, engineers conduct costly and time-consuming test series with specifically built cabin mock-ups to obtain some information about the expected passenger’s sensation of comfort already in the design process.
Read more... Race Car Aerodynamic Simulation and Optimization via CFD
We provide Engineering Analysis of fluid flow over a body, wing or component with Star-ccm+ and Ansys Fluent. We can work from a drawing, CAD file or can scan the geometry of your car or component. A standard analysis includes a report including the following information: Drag Force, Down Force, Drag Coefficient, Pressure Coefficient, Pressure Contour Plot, Velocity Contour and Velocity Streamlines.
Read more... Vehicle Thermal Management Simulation
We analyze system-level thermal management of vehicle component, including underhood, underbody and brake systems, and design for heat shields, electronics cooling, HVAC, hybrid systems and human thermal comfort and covers a wide range of Industries.
Read more... Innovative Design and Virtual Test
- Engine Simulation Technologies including steady-state, semi-anechoic and highly-dynamic Simulation beds with road-load simulation and constant-volume sampler systems
- Base engine Simulation beds adapted to address project requirements –include specialist capabilities such as ’tilt’ where engines may be subjected to dynamic and static inclination in loaded and unloaded conditions
- Performance and emission Simulation using the latest advanced tools and techniques including automated mapping and design of experiments
- For driveline and transmission Simulation, we provide two- and four-wheel drive fully dynamic electrical rigs; an anechoic Simulation chamber; and gearshift Durability, functionality and lubrication development rigs
- Chassis dynamometers covering a range of FEA and CFD simulation from emission and durability to noise, vibration and harshness (NVH), addressing applications including motorcycles, scooters and small commercial vehicles
- Rig systems to support development on components and sub-assemblies
- Particle size and number measurement
- After-treatment and fuels and lubricants Simulation
- Training and support for clients’ Simulation engineering teams.
Battery Thermal Management: Simulation Based Design
Safe, efficient, and cost-effective designs of Electric Vehicles (EVs) batteries become more important. Lithium-ion batteries are the mainstream battery solution for today’s EVs but are sensitive to their operational thermal conditions. Therefore, thermal simulation of these battery packs is paramount in the designing phase, which includes consideration of heat production by battery electro-chemistry, internal resistivity and cooling, EV cooling system, etc.
Read more... Underbody & Underhood Simulation for Thermal Management
An underbody/underhood and exhaust system modeling effort is a complex thermal management challenge, but Enteknograte engineering team uses MSC Cradle, Ansys Fluent and Siemens Star CCM+ in coupled with Structural Solvers(Abaqus, LS-Dyna, Ansys, MSC MARC) to solve this issue daily. Our team establishes an efficient process for modeling the exhaust system in a realistic, time-dependent environment. CFD and FEA simulation of the systems, allows our team to make design changes to protect unwanted thermal load on critical components. This could reduce overall vehicle development costs, reduce your testing expenses.
Read more... Audio Device Design: Acoustic simulation for Sound Quality Analysis in Consumer Electronic Devices
When designing an audio device, the most important thing for an engineer to consider is the quality of the sound. From loudspeakers to headsets, from hearing-aid devices to digital cameras the sound quality is of primary importance and shall be carefully evaluated while designing such applications. A set of predictive numerical tools are thus needed to efficiently design consumer audio appliance.
Enteknograte engineering team provides predictive simulation consultant and models to assess the vibro-acoustic performance of audio devices such as loudspeakers or headsets.
Read more... AeroAcoustics and VibroAcoustics in Automotive Industry
Even low noise levels can significantly degrade the comfort for the user. AeroAcoustics help us to predict and understand how to design quiet workplaces, quiet car and aircraft interiors, or silent electronic devices. In the next level, in order to study the interaction of structural vibration with the adjacent fluid, it is necessary to model the acoustic behavior of the involved structural components and VibroAcoustics aspects.
Read more... Finite Element Analysis of Durability and Fatigue Life
Vibration Fatigue, Creep, Welded Structures Fatigue, Elastomer and Composite Fatigue with Ansys Ncode, Simulia FE-Safe, MSC CAEFatigue, FEMFAT
Durability often dominates development agendas, and empirical evaluation is by its nature time-consuming and costly. Simulation provides a strategic approach to managing risk and cost by enabling design concepts or design changes to be studied before investment in physical evaluation. The industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life and FEMFAT used to calculate fatigue life of multiaxial, welds, short-fibre composite, vibration, crack growth, thermo-mechanical fatigue.
Read more... Vibration Fatigue Finite Element Simulation: Time & Frequency Domain
Structural vibration can be a source for many product related problems; it can cause fatigue and durability problems as well as adverse reactions to the user or bystanders in the form of undesirable vibrations that can be felt or heard. As well, undesired structural vibrations can prevent products from operating as required and potentially becoming a safety concern. The Vibration Fatigue simulation predict fatigue in the frequency domain and it is more realistic and efficient than time-domain analysis for many applications with random loading such as wind and wave loads.
Read more... Casting: Finite Element and CFD Simulation Based Design
Using Sophisticated FEA and CFD technologies, Enteknograte Engineers can predict deformations and residual stresses and can also address more specific processes like investment casting, semi-solid modeling, core blowing, centrifugal casting, Gravity Casting (Sand / Permanent Mold / Tilt Pouring), Low Pressure Die Casting (LPDC), High Pressure Die Casting (HPDC), Centrifugal Casting and the continuous casting process. The metal casting simulation using FEA and CFD based technologies, enable us to address residual stresses, part distortion, microstructure, mechanical properties and defect detection.
Read more... Additive Manufacturing and 3D Printing
FEA Based Design and Optimization with Simufact, Abaqus, ANSYS and MSC Apex for powder bed fusion (PBF), directed energy deposition (DED) and binder jetting processes
With additive manufacturing, the design is not constrained by traditional manufacturing requirements and specific number of design parameters. Nonparametric optimization with new technologies such as Artificial Intelligence in coupled with Finite Element method, can be used to produce functional designs with the least amount of material. Additive manufacturing simulations are key in assessing a finished part’s quality. Here at Eneteknograte, dependent of the problem detail, we use advanced tools such as MSC Apex Generative Design, Simufact Additive, Digimat, Abaqus and Ansys.
Read more... Finite Element Welding Simulation: RSW, FSW, Arc, Electron and Laser Beam Welding
Enteknograte engineers simulate the Welding with innovative CAE and virtual prototyping available in the non-linear structural codes such as LS-DYNA, Ansys, Comsol, Simufact Welding, ESI SysWeld and ABAQUS. The Finite element analysis of welding include Arc Welding, laser Beam Welding, RSW, FSW and transfer the results of welding simulation for next simulation like NVH, Crash test, Tension, Compression and shear test and fatigue simulation. We can develop special purpose user subroutine (UMAT) based on clients need to empower simulation environment to overcome any complicated problem in heat load condition, phase change and user defined material constitutive equation.
Read more... Seat Design: Finite Element and CFD Simulation for Static & Dynamic Comfort, Whiplash, Acoustic & Thermal Comfort, Crash Test
Simulation Based Design can help us to ensure the right occupant posture, which is essential for safety, Static and Dynamic Comfort, for example by predicting the H-Point and incorporating whiplash, thermal and Acoustic comfort simulation. The ability to predict the comfort of innovative seat designs using simulation tools, a library of human models with our team experience in CFD (Siemens Start-ccm+, Ansys Fluent and OpenFoam) and FEA (Ansys LS-DYNA, Simulia Abaqus, ESI Pam-Crash and Altair RADIOSS) simulation software with integrated Artificial Intelligence and Machine Learning for innovative design, can help manufacturers to create seats that provide a superior driving experience for their customers.
Read more... Hydrodynamics: Coupled CFD and FEA Simulation for FSI Analysis
System properties such as mass flow rates and pressure drops and fluid dynamic forces such as lift, drag and pitching moment can be readily calculated in addition to the wake effects. This data can be used directly for design purposes or as in input to a detailed stress analysis. Coupling Hydrodynamic CFD Simulation in Ansys Fluent, Siemens Star-ccm+ and MSC Cradle with structural finite element solver such as Abaqus and Ansys, enable us to Simulate most complicated industrial problem such as Cavitation, Vibration and Fatigue induced by hydrodynamics fluctuation, Transient Resistance, Propulsion, considering two way FSI (Fluid Structure Interaction) coupling technology.
Read more... Metal Forming Simulation: FEA Based Design and Optimization
Using advanced Metal Forming Simulation methodology and FEA tools such as Ansys, Simufact Forming, Autoform, FTI Forming, Ls-dyna and Abaqus for any bulk material forming deformation, combining with experience and development have made Enteknograte the most reliable consultant partner for large material deformation simulation: Closed die forging
Open die forging processes such as cogging, saddling, and other GFM, processes
Rolling for long products,
Extrusion,
Ring Rolling,
Cross Wedge Rolling and Reducer Rolling for pre-forming
Cold forming,
Sheet metal forming.
Read more... Electromagnetic Multiphysics
FEA & CFD Based Simulation Including Thermal Stress, Fatigue, and Noise, Vibration & Harshness – NVH for Electric Motors
Enteknograte Finite Element Electromagnetic Field simulation solution which uses the highly accurate finite element solvers and methods such as Ansys Maxwell, Simulia Opera, Simulia CST, JMAG, Cedrat FLUX, Siemens MAGNET and COMSOL to solve static, frequency-domain, and time-varying electromagnetic and electric fields includes a wide range of solution types for a complete design flow for your electromagnetic and electromechanical devices in different industries.
Read more... Integrated Artificial Intelligence (AI) & Machine Learning - Deep Learning with CFD & FEA Simulation
Machine learning is a method of data analysis that automates analytical model building. It is a branch of Artificial Intelligence based on the idea that systems can learn from data, identify patterns and make decisions with minimal human intervention. With Artificial Intelligence (AI) applications in CAE, that is Mechanical Engineering and FEA and CFD Simulations as design tools, our CAE engineers evaluate the possible changes (and limits) coming from Machine learning, whether Deep Learning (DL), or Support vector machine (SVM) or even Genetic algorithms to specify definitive influence in some optimization problems and the solution of complex systems.
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