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Not only for Gear Design Optimization specialists For the literal among you, gear grinding is the process of abrading a gear surface to give it its final shape and polish. However, it is also a common expansion to express annoyance at something, i.e., Do you know what grinds gears? X, Y, and Z but not necessarily in that order. Extremely repetitive processes that are easy to make mistakes during, grind our gears. This is especially true when we know a computer could do it in a flash if only I had the code to do it. As a very infrequent coder there is always the urge to code something, but cleaning up buggy code will likely take longer to fix than it would have taken to do the original task. So, it is only worthwhile if the code is likely to get used somewhat regularly. Consider macro and micro geometries Therefore, we sympathize with gear specialists who may face both the literal and metaphorical incarnation of this expression. When developing a transmission, you may need to optimize it for NVH, durability, efficiency, or a combination. To do this, you need to consider both the macro and micro geometry of the gear pairs. In a case with just two gear pairs, there will be approximately 40 design variables, and several objective functions for the microgeometry, plus several more objectives with multiple constraints for the macrogeometry. Code that works As described, setting up a test that looked at two gear sets in mesh could take an experienced engineer weeks. However, you could reduce this to days if you were fortunate enough to be in a company that already has and does a good job of maintaining a script that evaluates gear key performance indicators. Much time is spent by gear specialists on repetitive workflows or maintaining code at much expense to their companies. This is why Simcenter 3D Motion has developed the Simcenter 3D Motion Gear Design Optimization Software, released as part of the Simcenter Mechanical Solution 2412 release. Simcenter 3D Motion Gear Design Optimization This new tool removes the need for coding and maintaining internal scripts. Simcenter 3D Motion Gear Design Optimization enables you to fine-tune the micro geometry of gear faces. Furthermore, it works with Simcenter 3D Motion Transmission builder and HEEDS in an intuitive workflow to optimize your macro and micro gear geometries to ensure a fully optimized design. Do not pass Meshing, Do not collect a designer, Go straight to gear design optimization. Those of you who have had the pleasure of rapidly developing gear systems using Simcenter 3D Motion Transmission builder will know that you can use its wizard to select your required gear parameters and generate a model without having to produce any CAD yourself. You will also see your model generated in Simcenter 3D , where you were able to conduct simulations and test your designs. You may even have included HEEDS in your workflow to optimize your design. With the New Simcenter 3D Motion Gear Design Optimization tool, you follow the same steps to produce your initial macro and micro geometry as Simcenter 3D Motion Transmission builder. But now, with the addition of the new tool, you can also optimize the design using HEEDS and evaluate non-motion Key performance indicators such as efficiency and durability. The new workflow Start in Simcenter 3D Motion Transmission Builder. As you did previously, you start by defining your baseline layout using the Simcenter Motion Transmission builder wizard to parameterize the shaft, gears, and bearings from the selection menus. Once you have your gears defined, you can define/ choose your meshing pairs. Flanks can be either predefined by common standards or loaded from a CSV file to provide your own initial design. Note that if you are planning to complete an optimization using HEEDS , this initial input is only used for the baseline; HEEDS will alter it. To control the level of detail at the contact location, you define the number of gear slices. Where, the number of slices can be set to create imaginary gear layers in a sandwich-like fashion. Once your initial parameters are set, you can generate a model for the entire gear set with just one button. You can watch the model materialize as you watch in Simcenter 3D . The level of fidelity for Gear contact and bearing analysis can also be defined in the transmission builder tool and exported directly into your Simcenter 3D model by simply clicking ‘export all elements.’ Drivers and load cases can now be added, which is done in the Simcenter 3D Motion application. While the user does this, the total time to complete this task is measured in seconds. Now is a good time to create a solution and run the solver to check your setup. Once complete, you should review the outputs and results. Finding any errors in your setup at this stage will prevent you from wasting a lot of time later. Setup Simcenter 3D Motion Gear Design Optimizationn You can load the Simcenter 3D Motion Transmission builder and Simcenter 3D Motion files in the new wizard menu screen. Suppose you wish to optimize the durability of your gear set. In that case, you start by choosing the macro geometry features you want to include and setting your durability test by defining the speed, torque, and required life. Further parameters for this test are also needed, such as the material that can be selected from a menu and the microgeometry convention you wish to follow. Finally, you choose your desired post-processing, select the bearings you want, and set the optimization parameters. Start the design of experiments (DOE) study for your gear design optimization While you are still in the Simcenter 3D Motion Gear Design Optimization tool, initialize the calculation modules to compute the baseline model. This confirms that the model will run in HEEDS and provides HEEDS with the baseline result from which it needs to start. Now, when you open your project in HEEDS , you will find that over 70 design variables for the macro and microgeometry have already been created for cases with just two gear pairs. You will also find that all your output responses have been made, saving you considerable time. All that is left is to set the output responses you want to consider for the objective function and the constraints. You can also set the range to the input parameters if you want to. Getting a gear design optimization result Now, you can run the full DOE in HEEDS and, finally, post-process the results in HEEDS . Conclusion The New Simcenter 3D Motion Gear Design Optimization tool builds on the existing capabilities of the Simcenter Motion 3D Transmission builder with new capabilities that allow you to optimize your design using the power of HEEDS and evaluate non-multibody key performance indicators such as efficiency and durability. You can now develop designs you may never have conceived in a time frame you would have never thought possible in a general-purpose simulation tool. Schedule a meeting with CAEXPERTS and learn how to optimize your gear design with Simcenter 3D Motion Gear Design Optimization ! Reduce time, eliminate rework, and take your designs to a new level of efficiency. Talk to our experts today! WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

After successfully using Simcenter 3D Smart Virtual Sensing to predict loads for strength and fatigue analysis by combining testing and simulation, the well-integrated workflow optimized the efficiency of the entire team. This approach also included the possibility of “measuring the unmeasurable” on a larger scale. Challenges in durability analysis When analyzing potential damage under all possible load scenarios to validate a design, it is essential to obtain accurate data on operational loads. For those who are not experts in durability analysis, designing and validating mechanical structures under static and dynamic loads can be challenging, especially when trying to include operational loads in the study. With smart virtual sensing, operational loads can be obtained for durability analysis. The resulting information on remaining service life is extremely valuable. Despite the specialized tools available for detailed analysis, there is also a need for simpler and more integrated methods for everyday use. The old problem Traditionally, strain gauges are installed on prototypes to perform durability and validation testing. The big challenge is not that critical damage often occurs in areas where it is difficult or impossible to obtain direct formation effects due to geometry limitations. A new approach For load prediction, Simcenter 3D Smart Virtual Sensing can use just a few strain gauges in easily accessible locations to predict operational loads. The question was: could this approach be used continuously to measure unmeasurable loads and predict structural failures? Simcenter 3D Smart Virtual Sensing 2412 is dynamic and has a new feature – the Virtual Damage Sensor . This feature improves structural failure detection, providing a practical solution to a recurring problem. Solution Implementation With the Smart Virtual Damage Sensor solution, strain gauges can be placed in accessible locations to provide the smart virtual sensing tool with the necessary data. This enables data fusion between the physical measurement and the FE model, providing measurements in locations that are difficult to physically measure. Virtual sensors provide detailed results, including strain, stress, velocity, and displacement. In addition, the newly added virtual sensors integrate virtual sensing with durability analysis to provide important damage information, such as remaining service life, accumulated damage history, and damage increments. When combined, these results provide insights into the durability of the structure, indicating when damage is likely to occur and how much useful life is left. The workflow The process for implementing this solution follows these steps: Step 1: Use Simcenter 3D Smart Virtual Sensing Optimal Sensor Placement to determine where to place the physical strain gauges Parallel instrumentation with Simcenter SCADAS RS Step 2: Perform physical testing using Simcenter SCADAS and obtain strain measurements with operational loads. Step 3: Predict operational loads by feeding the measurements and the reduced-order finite element model into Simcenter 3D Smart Virtual Sensing . Step 4: Complete the durability study in Specialist Durability by connecting it to the Smart Virtual Sensing events. Step 5: Perform a durability study and figure out where the potential damage area is. (Step 4 and 5 are a recommended but optional way to find the critical areas). Step 6: Put virtual damage sensors on the potential damage area and run the smart virtual sensing solution to get damage information in the selected locations   The results With this workflow, data on remaining useful life, accumulated damage history, and damage increments can be obtained, allowing for more accurate analysis of the root cause of damage. By following this process, structural damage analysis becomes more efficient and reliable. The Smart Virtual Damage Sensor is a valuable tool for design and validation, offering a practical way to measure damage and assess remaining service life at critical locations. In addition, by making the Virtual Damage Sensor a real-time solution, it is also possible to implement predictive maintenance. This allows potential problems to be identified before they occur, avoiding costly downtime. Optimizing maintenance task scheduling can reduce large safety factors typically included in worst-case scenarios, making structural engineering more accurate and cost-effective. Schedule a meeting with CAEXPERTS and find out how the Simcenter 3D Virtual Damage Sensor can transform your durability analysis, making it more accurate and efficient. Talk to our experts and take your structural engineering to the next level! WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

Don’t try this at home – unless you’re simulating it! Thermal Runaway: a recap Thermal runaway of batteries is a dangerous phenomenon where the battery cell overheats uncontrollably. A self-sustaining feedback loop occurs where the battery receives a certain amount of heating, and if left unaddressed, this in turn triggers a series of chemical reactions inside the battery cell. These reactions release even more heat and gases, which can result in huge pressure build up inside the battery. Extremely hot (over 1000oC!) and combustible venting gases are then emitted from the battery cell. When these gases ignite, fire spreads to other battery cells and catastrophic damage can occur to an electric vehicle, property and of course presents a high risk to life. Look at this short video which shows the violent nature of a thermal runaway event: It should be clear that these scenarios should be avoided, and battery systems designed to ensure safe operation if a thermal runaway event occurs. Indeed there are now various national and international regulations that cell makers and electric vehicle manufacturers must adhere to. Time to test? – Accelerated rate calorimetry (ARC) The most intuitive way to understand the behavior of batteries as they undergo a thermal runaway event is to replicate the causes of thermal runaway and see how the battery behaves. In the case of overheating, a common methodology to understand the heat release of the battery is an accelerated rate calorimetry (“ARC”) test. These tests provide clear insights but come with some issues: primarily that the tests themselves are expensive, require access to test facilities and require a physical prototype of the battery cell! Of course, this is where simulation can fit in and allow for rapid design iterations early in the design cycle, with safety in mind. Simcenter STAR-CCM+ already has a wide range of models and functionalities for battery modelling and battery safety, from the 3D cell design right through to the full battery pack and thermal propagation during a runaway event: In version 2502, another layer of functionality will be added – most notably the ability to model detailed thermal runaway at the cellular level with the Homogeneous Multiphase Complex Chemistry (HMMC) model. Thermal runaway chemistry When we consider the inside of a battery cell then there are multiple solids (anode, cathode and separators), as well as liquid electrolyte. When thermal runaway reactions occur, these components can react and decompose to release flammable gases such as hydrogen and methane. This results in multiple phases all reacting with each other e.g multiphase. To capture this complexity, a framework has been developed in which the early stages of a thermal runaway event can be modeled with detailed chemical modeling. This allows designers to explicitly model the fundamental reactions that are triggered during a thermal runaway event. The reactions are considered as a homogeneous mixture, allowing for simple and easy setup in conjunction with our multiphase mixing model. Furthermore, this is all built on top of a proven complex chemistry solver, allowing reactions to be easily defined using standard chemkin file import and accounting for intra- and interphase reactions. This provides unique modeling functionality to deeply understand battery behavior. For example, one can directly configure reactions for SEI decomposition/production, conductive salt decomposition, hydrogen fluoride production, and cathode decomposition; see the example of imported reactions for thermal runaway testing above. Let’s get cookin’ – Heat-Wait-Seek Armed with a new modelling tool, let’s apply it to the simulation of an ARC test and see how it performs. The ARC test involves an initial period of heating the battery called Heat-Wait-Seek (HWS) where the battery is gradually heated before waiting to see if exothermic reactions begin. When those reactions begin, no more heat is applied to the battery, and it is left to continue reacting / self-heating until the onset of thermal runaway. Unveiling the interaction of reactions and phase transition during thermal abuse of Li-ion batteries https://doi.org/10.1016/j.jpowsour.2021.230881 One great thing about having this physics functionality inside Simcenter STAR-CCM+ is that it can leverage the automation capabilities. The ARC testing process can be easily implemented using Simulation Operations and Stages without any scripting. And the results are excellent: As can be seen, the new HMMC model can accurately capture the onset of both the exothermic reaction and thermal runaway. Being able to accurately capture this behavior allows for effective countermeasures or mitigation strategies such as heat shields to be implemented by engineers much earlier in the design process in a safe and cost-effective manner. For example, the predicted heat generation from this simulation can be used as an accurately calculated heat source directly in a larger pack level model, or the predicted vent gas compositions used for a further combustion analysis. An excellent example of how simulation is vital in the battery design cycle. Schedule a meeting with CAEXPERTS and find out how we can help your team design safer, more efficient battery systems using advanced simulation to predict and mitigate thermal runaway events. Contact us now and take your innovation to the next level! WhatsApp: +55 (48) 98814-4798 E-mail: contato@caexperts.com.br

Find out why CAEXPERTS is the best technological partner to boost your company's competitiveness and innovative potential. Advanced Engineering; Digital Twins; Knowledge Transfer; Assertive Solutions; Cost Reduction; R&D and Innovation Contact us Find out why CAEXPERTS and the best solution for your company's engineering to go even further. Whatsapp WhatsApp: +55 (48) 98814-4798 Schedule an online meeting E-mail: contato@caexperts.com.br Name Last name Email Telephone Company Subject Write your message... To send Thank you for contacting us

CAEXPERTS brings together an experienced and multidisciplinary team of CAE experts, prepared to deliver advanced engineering and computational simulation at different scales and levels of maturity. We use high-performance hardware and software resources that are scalable in the cloud. SIMULATION SPECIALISTS We are a team prepared to deliver results , innovation and competitiveness . Resquest for Quotation Areas of expertise Advanced Engineering Digital Twins Knowledge Transfer Assertive Solutions Cost Reduction R&D and Innovation Digitization of Engineering With the advancement of globalization and technological competitiveness, products and their manufacturing processes are increasingly complex , with more restricted life cycles . In response to this, vanguard companies use computer simulation to virtually test their projects, concepts, inventions, products, equipment and processes, in the most critical scenarios, seeking to always be ahead and go even further. SIEMENS Digital Industries takes this seriously and brings the broadest range of software tools for digitization and computer-aided engineering to the market . Know the Tools Discover the Disciplines Why CAEXPERTS CAE implementation As official resellers of SIEMENS Digital Industries software, we help your company build a high-performance CAE team for your engineering, combined with the ideal simulation tools in conjunction with our technical team, so that your production generates assertive results in an intelligent and fast way. We are simulation experts and know how industries can obtain a high return on their CAE investments. Engineering Services We help industries increase their competitiveness and raise their level of innovation. We work with projects and consultancy for the development of products and equipment, as well as conduct studies aimed at reducing Capital Costs and Operating Costs of industrial enterprises, owner engineering, R&D in industrial processes, integrity analyses and increased operational reliability of production assets. In addition, we are official resellers of Siemens software, which allows us to offer the best technological solutions to our customers. Conheça os nossos serviços Discover our Services Softwares ofertados Software Licensing 3D Multiphysics Simulation Simcenter 3D Star-CCM+ FloEFD Femap CAD Design Solid Edge NX 1D Systems Simulation Flomaster Amesim Electromagnetic Simulation and Design Magnet E-machine Design Speed HEEDS Optimization Learn more Why CAEXPERTS Professional Development: Program designed for engineers and professionals who want to master the use of computer simulation tools in real industry applications. Personalized: We work side by side, from the selection of relevant topics, the study of the state of the art, the scientific technical development stages, training until the completion of the project. Real Projects: The training is developed based on real industry challenges, providing applied and practical learning that prepares you for concrete challenges. Recognition: Master computer simulation in practice and become an expert valued by the industry. Discover our specialization program Areas of expertise ACOUSTICS ELECTROMAGNETIC COMPATIBILITY DESIGN OF ELECTRONICS CIRCUI S COMPUTATIONAL FLUID DYNAMICS THERMOFLUID DYNAMIC SYSTEMS WIRING AND WIRING HARNESS ELETRIC MACHINES STRUCTURAL ANALYSIS PROJECT OPTIMIZATION MATERIALS ENGINEERING ADDITIVE MANUFACTURING AUTOMATION Âncora 1 Know more Recent Posts 2 days ago 5 min read Case study: using Femap helps NASA develop next-generation space telescope Simulating the performance of James Webb Space Telescope components Challenges Design a next-generation space telescope Coordinate... Feb 12 3 min read Rapid axial-flux motor analysis – New in Simcenter E-Machine Design 2412 The analysis of an axial-flux machine requires three dimensions because of its inherent three-dimensional magnetic flux paths. Thus, to... Feb 5 7 min read What’s new in Simcenter FLOEFD 2412? CAD-embedded CFD simulation The new Simcenter FLOEFD 2412 software release is now available in all its CAD-embedded CFD versions, and... Jan 29 8 min read CFD for clean air 3 ways to fight contamination in public buildings, transportation and production facilities Until 2020 Computational Fluid Dynamics aka.... 1 2 3 4 5 See it all Let's start Get in touch and find out why CAEXPERTS and the best solution for your company's engineering to go even further. Name Last name Email enter a message I agree to receive information and news by email To send Thank you!

Acoustic simulations help analyze noise quality in designs, Productive tools for designing, refining and validating prototypes throughout the development cycle. Aeroacoustics; Boundary Element, Ray Acoustics, FEM/BEM solvers; acoustic modeling; 3D Meshing for Acoustics; SIMCENTER 3D; SIEMENS Specialization Program in CAE At CAEXPERTS, we understand that digitalization and computational simulation are a reality for the industry and in this context, training is essential to face real engineering challenges. The CAE Specialization Program was designed for professionals who seek to deepen their knowledge by applying computational simulation tools to solve real engineering challenges, ensuring that you or your team are prepared to transform ideas into solutions. Master computational simulation in practice and become an expert valued by the industry. Join Our CAE Specialization Program Fill in the details below and we will build this chapter together. Name E-mail Phone/WhatsApp Company Submit Thanks! We will be in touch soon. Why choose our Specialization Program? What will you learn? Who should participate? Personalized: we work side by side, from the selection of relevant topics, the study of the state of the art, the scientific technical development stages, training until the completion of the project. Technology: this program provides access to the best CAE software on the market and is focused on the efficient use of software applied to practical cases. Real Projects: the training is developed based on real industry challenges, providing applied and practical learning that prepares you for concrete challenges. Articles and Procedures: the combination of theory and practice culminates in the technical scientific production of materials based on practical experiences, creating a legacy of knowledge and documentation for the industry. Our program includes: Exploring Advanced Technologies: Stay up to date with the latest in software and engineering techniques. Solving Real Problems: Learn from projects inspired by challenges faced by real companies, ensuring direct and meaningful learning. Creating Specific Procedures: Develop procedures that can be immediately applied in your organization. Our program is ideal for: Engineers who want to improve their skills in computational engineering and the use of CAE software. Companies looking to empower their teams to deal with complex problems. CAEXPERTS Differentiators With an experienced team, we are experts in combining technology and practice to generate concrete results. Our support goes beyond training, offering consultancy and monitoring to ensure that you or your team reaches their maximum potential. How to register? Contact us to schedule a personalized conversation. We are ready to adapt the program to your needs and contribute to your success. ⇐ Back to Disciplines