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Area of expertise 02

FEM & CFD simulation

Simulate instead of trial and error: strength, deformation, natural frequencies, flow and heat are verified on the 3D model – before anything is manufactured.

Simulation of flow and heat dissipation in a device housing
Simulation of flow and heat dissipation in a device housing – each line is the path of the cooling air

Simulations replace costly manufacturing iterations. Forces and moments are applied as they act in operation – derived from the design, not estimated. The result is a release for manufacturing that is based on numbers: stresses, deformations, safety factors, temperatures.

Because design and simulation come from a single source, the results flow straight back into the model: material where it is needed, saved where it is not. Geometry adjustments shift natural frequencies out of the critical range, and flow paths are improved before a prototype is built.

fem · angle bracketequivalent stress

FEM · structural analysisA real 3D FE calculation of an angle bracket (F = 1 kN), first with tetrahedra, then with hexahedra (quads): linear tetrahedra are too stiff and show the peak 9 % lower. A larger radius lowers it by 48 % (deformation exaggerated).

cfd · wind tunnelcomputed live

shape
view
10.0 m/s · 36 km/h
1.225 kg/m³ · 0 m altitude

Drag the body with the mouse – or click it and use the arrow keys.Drag the body with your finger.

dragFD– mN/m

cD = – · mean – mN/m · last 10 s

liftFL– mN/m

cL = – · mean – mN/m · last 10 s

cylinder Ø 0.1 mm · forces per metre of span · Re = 68 · 2D

CFD · wind tunnelThe flow is computed live in your browser (lattice Boltzmann on a rectangular grid, 2D), true to scale for a cylinder of 0.1 mm diameter – about as thick as a hair. Move the body, change shape and view, set wind, air density (with altitude from the standard atmosphere) and, for the wing, the angle of attack: drag and lift follow immediately, in millinewtons per metre of span. Whether vortices separate depends on the Reynolds number Re = ρ·v·d/μ. If nothing is touched, the typical CFD mesh appears after 8 s: polyhedra with 12 fine prism layers (growth rate 1.2).

Scope of services

Structural analysis (FEM)

Stresses, deformations and safety factors of highly loaded structures. Components are dimensioned precisely and operational strength is verified before manufacturing.

Natural frequencies & vibration

Modal analysis of components and assemblies. Frequency ranges are shifted by adapting the geometry so that nothing vibrates or fatigues in service.

Flow simulation (CFD)

Air and fluid flows in housings, devices and plants: vortices, dead zones and bottlenecks become visible – and the flow path is improved before a prototype is built.

Heat & cooling

Combined simulation of heat and air flows shows which temperatures occur in operation – and whether the cooling is sufficient.

Dynamics & crash

Time-dependent processes, impact and crash with LS-Dyna – when static analysis is not enough.

Calculation & dimensioning

Analytical dimensioning and verification with MathCAD – traceably documented, as a supplement or cross-check to the simulation.

How we work

  1. Question & loadsWhat should the simulation answer? Load cases and boundary conditions are derived from the design.
  2. Model & meshThe 3D model is prepared for calculation: sensibly simplified, meshed, assigned materials and boundary conditions.
  3. CalculationFEM with Nastran, CFD with Ansys Fluent, dynamics and crash with LS-Dyna.
  4. EvaluationStresses, deformations, temperatures, flow images – assessed against your requirements and safety factors.
  5. Back into the designChanges are implemented directly in the model and recalculated if necessary – until release.

Tools

The right program for every task – the models come straight from the design.

  • Nastran FEM
  • Ansys Fluent CFD
  • LS-Dyna dynamics & crash
  • MathCAD calculation
  • Inventor 3D models

What you get

  • Report with load assumptions, boundary conditions, results and assessment
  • Stress, deformation and temperature plots – as animations on request
  • Safety factors and a clear release recommendation
  • Design change proposals – implemented directly in the model on request

Examples from our projects

Flow field – simulation of the air flowFlow fieldFlow made visible · CFDStructural analysis – loading of a structure, the colour scale shows the stressLoads made visibleStructural analysis · FEM

Frequently asked questions

Do we need a 3D model?

Not necessarily. If you have a model, we use it – as a native file or as STEP. Otherwise we build it from your drawings or sketches.

What is the difference between FEM and CFD?

FEM (finite element method) calculates the structure: stresses, deformations, natural frequencies. CFD (computational fluid dynamics) calculates the flow of air or liquids and heat transfer. The two often go together – for example when a housing has to be cooled and stiff at the same time.

Can we commission the simulation alone?

Yes. Simulation is available as a stand-alone service for your design – or as part of a design carried out by us.

Other areas of expertise

From Pforzheim for clients throughout Germany – with on-site meetings as well as installation and assembly support. More about the region