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Success Stories

  • Implementing Rules-Based Simulation Automation for Democratizing Automotive Wheel Design

    CAE Engineers Tim Hood and Jeromy Elder present the Goal, Challenges and Successes of Democratizing Simulation at Superior Industries.

    Solution Providers:

    Comet Solutions

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    Implementation Goals:

    Reduce the time required to clean up CAD geometry and generate a precise FEA mesh based on known criteria. The current average time for geometry cleanup and mesh creation is more than eight hours. For complex asymmetric wheels, this time can be sixteen hours. It is desired to reduce this time to less than four hours

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  • Wind ITO Fulfillment Center: Capturing Proprietary Processes for Wind Farm Siting Analysis

    Democratizing Simulation at General Electric Global and General Electric Renewables wind farm engineering.

    Solution Providers:

    View Summary

    Program Advantages:

    – Automates multiple sequential or parallel siting analyses, where each analysis may itself execute multiple steps.

    – Provides the flexibility to define the workflow and the set of steps that form the analysis, as well as the dependencies among them.

    – Serves as a corporate knowledge base while providing automated reporting & searching of previous analyses.

    – Provides the same simplified user experience and global access to the entire wind farm engineering team and the sales organization

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  • Analysis Template Development at NASA Langley

    Achieving safe, robust, and feasible Democratization at NASA Langley Research Center.

    Solution Providers:

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    From the CAASE 18 conference, this presentation outlines NASA Langley’s Democratized Simulation implementation and how challenges were overcome with intelligent templates.

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  • GKN Driveline: Propshaft Analysis

    Implementing and leveraging Democratized Simulation at GKN Driveline delivers big results.

    Solution Providers:

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    Presented at CAASE 18, this presentation outlines the challenges and benefits of Democratized Simulation as implemented by GKN Driveline. The presentation compares and contrasts traditional analysis methods with Democratized Simulation.

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  • Semiconductor Optimization at First Solar Achieved through Democratization

    By using high performance computing to process these large data models, First Solar is able to continue innovating in advanced technologies that lower electric costs, increase energy yield and provide stable and reliable grid integration. Through First Solar’s research and development, their large-scale solar farms can deliver energy to utilities at prices that are lower than fossil fuels.

    Solution Providers:

    awesim

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    With more than 13.5 gigawatts sold worldwide, enough to power more than 2 million homes, First Solar is a globar leader in photovoltaic solar energy solutions. The performance of
    semiconductor devices such as solar cells depends strongly on the properties of materials used in their fabrication. Deep understanding of these properties and the ability to tune them is
    critical for the development of new generations of advanced photovoltaics and electronics. First Solar, the world’s largest manufacturer of thin-film solar panels, is using AweSim resources from the Ohio Supercomputer Center (OSC), to predict and optimize semiconductor properties in crystalline
    structures such as cadmium telluride (CdTe). Although the efficiency of commercial CdTe photovoltaic material has grown dramatically in recent years, the advances in performance and stability of CdTe devices are achieved mostly through costly experimentation and process development while lacking theoretical guidance.

    Through First Solar’s research and development, their large-scale solar farms can deliver energy to utilities at prices that are lower than fossil fuels.

    Published in 2016

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  • Democratization at Jeco Plastic Products Lands New Opportunities

    Jeco Plastic Products is a small custom-mold manufacturer of high-tolerance products with a customer base that includes large U.S. and
    international original equipment manufacturers (OEMs) in the automotive, aerospace, printing and defense industries. When faced with a very difficult situation in its ability to quickly change a product design for a major large German automotive OEM, Jeco needed to upgrade its modeling and simulation from tedious physical testing to a quicker, HPC-based strategy.

    Solution Providers:

    awesim

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    Though it took a frightening situation to spur Jeco Plastic Products to jump into HPC, the company has now demonstrated its ability to use HPC modeling and simulation, which has helped pave the way for lucrative projects with major aerospace, automotive and joint product development projects. Those projects include a multi-year contract with annual orders of $2.5 million during the next five to 10 years along with 15 more jobs and a capital investment of more than $500,000.

    Published in 2012

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  • NASCAR Models Aerodynamics to Boost Safety and Performance

    Drive a car not originally built for racing around an oval track at 200 mph for a couple hours and you begin to understand why stock car drivers want the latest and greatest information on how their car will handle in close traffic on a banked curve. Traditionally, engineers in NASCAR relied on wind-tunnel and track testing. But in recent
    years, NASCAR began looking for an alternative.

    Solution Providers:

    TotalSim

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    In 2012, NASCAR turned to TotalSim USA, an engineering services provider and stalwart AweSim partner, to help teams and drivers
    leverage the valuable information computational fluid dynamics (CFD) can offer. TotalSim worked with Eric Jacuzzi, aerodynamics and vehicle performance engineer at the R&D Center for
    NASCAR, to teach him the necessary software tools and Ohio Supercomputer Center usage.

    Published in 2015

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  • Clippard Avoids Manufacturing Process Defect with Democratization

    Clippard Instrument Laboratory, a community-oriented company near Cincinnati, specializes in miniature pneumatics. So, when the team encountered a proportional valve that was not delivering consistent performance, they knew they needed to take a closer look at the valve components and design.

    Solution Providers:

    awesim

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    Thanks to the results provided through modeling and simulation and a quick turnaround, the Clippard team was able to make changes in their computer translation to correct the issue and manufacture a better product. Since the valve solution, Clippard has developed new methods to measure their material surface, improving processes from initial computational design to the finished product. According to Robertson, modeling and simulation has saved the team valuable time and resources.

    Published in 2016

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  • Rapid Concept Engineering at The Aerospace Corp.

    In this article, published in 2012 as an MSC Partner Showcase, Don Tolle, now at CIMdata, describes how Comet’s Intelligent Templates are used at the Aerospace Corp., to rapidly perform STOP (integrated Structural/Thermal/Optics) analysis using the platform’s Abstract Modeling techniques.

    Solution Providers:

    View Summary

    The long desired goal of simulation driven design has been to enable engineering analysts to focus on achieving the product’s functional requirements starting early in the R&D cycle. By putting simulation analysts in control of the “engineering geometry” starting at the conceptual design stage, reusing CAE best practices, and automating highly manual and repetitive

    design simulation tasks, performance simulation results can finally drive critical new product development decisions.

    As Dr. David Thomas (Engineering Team Lead, The Aerospace Corporation) commented, “The Comet-enabled integrated STOP process allowed our interdisciplinary engineering team to conduct an analysis that normally takes several days or weeks to perform to be completed in a single day. These savings are realized for each design cycle in the iterative process needed to converge to a satisfactory overall design for the IR telescope.”

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  • GDLS Achieves Early Simulation using Simulation Automation Platform

    In this 2008 case study whitepaper, Bruce Jenkins interviews senior engineer Mike Patterson at General Dynamics Land Systems, about their use of the Comet simulation automation and Abstract Modeling technology to bring simulation upfront.

    Solution Providers:

    View Summary

    How to bring simulation earlier in the product design process has been discussed for years but few have been able to overcome the technical and work-process barriers to doing so. General Dynamics Land Systems (GDLS) has launched a process where automation through templates with abstract modeling technology creates a seamless modeling/simulation process. By eliminating manual steps and allowing engineering and analysis processes to be built around an abstract model, this new process condenses project timelines – in a project piloting the new technology, extracting data from a CAD model and using it to populate an analysis database was slashed from an all-day job to just two hours. Even more, the new process makes it feasible to begin analysis early in design, while alternative geometries and product configurations are still being evaluated.

    Mike Patterson emphasizes how this rapid-response capability (based on Comet’s automation platform) promises to transform the role of simulation and analysis in product development, radically increasing the value it offers to a program. “We want to change analysis from a reactive process occurring late in development, to a proactive process used early and throughout design.”

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  • AAM Sees Dramatic Productivity Gains

    In this 2014 case study whitepaper, Bruce Jenkins of Ora Research interviewed the engineering team at AAM about their use of the simulation automation platform from Comet Solutions and the ROI they have measured.

    Solution Providers:

    View Summary

    American Axle & Manufacturing, Inc. (AAM) is a leading global Tier-One automotive supplier of driveline and
    drivetrain systems and related components for light trucks, SUVs, passenger cars, crossover vehicles and commercial
    vehicles. The company has a long history of successfully using FEA to master the many NVH (noise, vibration and
    harshness) challenges in any driveline engineering project – gear whine, gear rattle, shudder/moan/chatter, clunk,
    prop-shaft instability and others. Nevertheless, its traditional simulation methods had limitations.

    Glen Steyer, AAM’s Executive Director of Product Engineering, reports major benefits from the new tool:

    • Average 75% time reduction for each analysis iteration.
    • Approximately $130,000 in annual cost savings at a single engineering site.
    • Improved quality through globally enforced standards and practices which remove human error.
    • Ability to run many more NVH analysis iterations, leading to more design decisions, earlier.
    • Ability to redeploy resources as less experienced engineers are now able to safely run simulations.

     

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  • Numerous Democratization Success Stories at CAASE18

    CAASE18 (the Conference on Advancing Analysis & Simulation in Engineering) will showcase 22 presentations, workshops and discussions all focused on democratization.

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    Dating back to the 2015 NAFEMS World Congress, interest in democratization has grown from a single session to a full conference track at NAFEMS events.

    CAASE18 (the Conference on Advancing Analysis & Simulation in Engineering) an event hosted by NAFEMS and Digital Engineering Magazine, will take place June 5-7 in Cleveland. What makes CAASE18 so noteworthy is that it highlights the first time that democratization has earned a leading role as a key topic running the duration of the three day conference.

    We have pulled together a list of democratization-themed abstracts covering presentations, workshops and discussions taking place at CAASE18. Click on the link below for details.

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  • Democratization & Enterprise Wide Deployment at Pfizer

    A major limitation of most modeling and simulation tools is that only subject matter experts can use them. Pfizer has overcome this limitation by using EASA’s patented “application” technology to create a proprietary “app store” of intuitive web apps that drive a wide variety of models created with tools such as gPROMS, Aspen Plus, DynoChem, Fluent, and MATLAB, as well as in-house codes and scripts. These web apps incorporate both expertise and comprehensive error checks, enabling users who are not familiar with the underlying modeling tools to safely use them.

    Solution Providers:

    EASA

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    For pharmaceutical giant Pfizer, modeling technology serves as the backbone for product design, testing, and improvement. Streamlining and integrating the modeling process and workflows is essential for maximum efficiency as well as for enabling non-experts practical access to these tools.

    Using EASA, Pfizer can create custom GUIs without any programming, for various modeling applications, from simple to complex multi-software workflows, providing:

    • Web accessible models running with complete reliability throughout the IT infrastructure, including mobile devices
    • GUIs with a consistent look and feel, enhancing ease of use and eliminating the need to be familiar with complex software codes
    • Complete security of the intellectual property embedded in software models
    • Full version control and automated audit trail of usage

    Published: Fall 2016

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  • Simplifying CAE with Automation & Embedded Expert Knowledge at Air International Thermal Systems

    Air International reduces design lifecycles while putting simulation technology into more hands by creating custom, task-specific applications simplifying the use of many of its powerful computer-aided engineering (CAE) tools.

    Solution Providers:

    EASA

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    At Air International, computer simulation has long been viewed as a key competitive advantage, permitting early evaluation of many different design alternatives before building a prototype. With EASA, Air International has leveraged these benefits by creating custom, task-specific applications simplifying the use of many CAE workflows, including tools such as Fluent, NX/NASTRAN, and CATIA. Furthermore, expert knowledge was embedded into the streamlined user interface, making modeling and simulation available to engineers and designers with little or no CAE experience while also significantly accelerating the process for experienced users.

    In addition to significant ease of use improvements, Air International benefited from many other EASA advantages, including:

    • Deployment of tools and models was easy and fast
    • Access control (who could see results, use apps and collaborate) was implemented, as well as audit information tracking
    • Critical intellectual property embedded in the models was completely secured
    • Custom apps could be developed by experienced modelers without relying on programmers, enabling a highly efficient implementation and knowledge capture process

    Published: Fall 2016

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  • Modernized GUI-Driven Apps at Monsanto

    Monsanto extends the life of legacy applications, replacing ancient text based interfaces with modernized GUI driven EASA apps.

    Solution Providers:

    EASA

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    Modernizing Legacy Applications

    Monsanto was able to breathe new life into extremely valuable legacy codes which had become – by modern standards – only marginally usable. The transformed tools were greatly enhanced with new characteristics endowed by EASA, including:

    • Substantial improvement in ease of use and a dramatic reduction in learning curve, particularly for those unfamiliar with the process of running the legacy applications
    • Web accessibility (including via mobile devices) to specific tools for defined user groups, with a full audit trail of usage automatically logged
    • Reliability of execution, regardless of locally installed software
    • Full version control and security of intellectual property embedded in the legacy codes

     Published: Fall 2016

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  • Democratization of CAE at P&G

    Proctor & Gamble democratizes simulation to a much broader user community, creating easy to use but intelligent apps to drive complex multi-step, multi-software workflows.

    Solution Providers:

    EASA

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    P&G determined that software modeling tools are critical for the kind of innovation necessary to develop thousands of consumer products competitively, and has therefore invested heavily in a variety of modeling and simulation technologies. Realizing that the benefits of modeling and simulation could be scaled by orders of magnitude if only these tools could be made usable by a much wider and larger group, P&G turned to EASA to help democratize modeling tools as intuitive streamlined web apps.

    Published: Unknown

    Previously limited to specialists, many tools (and related workflows) such as spreadsheets, legacy codes, databases and CAE applications were quickly repackaged as EASA web apps, which offer:

    • Ease of use, built in intelligence, consistent look-and-feel, and error-checking
    • Ease of access, running with complete reliability (even on mobile devices), with no dependence on locally installed software
    • Intellectual property security and audit trail of usage

    Published: Fall 2016

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  • Cloud Infrastructure Enables Easy & Fast Simulations in Shipbuilding

    In this user success story, readers will find an UberCloud Experiment on a CFD Study of the Maneuverability of a KRISO Container Ship Model in the Cloud. This case study highlights how cloud infrastructure enabled easy and fast simulations, accessible with one click through the browser-based GUI, resulting in a dramatic increase in the engineer’s productivity and the ability of focus on the simulation experiment at hand.

    Solution Providers:

    View Summary

    The aim of this UberCloud Experiment #201 was to verify the feasibility of overset grids for direct zigzag test using “appended” KRISO Container Ship (KCS) model by means of the NUMECA UberCloud container on the cloud. The commercial CFD software FINETM/Marine packaged by NUMECA International S.A. was
    employed during this experiment. All simulations were run on the newest software version 6.2, whose robustness has been drastically improved. Meanwhile, it was hoped to accelerate simulations through the powerful HPC Cloud resources provided by UberCloud Inc. and NUMECA.

    Published April 2018.

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  • When fast isn’t fast enough

    If you would get access to the heart of development at a top Formula 1 team, chances are high that you would find they simulate their vehicle-handling behavior using Modelica models. Dymola and the Vehicle Dynamics Library (VDL) are the de-facto standards for simulating car handling in the premiere motorsports leagues.

    Solution Providers:

    View Summary

    If you would get access to the heart of development at a top Formula 1 team, chances are high that you would find they simulate their vehicle-handling behavior using Modelica models — the same holds true for NASCAR. Dymola and the Vehicle Dynamics Library (VDL) are the de-facto standards for simulating car handling in the premiere motorsports leagues. In this post, I will explain why.

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  • Democratization Success Stories to be Presented at CAASE18

    On June 5-7, more than 500 individuals will gather in Cleveland for the 2018 Conference on Advancing Analysis & Simulation in Engineering. At CAASE18, numerous customer success stories covering democratization and simulation governance will be presented.

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    CAASE18Take a moment to review the CAASE18 agenda, which contains a listing and abstracts for all democratization and simulation governance focused presentations.  Democratization presentations from end-users include: Accuride, GE Global Research & Development, Shanghai Zhongli Investment Co., John Deere, ZPMC, BISME,  and Superior Industries. Presentations from software and services providers highlighting customer cases will be delivered by: ANSYS, HBM Prenscia, EASA, Eckdyn Analysis Solutions, Siemens AG, Romax Technology, and Comet Solutions. Furthermore, CAASE18 will showcase a Democratization Round-Table Discussion, hosted by the Revolution in Simulation moderators.

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  • Cross Tidal Kites to Harvest Ocean Energy

    Ocean Energy Tamed by Modelon. Modelica based system simulation is the key enabler for product innovation.

    Solution Providers:

    View Summary

    Tidal energy is an enormous sustainable resource. The challenge is to harvest this energy. It is offshore, which makes it one of the harshest environments. It needs large investments. It bears significant risks.  The company Minesto from Gothenburg in Sweden has developed a new green technology to exploit this energy in places where conventional techniques fail.

    Modelica models are used to explore the design and validate the complete multi-physics system model.

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  • ROI of 300% After Discovering CAE

    Design and Innovation Solutions O&G CaseHow does one company undertake the herculean challenge of testing a product in a working environment 500m underground and submerged under water? By discovering and leveraging cloud-based CAE for CFD simulations, of course. Learn how Design and Innovation Solutions was able to understand the behavior of the system at play and what decisions were made to have the best design.

    Solution Providers:

    SimScale

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    Read how Design and Innovation Solutions came to discover CAE and shortly thereafter was able to leverage cloud-based CAE solutions from SimScale to realize a 300% ROI while reporting on 10 different simulation configurations, giving full confidence in the results.

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  • Accessibility at BWAY Corp.

    Forrest Burney describes the success he experienced with the adoption of cloud-accessible simulation apps and the ROI realized at BWAY Corp.

    Solution Providers:

    Comet Solutions

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    As part of a one-hour NAFEMS webinar on,  “Democratization: Accessibility,” Forrest Burney compares the benefits of simulation apps to the “cut-and-try” and vended CAE processes. Forrest also delivered a demo of a top load analysis simulation application process with cost and time-to-market comparisons.

    Presented on: October 27, 2015

    Password: &nJj8z

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  • Highly Usable Apps at Intel

    Zack Eckblad shares his views on the importance of usability, highly-usable simulation apps, speaking the language of the user for non-experts at Intel.

    Solution Providers:

    Comet Solutions

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    As part of a one-hour NAFEMS webinar on,  “Democratization: Usability,” Zack Eckblad shares his vision for applying numerical structural analysis to all products and associated best practices metrics at Intel. In this presentation, Zack delivers a demo highlighting analysis processes for a socket stack while comparing old processes lasting three months to a new process that only took three days. Additionally, he covers the value of webtools and the changing roles and responsibilities in the organization.

    Presented on: October 1, 2015

    Password: $g4SyY

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  • Expert Knowledge Capture & Reuse at American-Axle & NASA

    Ravi Desi (American-Axle Manufacturing) and Tory Scola (NASA Langley) discuss the importance of knowledge capture & reuse and why companies need to embrace targeted, solution-focused simulation apps to gain measurable improvements in innovation, development time, and related product quality.

    Solution Providers:

    Comet Solutions

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    As part of a one-hour NAFEMS webinar on,  “Democratization: Expert Knowledge Capture & Reuse,” Ravi Desi explains why knowledge capture and reuse is critical in developing new vehicle architectures and for faster decision making at American-Axle Manufacturing. Tory Scola shares how NASA Langley adopted a new process for automated design space exploration (with complex multiphysics calculations, including design changes) resulting in a single iteration taking a full week down to 140 analyses in a single overnight run.

    Presented on: September 17, 2015

    Password: a?p9K?

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