Breakthroughs in Automotive Applications with Simpleware Image-Based Solutions

Challenges and Solutions in Automotive Metrology, Reverse Engineering and NDE

Analyzing parts and components during different manufacturing and testing stages can be a challenge. CAD models typically represent idealized geometries that do not fully reflect the structure of the manufactured part. Original equipment manufacturers (OEMs) wanting to rapidly and accurately reverse engineer parts and analyze components therefore require solutions that preserve complex features while potentially cutting down on research time. In addition, those working on components such as fuel cells have to overcome the challenges of complex materials characterization.

With image-based workflows, it is straightforward to visualize, segment, quantify and export models based on 3D scans for CAD and simulation processes. Our software solutions are used by automotive engineers to reduce the complexity associated with these models, from visualisation and analysis through to the creation of robust numerical models, or meshes.

Creating a Bridge to Physics-Based Simulation

Once relevant information has been segmented and image data quantified, models are exported, for example, as NURBS (Non-Rational-B-Splines) for CAD, or as multi-part meshes for FEA/CFD to analyse performance under different conditions, as well as internal fluid structures in parts. The meshing techniques in Simpleware software module +FE are particularly robust for handling complex multi-part geometries. Models exported for FEA and CFD are used for a wide range of physics-based simulation, including performance evaluation, part durability, test part crashworthiness and safety, taking full advantage of the complex geometries generated in Simpleware software.

When analysing automotive parts, established image-based approaches are now being extended to use our recent breakthroughs in calculating effective material properties using homogenization methods through our Physics Modules. Homogenization aims to approximate a complex heterogeneous material, such as a metallic alloy, with a homogeneous material whose response to external loading resembles as closely as possible that of the original material. With this approach, materials image data is analyzed by working with 'effective' material properties that link micro and macro-scale modelling.

A built-in finite element solver calculates the response of a cuboidal sample of a material to a sequence of boundary conditions, enabling effective properties such as stiffness, elasticity, absolute permeability and electrical conductivity to be obtained. Researchers are using this approach to rapidly and accurately obtain material properties from their image data, with specific application to inspecting and characterizing composite parts for permeability, stiffness and other material characteristics.

Realistic Simulations with Human Body Models

As well as visualisation and materials applications, Simpleware software is being used to generate very robust human body models suitable for simulating different forms of impact. High-quality meshes are adapted to a range of simulated crash scenarios, offering users more flexibility than the 'fixed' models usually created for automotive projects. Users are customizing meshes to suit specific applications, rather than relying on existing generic models. Models created from segmented image data are available through our Human Body Models service for these types of simulations.