Sandeep Sovani is automotive director for Ansys Inc. (Canonsburg, PA), a developer of simulation software solutions.
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Simulations Speed Product Designs, Cut Manufacturing Costs PASSWORD
Manufacturing Engineering: How is simulation software helping automotive manufacturers today? Sandeep Sovani: The automotive industry has been one of the early adopters of simulation ahead of other industries, and is one of the most intense and extensive users of it. Simulation is now part of the ‘DNA’ of automotive product development, an essential tool that helps manufacturers cut design and prototype costs. It is estimated that automotive companies globally invest about $1 billion in simulation software each year and that investment is growing at a rate between 10% and 20% annually. Simulation is used heavily in the development of almost every major vehicle system and subsystem, from chassis and
There are hundreds of examples of critical uses of simulation throughout the vehicle. For example, the size and orientation of the front grille needed to provide adequate air flow under the hood to cool the engine is almost exclusively designed by using simulation. In the past, this has been done using expensive wind tunnel trials. For automotive manufac- turers, the use of simulation is a strategic investment that not only eliminates expensive processes involving physical testing, but also improves the quality and life of vehicles. ME: How will simulation help automakers meet the 54.5-mpg
CAFE mandate in 2025? Sovani: Apart from improving the quality and reliability of vehicles, simulation software plays a critical role in the design
“Simulation is now part of the ‘DNA’ of automotive product development, an essential tool that helps manufacturers cut design and prototype costs.”
powertrain design to interior and electronic components. For in- stance, crash simulation is a key component of the development of the vehicle body. Auto manufacturers have been relying heav- ily on crash simulation—which has been proven to be accurate and reliable—to study a wide variety of crash scenarios. Because physical crash tests are so expensive and time- consuming, requiring production and preparation of prototype vehicles, dummies and elaborate crash-testing facilities, com- panies are making the transition to simulation software.
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ManufacturingEngineeringMedia.com | August 2013
and development of fuel-efficient vehicles. There are three major areas of focus for improving fuel efficiency: body aero- dynamics, engine/transmission and electric powertrain. Developing aerodynamic vehicle body shape is essential
for better fuel efficiency, since at typical highway speeds, a major portion of fuel consumption is caused by air resis- tance. To improve fuel economy, car manufacturers use simulation software to explore body line possibilities to find the design that provides the least resistance, while still pro-
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