Engineering Advantage. Engineering Simulation to Drive Optimum Design and Innovation

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1 Engineering Advantage Engineering Simulation to Drive Optimum Design and Innovation

Engineering Simulation for Competitive Advantage CAE Associates provides an industry-leading combination of expert engineering consulting, straight advice, real-world training, and market-leading

2 Engineering Simulation for Competitive Advantage CAE Associates provides an industry-leading combination of expert engineering consulting, straight advice, real-world training, and market-leading ANSYS software solutions. Whether working with leading global engineering companies like GE, IBM, and United Technologies, or a smaller local firm, our engineers apply every facet of their diverse experience towards maximizing the benefits our clients receive from engineering analysis and simulation. We share our advanced knowledge across a wide range of industries, collaborating with clients to resolve a wide variety of complex structural, thermal, electromagnetics, and fluid design challenges. For our clients, this expertise translates to optimized product and process designs, reduced development timelines, streamlined prototype costs, and improved quality. Converting Insight into Action CAE Associates works with the most innovative engineering companies in the world, continuing a tradition from our inception in These organizations choose CAE Associates because each engineer brings an unmatched combination of a graduate-level education, simulation expertise, insight, and many years of practical engineering experience. Our clients value our ideas and fresh approaches, and become accustomed to receiving the unexpected at every project phase. Most become long term partners, a testament to our commitment to Engineering Advantage. Read more at caeai.com 1

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Structural Analysis of an Artificial Knee Joint Conjugate Heat Transfer Analysis of a DC Motor Explicit Dynamics Analysis of a Turbine Disk Containment Shell Structural & Thermal Analysis CAE

generation, and industrial machinery. FEA is at the core of our advanced engineering analysis services.

Our engineers are experts in the use of the ANSYS suite of finite element software, widely recognized as best-in-class.

4 Structural Analysis of an Artificial Knee Joint Conjugate Heat Transfer Analysis of a DC Motor Explicit Dynamics Analysis of a Turbine Disk Containment Shell Structural & Thermal Analysis CAE Associates engineers apply leading-edge, real-world experience with finite element methods to a broad spectrum of industries, including: aerospace, automotive, civil-structural, biomedical, power generation, and industrial machinery. FEA is at the core of our advanced engineering analysis services. Tapping this technology, we generate system performance improvements that foster innovation, save significant prototype costs, while decreasing the timeframe from concept to production. Our engineers are experts in the use of the ANSYS suite of finite element software, widely recognized as best-in-class. In addition to analysis of specific designs, we often develop customized, automated processes so our clients can leverage the finite element method for future product development. Explicit Dynamics Analysis Short-duration, highly nonlinear, transient dynamic events are often the most challenging to simulate because they involve very complex physics, including wave propagation, material failure, very large deformations, and complex part interactions. Accurate, predictive, simulation is critical for these applications because physical testing is often very expensive or impossible to conduct. They require specific engineering knowledge along with specialized analysis methods in order to accurately predict response and validate design decisions. CAE Associates engineering team brings many years of practical experience with a wide variety of explicit dynamics applications to each project. We employ the industry-leading ANSYS Autodyn and LS-DYNA software solutions to solve a wide variety of explicit problems, including crash testing, blast, metal forming, drop testing, impact, and failure analysis. 3

Pressure & Streamlines in a Centrifugal Pump Magnetic Field Around a Double Pancake Coil Computational Fluid Dynamics CAE Associates applies CFD solutions to the same broad range of industries we

We perform many forms of advanced fluid dynamics calculations involving complicated flow physics, multi-phase flow, mixing, chemical reaction kinetics, and heat transfer.

5 Pressure & Streamlines in a Centrifugal Pump Magnetic Field Around a Double Pancake Coil Computational Fluid Dynamics CAE Associates applies CFD solutions to the same broad range of industries we serve for structural and thermal consulting. We perform many forms of advanced fluid dynamics calculations involving complicated flow physics, multi-phase flow, mixing, chemical reaction kinetics, and heat transfer. CFD is a rapidly evolving field that is new to many engineers. Our team works with clients to first define global performance parameters and then refine them to yield improved designs and development processes. During each step of the process, we make sure to educate and mentor clients so they are comfortable with the technology and confident in the results. We employ CFX and FLUENT, the technology-leading CFD software from the ANSYS family, to produce accurate, practical solutions. Electromagnetics CAE Associates engineers provide a diverse spectrum of Electromagnetics analysis to our clients, helping them to design and optimize a wide array of products. These include power electronics, motors, drives, and critical electromechanical components such as actuators, sensors, relays, and converters. We bring together the extensive suite of industry-leading solutions from ANSYS to simulate electromagnetic fields and compute electrical parameters that govern electronic device behavior. The results yield robust, timely solutions at the component and systems level, with input across multiple engineering disciplines, helping ensure that our clients achieve their business objectives. Read more at caeai.com 4

6 Consulting Services Mechanisms Rigid and Flexible Body Dynamics and Kinematics Mentoring and Quick-Start Programs Getting your analysis tools to work for you quickly Parametric Model/Analysis Development Automated ANSYS Parametric Analysis Procedures Stress Analysis Nonlinear, Contact, Plasticity, Creep, Fracture, Fatigue Design Optimization DOE Studies, Robust Design, Automated Multidisciplinary Optimization CAE Associates assistance was crucial during the first phase of developing gelatin impact models. Their technical approach was very effective, including an incremental approach from simple Lagrangian to complex Eulerian models. They have repeatedly proven to have outstanding skills in the field of engineering and FEA. CAE Associates is continuously helpful to the U.S. Army and its efforts. Mark Minisi, U.S. Army, ARDEC Dynamics Vibration, Shock/Impact, Containment, Random Vibration, Rotor Dynamics Heat Transfer Steady State and Transient, Linear and Nonlinear, Coupled Thermal/Structural Fluid Mechanics CFD, Multiphase Flow, Rotating Machinery, Mixing, Reaction Kinetics, Heat Transfer Custom Engineering Software Development ANSYS Macro and Template Development, ANSYS GUI Customization, Automated Simulation Processes Material Modeling Composites, Ceramics, Concrete Cracking/Crushing, Polymers, Shape Memory Alloys, Constitutive Model Development Electromagnetic Analysis Low-Frequency, High Frequency Applications, Motors, Actuators, Relays, Sensors Multiphysics Analysis Coupled Field Problems, Electromechanical, Thermomechanical, Thermal-Fluids, Piezoelectrics, Acoustics, Fluid-Structure Interaction Impact and Drop Test Analyses Multi-Component, Highly Non-Linear Permanent Plastic Deformation, Penetration and Blast Analysis, Manufacturing and Forming Processes Quality Assurance Program Meets 10CFR50 Appendix B and ASME NQA-1 requirements 5

CASE STUDY VTOL Vehicle Design & Development Morgan Aircraft is developing a novel Vertical Take-Off and Landing Vehicle a hybrid helicopter and passenger jet that can take off and land from any

CAE Associates performed hundreds of CFD analyses to determine optimal ducted fan performance, rotor placement, as well as the overall aerodynamic performance of the proposed aircraft.

7 CASE STUDY VTOL Vehicle Design & Development Morgan Aircraft is developing a novel Vertical Take-Off and Landing Vehicle a hybrid helicopter and passenger jet that can take off and land from any location. A patented ducted fan propulsion system provides vertical lift for takeoff, and the aircraft then transitions to a traditional propulsion system for cruising. CAE Associates performed hundreds of CFD analyses to determine optimal ducted fan performance, rotor placement, as well as the overall aerodynamic performance of the proposed aircraft. CAE Associates has provided Morgan Aircraft with valuable insights into the aircraft s aerodynamics and propulsion systems, helping to bring both the commercial and UAV prototypes one step closer to reality. Read the complete case study at caeai.com 6

CASE STUDY Worldwide Face Shield, Impact Modeling to Improve Product Design Honeywell Safety Products designed its new Face Shield to meet the highest impact standards, which require the visor to

8 CASE STUDY Worldwide Face Shield, Impact Modeling to Improve Product Design Honeywell Safety Products designed its new Face Shield to meet the highest impact standards, which require the visor to remain completely attached to the crown protector when impacted by a projectile dropped from 50 inches. CAE Associates developed several finite element simulations that helped Honeywell understand the complex interaction between the face shield and crown protector during impact. Using ANSYS LS-DYNA, CAE Associates determined that the shield was separating at the tab connections with the crown protector. A new design with a reinforcement was developed, and a subsequent dynamic analysis indicated the new design would not separate. This allowed Honeywell to move forward with production, saving significant product development time. Read the complete case study at caeai.com 7

CASE STUDY Advanced Light Weight Weapons Integration Structural Finite Element Analysis An ALWiP is a weapons mount platform that enables the weaponization of commercial helicopters.

flightworthiness. Finite element models provided vital information about the response of the hardware under operational and extreme loading conditions early in the design phase.

9 CASE STUDY Advanced Light Weight Weapons Integration Structural Finite Element Analysis An ALWiP is a weapons mount platform that enables the weaponization of commercial helicopters. Cantine Armament developed the ALWiP as a conceptual prototype and enlisted CAE Associates to perform a finite element analysis to evaluate the prototype s structural integrity and subsequent flightworthiness. Finite element models provided vital information about the response of the hardware under operational and extreme loading conditions early in the design phase. Physical testing was performed on the mature design and test data closely aligned with the FEA results, allowing the use of the FEA model for accurate predictions of other behaviors which could be difficult to test. The prototype version was certified as flight worthy, which led to further design improvements using finite element analysis prior to production. The final manufactured design is currently in operation. CAE provided thorough and professional data. They were always responsive and timely in creating reports for our project. We were thoroughly impressed with them, and plan to continue working with them in the future. Cantine Armament Read the complete case study at caeai.com 8

Software Applications CAE Associates was asked to be one of the original four ANSYS Distributors in 1985, exclusively responsible for sales and support of the ANSYS software in our section of the

10 Software Applications CAE Associates was asked to be one of the original four ANSYS Distributors in 1985, exclusively responsible for sales and support of the ANSYS software in our section of the country. Today, we remain the sole ANSYS Channel Partner in our region, representing the entire suite of ANSYS software to companies in Connecticut, New Jersey, Massachusetts, and the New York Metro area, including Long Island. ANSYS software is widely recognized as the leading fully integrated suite of CAE tools and technologies, providing the most innovative and powerful simulation solutions to satisfy the ever-growing needs of organizations worldwide. It helps companies achieve high quality products with fewer physical prototypes and reduced development time. Today, ANSYS forms the world s largest simulation community, with over 40,000 customers, and growing. I ve been a CAE Associates customer for over 11 years now, and during that time they ve been nothing less than knowledgeable, responsive, and dependable professionals in every sense of the word. Their training seminars and hotline tech support for all ANSYS products add substantial additional value to an already valuable product line. Current ANSYS users in the Northeast U.S. already know the great team they have in CAE; ANSYS users to come will find just the same. Robert Dillworth, ITT Defense Electronics and Services 9

ANSYS Technical Support CAE Associates provides full service ANSYS sales and technical support to a constantly expanding list of over 100 local companies and hundreds of engineers.

11 ANSYS Technical Support CAE Associates provides full service ANSYS sales and technical support to a constantly expanding list of over 100 local companies and hundreds of engineers. We offer the unique combination of practical engineering expertise, decades of experience using and supporting the software, and the flexibility to develop and teach customized training classes. We provide live, immediate, and exceptional hot-line support. Most questions are answered on the first call. Many large ANSYS users, among them divisions of General Electric, IBM, and United Technologies, realize the exceptional value this presents and have requested that CAE Associates service them exclusively for ANSYS support for locations throughout the country. This distinctive pairing of ANSYS software and the local resources of CAE Associates provides our clients with an unmatched opportunity to take advantage of the full measure of what the technology has to offer and maximize the return on their software investment. Certified ANSYS Distributor & Channel Partner 10

Practical Training As a world leader in ANSYS training, CAE Associates provides customized ANSYS training for the world s most sophisticated users of simulation software, including United

12 Practical Training As a world leader in ANSYS training, CAE Associates provides customized ANSYS training for the world s most sophisticated users of simulation software, including United Technologies, General Electric, IBM, and the U.S. Army Research Center. CAE Associates instructors bring unparalleled expertise from daily use of the software to solve real problems, many years of practical industry experience, and an engineering Master s or Ph.D. degree. With coursework drawn from real-world examples, training programs are structured to directly solve our clients daily business and operational challenges. Popular Course Offerings Finite Element Fundamentals CFD Fundamentals FEA Best Practices Fracture Mechanics Random Vibration Introduction to ANSYS ANSYS CFD - FLUENT / CFX ANSYS Structural Nonlinearities ANSYS Heat Transfer Advanced ANSYS Meshing ANSYS Explicit Dynamics LS-DYNA /Autodyn ANSYS Customization This is just a small sampling of the courses that we offer. Please visit caeai.com for a complete listing. 11

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14 Testimonials Vince Tomassetti, GE Aviation Excellent class. Received an in-depth understanding of what ANSYS does behind the scenes, and why certain settings/options work the way they do. The class notes will be an outstanding reference. We would be hard-pressed to find a better instructor! Ted Trembinski, Exelis Inc. Frances Gonzalez, Sikorsky Aircraft The Introduction to ANSYS Mechanical (Workbench) class CAE Associates taught me and my fellow peers was great! I am not exaggerating when I say that the instructor should have definitely considered becoming a professor. While the class taught me a lot, it left me eager to learn more. I ve known CAE Associates for over 20 years. They are knowledgeable, friendly and extremely helpful. Their team of experienced professionals has always offered courteous and immediate assistance. They are the best! Guan Zhixu, MAKO Surgical Corp. The one-on-one mentoring/consulting session was professional; the material delivery was clear, well structured and thorough. Not only am I happy with the results, but also enjoyed the process. They are truly pleasant to work with. 13

Mentoring As a central pillar of our services, mentoring gives clients one-on-one interaction with our highly experienced engineers to tackle specific analyses.

15 Mentoring As a central pillar of our services, mentoring gives clients one-on-one interaction with our highly experienced engineers to tackle specific analyses. Our clients benefit from our experience and obtain a quantum jump up the learning curve for some of the more sophisticated analyses they may encounter. Our engineers take great professional pride in sharing a wealth of learning, steering projects through potential pitfalls to productive outcomes. We convey knowledge that has taken us many years to acquire, saving you both time and the process of trial and error. Our programs are offered at our headquarters in Middlebury, CT, located about 90 miles from New York City and 35 miles from Hartford, CT. Onsite computer facilities support our training and mentoring activities. We also conduct these activities online or at our clients offices. 14

CASE STUDY Reconstruction of Tullio s Adam: Merging Art & Science In November 2014, The Metropolitan Museum of Art unveiled a reconstructed statue of Adam, created by 15th-century Renaissance

In 2002, the pedestal on which the statue was displayed collapsed and Adam fell to the floor, breaking into 28 large pieces and hundreds of small fragments.

16 CASE STUDY Reconstruction of Tullio s Adam: Merging Art & Science In November 2014, The Metropolitan Museum of Art unveiled a reconstructed statue of Adam, created by 15th-century Renaissance sculptor Tullio Lombardo, after a 12-year absence. In 2002, the pedestal on which the statue was displayed collapsed and Adam fell to the floor, breaking into 28 large pieces and hundreds of small fragments. Traditional restoration methods require drilling holes into the stone and inserting pins, causing permanent damage to the marble. One of the most important objectives of the conservation team was to employ repair methods that were fully reversible whenever possible, with the goal of returning Adam to his original beauty. The conservation team developed several new techniques that have changed the world of monumental sculpture conservation. 15 Tullio Lombardo (Italian, ca ), Adam, ca (detail), marble, The Metropolitan Museum of Art, New York, Fletcher Fund, 1936 Photo: The Metropolitan Museum of Art, Photograph Studio/Joseph Coscia, Jr.

By parametrically defining the pin size and location in the joins, CAE Associates provided the Met s conservators with a tool that could evaluate the need for pins as well as determine the optimum

17 CAE Associates worked closely with the Met s conservators, performing strength analysis of the critical joins of the statue. Using the digital model of the assembled pieces, structural finite element models of the entire statue were created, with particular focus on the left ankle and left knee. By parametrically defining the pin size and location in the joins, CAE Associates provided the Met s conservators with a tool that could evaluate the need for pins as well as determine the optimum number of pins, their size, and location. CAE Associates analytical contribution was critical to the Tullio conservation team, allowing them to make difficult decisions that would have a major impact on the treatment of the sculpture. Carolyn Riccardelli, Conservator, Sherman Fairchild Center for Objects Conservation, The Metropolitan Museum of Art. Read the complete case study at caeai.com 16

18 Why CAE Associates In recent years, the use of engineering analysis has expanded dramatically across all industries, including biomedical, industrial machinery, and consumer products. It has become a requirement in the most innovative companies. Our consultations with clients have evolved from a discussion of the benefits of doing analysis to an examination of how to most effectively implement simulation in their organizations. Today, the question is how can we best employ engineering analysis, not if. For over three decades, CAE Associates has worked with clients on thousands of engineering simulations. We have analyzed the performance of components ranging from the nano-scale to large skyscrapers and dams. While the applications we work on are varied, the common thread is our ability to take the fundamental engineering theory and put it into practice, producing meaningful results and insights for our clients. We recently purchased ANSYS from CAE Associates to meet our growing requirements for advanced simulations, both structural and CFD. In order to take full advantage of the ANSYS features, I attended several classes at CAEA. The training was very valuable, and I was able to get right to work setting up and performing simulations upon my return to work. The instructors were all very knowledgeable, provided a great classroom experience, and made themselves available during and after class to answer questions. CAEA has helped prepare me to meet the growing simulation needs of ProtonOnSite. Certified ANSYS Distributor & Channel Partner - Andy Roemer, Proton OnSite 17

19 Selected Clients 3M ABB Alcatel Lucent AECOM Alstom Power American Standard Areva BAE Systems Bayer Bechtel Bristol-Myers Squibb Brookhaven National Labs Carrier CH2M Hill Chevron Corning Cummins Engine Doosan Fuel Cell Duke Power Duracell ExxonMobil Exelis Fuel Cell Energy GE Global Research GE Aviation GE Energy GE Industrial General Dynamics Electric Boat General Dynamics Mission Systems Honeywell IBM Intel John Deere Lockheed Martin Mako Surgical Medtronic Massachusetts Institute of Technology Metropolitan Museum of Art Mitsubishi Hitachi Power Systems NASA Naval Undersea Warfare Center Northrop Grumman Otis Elevator Parsons Parsons Brinckerhoff Pfizer Pratt & Whitney Aircraft Proton OnSite Raytheon Schlumberger Siemens Sikorsky Aircraft Simpson Gumpertz & Heger Stanley Black & Decker Stryker Orthopaedics Tyco Telecommunications U.S. Army Research Labs United Technologies Research Center UTC Aerospace Systems Westinghouse Electric 18

20 CAE Associates, Inc. / 1579 Straits Turnpike, Suite 2B / Middlebury, CT / P / F / caeai.com

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FINITE E LEMENT A NALYSIS Predictive Engineering Finite element analysis consulting services, software, training and technical support Composite analysis Drop-test, impact, burst analysis CFD thermal ﬂow