Simulation Driven Design

Manufacturing new products is a challenging task today, thanks to intense competition and ever increasing demands of customers. The manufacturing team comprises of design engineers, analysts and production managers. While the design engineers are responsible for developing the specifications for new products and processes, design analysts use their knowledge of engineering, mathematics, and computer science to analyze and improve the design of products, systems, and processes. Before commencing actual products, all manufacturing companies undertake various trials to test and evaluate the product in terms of usability, utility and safety. This process is called product validation.

There are two main types of product validations in manufacturing: virtual validation and production-driven validation.

• Virtual validation is the use of simulation and other tools to test the design of a product before it is manufactured. This can help to identify potential problems and make necessary changes before the product is produced. Virtual validation can be used to test a product's performance, safety, and manufacturability.
• Production-driven validation involves testing the physical product in a real-world environment. This can help to ensure that the product meets its performance requirements and that it is compatible with the intended operating environment.

Earlier, testing of prototypes was mostly production driven. Thanks to the introduction of sophisticated simulation tools, it is now possible for design engineers to expedite the manufacturing process by utilizing simulation for virtual validation. Simulation is the process of using mathematical models to predict the behaviour of physical systems. And simulation driven design basically implies the use of simulation software – say Altair OptiStruct™ or MotionSolve™ as examples – to test the design of a product for functionality, performance, and safety before it is manufactured.

Let’s take the case of aero plane wings. The challenge here is to make the wings lighter so that the plane consumes lesser fuel. Another challenge is to design the wings in such a way that they reduce turbulent friction drag and makes air flow around them laminar. It is not feasible to develop working prototype wings every time a new design idea is discussed in order to test if they really work. Design engineers take the help of simulation software to first narrow down the choices, and then commence the actual trials. In the automotive industry, simulation has been used to reduce the risk of car accidents by using simulation software to test the safety of new car design in a variety of crash scenarios. The medical device industry too uses simulation to improve the effectiveness of medical devices in a variety of conditions.

Some of the advantages of using simulation in design include reduced risk of product failure, which is one of the most important ways a manufacturing company can stay competitive. By simulating the product's behaviour under various conditions, designers can identify potential problems before the product is built. This can help to reduce the risk of product failure and improve the overall quality of the product. Other advantages of using simulation for products include improved manufacturability, quicker and more efficient design process, better decision making and lower costs. Simulation can often be used to replace physical prototypes, which can save time and money. This is especially true for products that are expensive or difficult to manufacture.

Types of Simulation
Technically, there are different types of simulation available. Here are some of the most common types:

• Discrete event simulation: This type of simulation models the behaviour of a system as it progresses through time, with events occurring at discrete points in time. It is often used to model systems with stochastic elements, such as queuing systems and traffic networks.
• Continuous simulation: This type of simulation models the behaviuor of a system as it progresses through time, with the state of the system changing continuously over time. It is often used to model systems with deterministic elements, such as fluid flow and heat transfer.
• System dynamics: This type of simulation is used to model complex systems with feedback loops. System dynamics models are often used to study the behaviour of social systems, such as the economy or the environment.
• Agent-based modelling: This type of simulation models the behaviour of individual agents in a system, and how their interactions with each other affect the system as a whole. Agent-based models are often used to study the behaviour of social systems, such as the spread of disease or the formation of traffic jams.
• Monte Carlo simulation: Monte Carlo simulation uses random numbers to generate a sample of possible outcomes from a probability distribution. Monte Carlo simulations are often used to estimate the probability of rare events or to calculate the expected value of a random variable.

These are just some of the most common types of simulation; there are many others. The type of simulation that is most appropriate for a particular application will depend on the specific needs of the application. For example, if you need to model a system with stochastic elements, then you would use a discrete event simulation. If you need to model a system with deterministic elements, then you would use a continuous simulation. And if you need to model a complex system with feedback loops, then you would use a system dynamics model.

The mathematical models used in engineering simulation are also important for determining the accuracy of the results. If the mathematical models are not accurate, then the simulation results will not be accurate. It is hence important to choose mathematical models that are appropriate for the specific problem being simulated. Likewise, the input data used in engineering simulation is also critical for determining the accuracy of the results. If the input data is not accurate, then the simulation results will not be accurate.

Onward and Upward...
It should be clear by now that engineering simulation for product design is a complex process, requiring intense mathematical computations, and choosing of the right simulation model. In 1965, Gordon Moore, one of the pioneers of integrated circuits, predicted that the number of transistors that could be fit on one chip would double every year. This prediction is known as Moore's Law. And while the law may or may be relevant as of date, computers are still getting faster and processing more data than ever. Leading simulation software designing companies like Altair are leveraging this data crunching power of computers to their advantage. HyperWorks, Inspire™ and SimSolid™ are just a few examples of how simulation driven design can help manufacturers expedite product delivery. Thanks to growing computer power, it is now possible for companies to offer better and powerful simulation software. One of the main advantages of simulation is working in the digital environment. If the product breaks or overheats in the digital environment, it does not cost the manufacturing company anything. As products get more complex, simulation driven design is slated to play an even bigger role in product development.