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How can you test automotive parts and assemblies with CAD software?

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If you are a product designer working on automotive parts and assemblies, you know how important it is to test your designs before manufacturing. Testing can help you optimize performance, durability, safety, and aesthetics of your products. But how can you test your designs without spending too much time and money on physical prototypes? One way is to use CAD software that allows you to simulate various scenarios and conditions that your parts and assemblies will face in the real world. In this article, we will show you how you can test automotive parts and assemblies with CAD software using some common methods and tools.

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Jinsiang Ong

Helping Entrepreneurs Build a Profitable Passion Through Design | Founder @ Aivant

1 Finite Element Analysis

Finite element analysis (FEA) is a technique that uses mathematical models to calculate how a part or assembly will react to different forces, such as stress, strain, temperature, pressure, and vibration. FEA can help you identify potential weak points, cracks, deformations, and failures in your design. To use FEA, you need to create a mesh of nodes and elements that represent your part or assembly in CAD software. Then, you need to apply the boundary conditions, such as loads and constraints, that your part or assembly will experience. Finally, you need to run the analysis and view the results, such as displacement, stress, strain, and factor of safety.

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Jinsiang Ong

Helping Entrepreneurs Build a Profitable Passion Through Design | Founder @ Aivant
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Using CAD software, automotive parts and assemblies can be tested through Finite Element Analysis (FEA) for structural integrity, Computational Fluid Dynamics (CFD) for aerodynamics, thermal analysis for heat management, and motion simulation for dynamic behavior. These virtual tests optimize designs, ensuring safety and performance while reducing costs and time-to-market. Physical validation complements these simulations for real-world verification.

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Jorge Vega, MID, SMPC

Project - Program - Engineering Management / NPI / R&D / Innovation / Product Development / Global / Launch / HVAC / Entrepreneur / Intrapreneur
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Realizar FEA’s en etapas tempranas de dise?o previenen de forma avanzada errores y redise?os cuando un producto ya está por lanzarse o incluso en el mercado, lo cual esto genera un impacto grande en costo y tiempo del proyecto.

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2 Computational Fluid Dynamics

Computational fluid dynamics (CFD) is a technique that uses numerical methods to analyze how a fluid, such as air or water, flows around or through a part or assembly. CFD can help you optimize aerodynamics, cooling, heating, ventilation, and fuel efficiency of your products. To use CFD, you need to create a geometry and a mesh of your part or assembly in CAD software. Then, you need to define the fluid properties, such as density, viscosity, and pressure, and the boundary conditions, such as inlet and outlet velocities, temperatures, and pressures. Finally, you need to run the simulation and view the results, such as velocity, pressure, temperature, and drag coefficients.

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Jorge Vega, MID, SMPC

Project - Program - Engineering Management / NPI / R&D / Innovation / Product Development / Global / Launch / HVAC / Entrepreneur / Intrapreneur
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Realizar CFD es una buena práctica, al igual emplearlo en etapas tempranas del dise?o. Por ejemplo estos análisis se utilizan en el dise?os de módulos de gasolina para verificar comportamiento del sistema en términos de caídas de presión, flujo y turbulencias dentro del sistema de gasolina.

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3 Motion Analysis

Motion analysis is a technique that uses kinematics and dynamics to study how a part or assembly moves or interacts with other parts or assemblies. Motion analysis can help you evaluate functionality, performance, and efficiency of your products. To use motion analysis, you need to create a model of your part or assembly in CAD software. Then, you need to define the joints, connectors, drivers, and forces that control the motion of your part or assembly. Finally, you need to run the animation and view the results, such as displacement, velocity, acceleration, and torque.

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Jorge Vega, MID, SMPC

Project - Program - Engineering Management / NPI / R&D / Innovation / Product Development / Global / Launch / HVAC / Entrepreneur / Intrapreneur
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Los análisis de movimientos son muy útiles, puedes probar de forma avanzada el ensamblaje de dos partes que van a tener interacción mecánica durante su funcionamiento. Otra ventaja es evaluar en movimiento las tolerancias en condiciones máximas y mínimas de ambas partes, así como identificar posibles conflicto de ensamblaje con otros partes secundarias, interactúan.

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4 Fatigue Analysis

Fatigue analysis is a technique that uses stress-life or strain-life methods to estimate how long a part or assembly will last under repeated loading and unloading cycles. Fatigue analysis can help you prevent premature failures and improve reliability of your products. To use fatigue analysis, you need to have the stress or strain results from a FEA or a motion analysis of your part or assembly in CAD software. Then, you need to define the fatigue properties, such as material, S-N curve, and mean stress correction, and the loading history, such as cycles, frequency, and amplitude. Finally, you need to run the analysis and view the results, such as fatigue life, damage, and factor of safety.

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5 Optimization Analysis

Optimization analysis is a technique that uses algorithms to find the best combination of design variables that meet certain criteria, such as minimum weight, maximum strength, or minimum cost. Optimization analysis can help you improve performance, functionality, and profitability of your products. To use optimization analysis, you need to have a model of your part or assembly in CAD software. Then, you need to define the design variables, such as dimensions, materials, or parameters, and the objectives and constraints, such as target values, ranges, or limits. Finally, you need to run the analysis and view the results, such as optimal values, sensitivity, and trade-offs.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you test automotive parts and assemblies with CAD software?

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2

3

4

5

6

1 Finite Element Analysis

2 Computational Fluid Dynamics

3 Motion Analysis

4 Fatigue Analysis

5 Optimization Analysis

6 Here’s what else to consider

Product Design

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How can you test automotive parts and assemblies with CAD software?

1

2

3

4

5

6

1 Finite Element Analysis

2 Computational Fluid Dynamics

3 Motion Analysis

4 Fatigue Analysis

5 Optimization Analysis

6 Here’s what else to consider

Product Design

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