Hema Group

Engineering Solutions offered by

Hema Engineering Industries Ltd

in

CAE & Simulation

Hema Group
Infrastructure
CAE Setup and tools :
4 CPU dual core processor
Solver
- Ansys
CAE
Pre/Post and linear analysis
- Hyper Mesh 9.0/ 10 Crash Analysis
Occupant Safety
- Hyper Works 9.0/10
Linear and Non-linear analysis
Crash Calculation Static and Dynamic
- LS DYNA R3/ 4 Modal analysis
- Radioss Random frequency response
Structural (static) Analysis Metal forming simulation
- Optistruct Meshing

Security Measures:
Data Security Firewalls (Sophisticated & latest hardware & software firewall systems)
Anti-virus protection
Dedicated & independent secured FTP server for data transfer
Secured data storage (NAS Server)
Dedicated back-up system.
Access control over external media and internet connectivity as regards engineers interfaces
Restricted access points for maintaining data confidentiality.
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Hema Group
Hema - Engineering Center

CAE Projects
Hema Group
Analysis & Simulation

Mesh modeling for various automotive simulation applications:

Crash
Noise Vibration and Harness(NVH)
Durability
Computational Fluid Dynamics(CFD)

Perform different types of analysis like:

Linear static analysis
Non linear static analysis
Transient steady state Dynamic analysis
Heat transfer analysis
Quasi static analysis
Manufacturing Simulation
Fluid structure Interaction

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 General Engineering/ Mechanical

SPM

Linear Static Analysis

Hema Group
Analysis Results: Displacement

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Hema Group
Analysis Results: Von Mises Stress

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Hema Group
Solutions provided

Evaluation of Helmet for Impact Absorption according to European

regulation ECE-22. The test is carried out at five different points and
different temperatures using LS Dyna.

B Energy Curve for B point.

P

S X (at opposite side)

This test position is for point B

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Hema Group
Solutions provided

Helmet Impact test at 50 degree temperature.

Von mises stress pattern for B point Maximum value HIC for point B is 1499 which is less than
. 2400 as per regulation 22

For B point

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Hema Group
Optimization of Composite Cargo Door

The original cargo door was made of aluminum alloy

Customer wanted to reduce the weight of the door by 100Kg.
The task was to use carbon fiber composite material wherever possible
The difficult task was to design the torsion box to take various loads
The loading conditions e.g Fuselage pressure, Fuselage temperature
the load on the antenna, the crane load were supplied by the customer
Four options of the door design were suggested. Out of four one was selected
by the customer for further studies
The main outer frame was made of composite material with the metallic
attachments to get engaged with fuselage when closed condition
The torsion box was made of composite material with longitudinal and horizontal
stiffeners
The connections between torsion box frame and stiffeners were made by
riveting and bonding
The complete door design was optimized by using Nastran solver
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Hema Group
Formability Analysis
Objective:

Formability analysis for hinge Reinf

Work Executed:

Input of die-face in IGES or CAD part

Executed in LS-Dyna
Formability simulation with strain plots
BHF 50 T & without bead
Team Size:
Three

Project Duration:

Two months

Key Outcomes:

FLD (Forming limit diagram) plot

Thinning
Plastic strain
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Hema Group
CAE Capabilities : Automotive

Front & Rear Impact as per FMVSS, ECE & AIS standards
Side Impact
Pole impact
Offset crash test
Roof Crush simulation
Head Restraint simulation
Back strength simulation
Luggage retention test
Seat belt anchorage test
Head impact & Knee impact on instrument panel
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Hema Group
Design Verification

CAE verifications (as per FMVSS regulations)

Seat belt Seat back

anchorage test strength

Frontal Impact Rear Impact

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Hema Group
Seat Belt Anchorage
Hema Group
Projects executed in child seat

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Hema Group
Analysis Results: Marine seat-base

Plastic Strain

Plastic strain=4.84 %
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Hema Group
Linear Stress Analysis

Linear stress analysis of luggage assembly structure using Nastran

Distributed load of 100kg is
applied as pressure of 3.71e-03
N/sq mm On the Piano plate.

Fixed

Fixed

Concentrated
load of 85 kg (834
N) is applied on
the extrusion as
shown.

Observations:
The maximum displacement in Al cast bracket is
0.98mm, thus the structure is safe for given loading Max displacement of
0.96mm is observed in
conditions the bottom portion of the
solid casting.
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Hema Group
Non Linear Analysis: Door Assembly

Objective :
To perform the Static Stress Analysis of Door Assembly to find Total and Permanent Yielding
under externally applied static load in three stages.

Introduction :
To find yielding of the door under following loads:
Gravity Load
Gravity Load + Point Load of 1000 N
Gravity Load

Units :
Analysis is carried out in SI system (Force in N, distance in mm, mass in Ton and time in Sec.)

Material and Section Properties :

Material and section Properties is as per CAD and FEM data

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Hema Group
Non Linear Analysis: Door Assembly

Non linear Static Stress Analysis of Door Assembly to find Total and Permanent
Yielding under externally applied static load in three stages using Abaqus

1000 N CLoad applied

at X=1114.5; Y=950.8;
Z=809.0 in vertical
direction in second
load step.

Observations:
The Total vertical deformation :
= Maximum value ( Deflection in Z direction at the end of second step) Set up value (
Deflection in Z direction at the end of First step) = 11.061 mm
The Permanent vertical deformation :
= Final value ( Deflection in Z direction at the end of Third step) Set up value ( Deflection
in Z direction at the end of First step) = 4.387 mm
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Hema Group
Impact Analysis: Rear Bumper

Objective :

To perform the Impact Analysis of Bumper Assembly according to Regulation-ECE42, to

find out stresses generated in the rear structure of the vehicle in a collision at low speed .

Introduction :

According to regulation ECE42, the bumper assembly is tested under two condition.

Longitudinal Impact Test.

Corner Impact Test.

Software Used :

Hyper mesh, Lsdyna

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Hema Group
Impact Analysis: Rear Bumper

Rear bumper analysis ( ECE R42) Longitudinal impact test using LS-Dyna

Unladen

Impactor moving at
1.11mm/ms ( 4km/hr)

Observations:
Localized deformation is observed in these parts
and no failure occurs . Laden

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Hema Group
FEM - Meshing

Rear Bumper

Total 2 lac elements 22

Shell mesh
Hema Group
Impact Analysis: Rear Bumper

Rear bumper analysis ( ECE R42) Corner impact test using LS-Dyna

Unladen

Impactor moving at 0.694

mm/ms (2.5km/hr)

Observations:
Localized deformation is observed in these parts
and no failure occurs .
Laden

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Hema Group
FEM - Meshing

Exhaust Muffler assy

Shell & Solid elements

Total 23,000 elements
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Hema Group
Value Engineering: Muffler Assembly

r1050550 Assembly Original Design: All Heat Guard

Natural Frequency of n9052440 Assembly is Thickness= 1.0 mm. Casing Thickness= 1.2 mm
68.88 Hz Natural frequency is 84.33 Hz

Modification-2
Modification 1: Heat Guard All Heat Guard Thickness= 0.8 mm
Plate Removed Casing Thickness= 1.0 mm
r1050550 Assembly
Natural Frequency is 115.88 Hz r1050550 Assembly
Natural Frequency of Assembly is 69.30 Hz

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Hema Group
Optimization for load case

Blue shaded area

can be removed

Engine-mount bracket
Hema Group
Static analysis after modifications w.r.t load case

Maximum displacement = 0.031 mm Maximum stress (von) =27.28 N/mm2

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Hema Group
FEM - Meshing

Transmission Case

2nd order tetra elements

Tetra collapse = 0.15
Hypermesh
28
Total 5 lac elements
Hema Group Powertrain

Objective:
Finite Element Modeling (Meshing)

Work Executed:
Checking quality according to clients
specification
Generating 3D FE Model using 2D FE Model

Key Outcome:
FE Tetra Modeling (Solid)
Forged Drop Arm
Analysis Results-Displacement

Max.Displacement at Drop Arm

Small End=2.21mm
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 Analysis Results-Von Mises Stress (Max)

Max.VonMises Stress=367Mpa
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 Analysis Results-Von Mises Stress (Min)

Min.VonMises Stress=0.13Mpa
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 Hema Group
RobCAD Simulation

Weld line project

Dynamic weld gun study
Critical weld gun path
Access for weld area

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Hema Group

THANK YOU

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