The importance of Product Simulation for the Company


June 22 2011

Nowadays, every company is under pressure to launch their products on the market rapidly...

 

Nowadays, every company is under pressure to launch their products on the market rapidly to gain maximum profit and reduce costs, but also ideally without compromising on the quality of the product itself.

 

Both globalization and the recent economic climate have exacerbated the competition and lowered prices, whilst at the same time the cost of raw materials has increased. Consequently companies are forced to reduce their safety margins.
In addition to the above, products are becoming increasingly more complex from a technological perspective, plus new materials are being introduced such as plastics, and composites. The behaviour of these new materials is hard to predict during the project development phase, as the designers involved in the project do not have the benefit of a long experience working with them.

 

The traditional development approach of a new product is outlined in Figure 1:
in the case of a defect in design, stages 3 - 4 - 5 become iterative, with a consequential prolongment in the time-to-market and hence an increase in the respective costs such as materials, resources and equipment.
To optimize this process it is possible to introduce virtual prototyping during the initial phases: this permits an analysis of the behaviour of components/parts when being subject to specific physical stresses, and so the possibility of reducing the quantity of material used by optimizing the geometry but without affecting the final performance.
Obviously, these simulations are unable to substitute experience accumulated over the years, but nevertheless may serve to compliment the companies’ know-how.
It is not possible to replace the physical tests, but the modelling of the work piece offers a convenient means to optimize them.
Finally, digital prototypes permit quick interactions at a lower cost, allowing engineers more freedom to explore design variations or unusual and innovative ideas.
After a profound and careful evaluation of the available products, the Camozzi group has taken the strategic decision to move to the ANSYS software platform, with state of the art technology for magnetic- thermo- and structural simulations. The companies of the Camozzi Group, by using the support of the Camozzi Research Center (CRC), may utilize the tools of structural mechanics and dynamic analysis of ANSYS to perform simulation studies related to potential issues and optimization of machines, components or parts.
The engineers will use numeric simulations to identify possible faults and develop projects which enable them to avoid potential errors in a relatively short time.

 

A typical example is the request by the automotive sector for new plastic components (fittings, valves, valve islands, regulators…) instead of the traditional materials such as aluminium, steel or brass. Thanks to the support of software for structural analysis, it is possible to design optimal geometries/shapes, and anticipate eventual faults/problems, avoiding re-doing, or re-molding with the consequential increase in cost and time.

 

 

Sebastian Bicelli
Camozzi Research Centre