Optimization and New Product Development @ Zeus Numerix

1Build-to-Specifications | Product Approval | Engineering Services | Software Development
Design, Optimization,
Development @ Zeus Numerix
Presentation on project leading to design for
manufacturing, fabrication and testing, optimization
V3
Abhishek Jain

2
©ZeusNumerixPvtLtd:ConfidentialDocument
Presentation Overview
11 July 2019 Design, Optimization, Build to Specification @ Zeus Numerix
 Zeus Numerix – an Introduction
 Started as an engineering simulation provider in CFD, FEM and CEM
 No 1 Know-Why company with build-to-spec and design optimization offerings
 Non-confidential Case studies
 Design by Analysis projects
 Multi-disciplinary design optimization projects
 Build to specification or turnkey projects
 Team and Closure
 The presentation is non-confidential and some data may be masked
 Legends in the presentation are not shown purposefully
2

3
3
2004
1st Project Completed
Large Defense Project
2005 2006
1st Software Export
System design software: Korea
2007
2008
CEM Software
UAV RCS Reduced
2009
1st Built-to-Spec project
Supersonic ground
vehicle developed
2010
Fire Safety & Comfort
Building fire and HVAC
2011
Control Software
In-house development
2012
2013
Parallel GPU code Devp
Visualize big data – 4 billion points
2015
Floating Panel Design
Solar Panels in Lake
2017
1st foreign missile project
Integration & Certification
2018
1st MSME TDF Winner
D&D of Composite Sea Water Pump
2019
Incubated at IIT Bombay
Journey Begins with India’s 1st
Commercial CFD software!
400th project completed
Lockheed Innovation
Medal & India Govt
R&D Certificate
CEM Software
CEMILAC Certification
1st Store Separation
project complete
www.zeusnumerix.com/portfolio
The Journey

4
4
Customers List: Partial

5
5
Accolades
R&D Recognition Innovation Medal
DST-FICCI-Lockheed Martin
India Innovation Growth
Medal 2007 for
“Numerical Simulations”
Recognition as an R&D Unit by
the Department of Scientific
and Industrial Research
“Design Approval” by Centre
for Military Airworthiness
and Certification certified
CEMILAC Certificate

6
6
Core Offerings
Product
Development
Initial sizing from first
principles
Detailed analysis
based design
Prototype
development
Testing and validation
Product
Approval
Performance
estimate by analysis
Detailed Report
Generation
Review with approval
agency
Final submission and
product approval
Engineering
Services
Design calculation
reports
Analysis – CFD, FEM,
CEM
Failure analysis and
design suggestions
Multi-disciplinary
design optimization
Software
Development
Pre-processing
Automation
Solver development
from Literature
survey
Visualization, parallel
code CPU/GPU & GUI
System simulation
tools

7
Design, Optimization, Build-to-Spec
7
Design
• Aerodynamic & Hydrodynamic design
• Structural design
• System design software
Optimization
• Genetic Algorithm based optimization
• Design of Experiments optimization
• Multi-disciplinary optimization
Build to
Specification
• Strategic sector products
• Industrial equipment
• Unconventional
Designoptimizedand3D
Printedweapon
Designoptimizationof
civilaircraftwing

8
Design Projects
Non-confidential examples of design projects in various
sciences
8

9
Enhanced Performance Coolant Pump
 Coolant pump for UAV Rotary Engine providing less than required oil flow rate
 Impeller and casing redesigned to increase the flow rate by 13.5%
 Dimensions of the pump remain the same
9

10
Concept and Design of Arrester
 Concept, Design and testing of an arrester
 Sizing based on deceleration requirements
 Detailed design based Coupled CFD + FEM simulations
 Design fabrication & experimentally verified
10

11
Composite Landing Gear
 Objective – Concept design of UAV composite landing gear
 Only structural perspective considered
 Main & nose landing gear design follow FAR 23 regulations
 Design consideration included one-wheel landing
11
Nose Landing Gear
Main Landing Gear
One Wheel Landing
Stress and deformation

12
System Software for Air-Breathing Engine
 System level software development for supersonic air-breathing engine
 CFD Analysis for intake
 1D atomization and combustion analysis
 Global and Local models for coupled simulations
12
Ramjet Circular Intake

13
Analysis-Driven Design
 Value Engineering – weight reduction of portable compressor canopy for same
performance
 FEA of Load-Bearing members to decrease weight
 New Design – 27% less weight, 14% less fabrication cost
13

14
Design Calculations as per FM Global Standard
14
 Estimation of shell thickness of large storage tank
 Diameter and height approx 10m
 Tank made from corrugated sheet for better strength
 Design calculations followed by FEM submitted for product approval
Stress on corrugation Tank Schematic

15
Design of In-Pipe Hydro Turbine
 Design of in-pipe hydro turbine for municipal applications
 Design for hydrodynamic efficiency and structural (static and torsional load)
 Generation of production drawings
 Turbine manufactured and being tested
15

16
Multi-Disciplinary Design Optimization
Non-confidential examples of optimization projects with
examples of automatic optimization
16

17
Aero-Acoustics of Landing Wing Configuration
 Unsteady CFD calculation for pressure variation
 Near-field & Far Field Noise Prediction
 Convert CFD data to noise sources
 Linear propagation theory (FWH solver) to farfield noise
17
Noise Amplitude vs. Frequency Directivity Plot (X) of SPL (dB)FWH Surface around Wing

18
Design of Winglet
 MDO framework built based on genetic algorithm (GA)
 Coupled CFD and FEA on computing grid of 256 nodes (2048 cores)
 14% drag reduction achieved w.r.t. base configuration
18

19
Inflight Nozzle Cracking : Design of Experiment
 Estimation of P-T curve for given propellant
 Cracking phenomenon predicted and validated
 Pressure estimation (CFD) and Transient thermal (FEM)
 Design of Experiments based optimization to find desirable liner material properties
19
Heat flux – nozzle surface
Temp profile after 5 sec
Pressuredevelopedby
propellants

20
Multi-disciplinary Simulation for Parachute
 Multidisciplinary software for parachute design
 Dynamics of Parachute opening
 Coupled CFD & FEM for membranes (parachute cloth)
 Validation with wind tunnel experiment
20
ADRDEwindtunneltestInflationinParaZ

21
Design Modifications of Artillery Recoil System
 To ascertain the failure of rings and small parts after firing
 Estimate the forces due to internal ballistics and movement of piston due to recoil
 Unsteady simulation for pressure & thermal stresses due to fluid and nitrogen compression
21
Recoil Location

22
Muzzle Brake Optimization
 Multi-disciplinary Design Optimization of Efficiency, Weight, Service Life and Noise
 CFD for Muzzle blast and pressure, FEM for fatigue,
 Erosion and muzzle entanglement code developed
22
Structural and fatigue
Animation: Shell coming out from barrel
Muzzle Blast seen just at exit

23
Build to Specification Projects
Projects from concept to detailed design, prototyping and
testing
23

24
Design of High-Speed Rocket Propelled Sled
 Aerodynamic, Structural & Dynamics design of recoverable supersonic land vehicle
 Acceleration and deceleration in given length
 Turnkey project from concept to production drawings
 Multiple concepts analyzed for severe aero loads, weight constraints & erosion of sliding shoe
 Production drawings delivered (150 drawings in total)
24
75% Less Drag,
50% Weight
OldDesign
New Design
Realized and Tested

25
Rocket Loading Trolley
 Semiautomatic rocket loader in 2×3 configuration
 Clearance 0.5 mm between rocket and pod
 Concept design – Adjustable in height and lateral motion;
 3.5 ton load on trolley; manual insertion of rocket
 FEA, Design drawings, fabrication and testing complete
25

26
Design, Development of Thrust Cradle
 IC Engine powered Airship requires testing of thrust, fuel flow rate, temperature
 Thrust cradle designed, integrated, tested and delivered to lab
 Integrated sensors with the mechanical model and developed GUI for visualization
26
Electronic sensors
GUI for sensor data
Mechanical Cradle

27
Centrifugal Sea Water Composite Pumps
 Conceptual design of composite sea water pumps for dewatering operations
 Pumps to be lightweight and corrosion resistant
 Hydrodynamic conceptual design using first principles of fluid mechanics
 Concept modified for manufacturability in composites
27
Pumpwithtestsetup

28
Trailer Design for Agricultural Use
 Ab initio design and development of tractor trolley with 6 ton maximum load
 Design to have lower base and lesser weight
 Achieved 19% lower base and 20.5% lower weight
28
FEM of main chassis & final CAD model
Manufactured trolley

29
Cyclone Separator for Food Industry
 Problem of leaking wheat flour causing loss and dust
 Factory surveyed and inputs collected like pressure drop
 Design by calculations, development of engineering sketches & fabrication coordination
 Cyclone separator collected dust with 90% efficiency (higher than client expectation)
29

30
Team and Closure
Details of the team and consultants and summary of
presentation
30

31
Core Team
31
 Prof Gopal Shevare (Chairman) – PhD IIT Bombay with 40+ years research exp
 Expert in MDO, fluid dynamics, numerical methods and simulation product development
 Basant Kumar Gupta (CEO) – Masters IIT Bombay with 16 years experience
 Expert in preliminary design, project management,
 Irshad Khan (COO) – Bachelor Mechanical with 22 years experience
 Expert in mesh generation, drawings, product development and vendor management
 Sumit Jana (Head – Solver Devp) – Masters IIT Kharagpur with 12 years exp
 Expert in parallel solver development for CFD, Electromagnetics and free surface flows
 Suman Mohandas (Head – Software Devp & Visualization) – Bachelors Computer
 Expert in new software development, visualization, parallelization and GUI
 Ten engineers certified by CEMILAC including above

32
Consultants and Collaborations
32
 MOUs and Collaborations
 Centre for development of advanced computing – HPC usage in Teraflops
 NIT Nagpur – Joint R&D projects in coupled problems (CFD+FEM)
 IIITDM – Joint projects of analysis adding to product development
 Expert Panel (partial)
 Mr. SG Joshi – 40+ years experience in pump design and manufacturing
 Prof S C Lakkad – 45+ years experience in composite design and manufacturing process
 Prof K Sinhamahapatra – 20+ years experience in acoustic prediction
 Mr S Panse and H Ketkar – 35+ year exp in tool room, jigs/fixture design, special projects
 Mr V Kamat – 40+ years experience in hydraulic machine design, fabrication & maintenance
 Mr A Patki – 40+ years experience in space systems for reliability and weight reduction

33
Closure
33
 Experience of 400+ high tech projects in both strategic and industrial sectors
 Engineers trained in Aerospace grade quality and confidentiality
 Robust engineering software development experience
 Modular code development with high reusability
 Experience of parallelization and cloud computing
 Domain expertise in aforementioned sectors
 Contribution by the engineering team enhanced to design suggestions
 Flexible engagement model
 Fixed cost, Time and Material, Cost plus or models as per problem statement
 Unafraid to take R&D projects – Test Us

34
www.zeusnumerix.com
+91 98190 09836
Abhishek Jain
abhishek@zeusnumerix.com
Thank You !

Optimization and New Product Development @ Zeus Numerix

Recommended

Recommended

More Related Content

What's hot

What's hot (17)

Similar to Optimization and New Product Development @ Zeus Numerix

Similar to Optimization and New Product Development @ Zeus Numerix (20)

More from Abhishek Jain

More from Abhishek Jain (20)

Recently uploaded

Recently uploaded (20)

Optimization and New Product Development @ Zeus Numerix