Simulation based Engineering methods maturity level has significantly increased. Now Simulation is considered as third pillar of Science and Technology development. With simulations you can stretch the limits without the physical constraints. Now, we take care various design requirements concurrently as against rain flow or sequential product development. This significantly reduces the product development cost and time. Multiphysics CAE plays a significant role for reliable, efficient and affordable product development.

1. ATOA Scientific Technologies | Multiphysics CAE | Engineering Apps | 3D printing
Dr Raj C Thiagarajan
ATOA Scientific Technologies Pvt Ltd
Multiphysics CAE for Engineering
Innovation

2. ATOA Scientific Technologies | Confidential | | 2
Why are we here?
• Mythology
• Theologist
• Philosopher
• Scientist
– Physics, Chemistry, Biology, Mathematics….
• Engineers
– Civil, Mechanical, Electrical, Chemical…
• Multidisciplinary
– Nano, Bio, Info, Cognitive
• Multiphysics CAE for Engineering Innovation

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Engineering Innovations
• Shelter, Tools, Pottery, Textile..
• Wheel
• Arch Bridge
• Gun powder
• Mariners Compass
• Paper Making
• Printing Press
• New paper
• Arc lamp, Stem locomotive, Automobiles
• Polymer: Jet Engine: Composites: www:
• Mobile Phones : 3D printing

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Industrial Engineering Innovation Cycle
4
• Wealth creation cycle
• Contributions for
overall economic
growth
• Long cycle and low
Success Rate
• Simulation based
product design for
acceleration of
Engineering
innovation
Basic
Research
Applied
Research
Industrial
Research
Innovation/
Product
development
Commercia
lization
Wealth
Creation
ACADEMICINDUSTRY

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Simulation Based Product Design
5
• Simulation is considered third pillar of Science &
Technology
• Simulations has No Cost constraints, harsh/unrealistic
parameter range, EHS concerns.
• Reliable, efficient and affordability is the key driver for
Concurrent Product Development and Innovation

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Design Change Cost in product development
• Cost of fixing = Stages X Times
• Cost of Design changes
increases exponentially with
product development cycle.
• 80% of the product cost is
determined or committed at
the concept design stage
• Management influence
reduces over time
• CAE for first time right product
development
Product
Planning
Concept
Design
Final
Design
Pilot
Production
Mass
production
HIGH
Low
Activity,InfluenceIndex,
DesignchangeCost
NPI Activity
@
Part
1X
@
Sub assembly
10 X
@
Final Assembly 100 X
@
Dealer
1000 X
@
Customer
10000 X
6

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CAE for Engineering Innovation
7
Engineering
Innovation
Multiscale Multiphysics
Multimaterial
Engineering is Conversion of Material into Useful Product
Industrial Drivers: Cost, Weight and Performance
CAX (CAD, CAE, CAM) product development for first time right
Multiphysics, Multimaterial and Multiscale for Innovative Design

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Multiphysics

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Multiphysics Modeling
9
• Product Design is Multiphysics but
are Designed for Dominant Physics
• Technology adaptation trend vs
industry
• Current Technology and maturity
level Enables Affordable and Reliable
Multiphysics Product Design
• Multiphysics Design for First time
right cost effective, faster product
development.

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Multiphysics Modeling
10
Constitutes more than
one component with
governing equation.
• Coupling at Bulk, interface level:
– Magneto hydrodynamics , Reaction transport
– Fluid structure, aero elasticity, laser heating
• Coupling at time and length Scale (multiscale):
– atomistic to continuum Damage mechanics
• Coupling at Material Scale (multimaterial):
– Homogenization from nano, micro, macro

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Multiphysics Examples
Multiphysics
Structural
Thermal
Flow
Acoustics
Dynamics
EM/Optics
Chemical
Bio-Medical
Particle
Industrial Examples
Aero elasticity Aircraft wing, wind turbine, helicopter blades, micro turbines, long
bridges,
Fluid Structure Offshore foundations, Sloshing, actuators, compressors, Induction
Conjugate Heat
transfer
Racing car, offshore pipes. Gas turbine, forming, welding,
electronic packaging,
NVH, aero acoustics Acoustic panels, sound barrier, sonar, Automobile, aero engine,
speakers
Chemical Transport Composite cure, reactive polymer flow, adhesive, Biomedical
Biomechanics
BioCAE
Medical Imaging, Orthosis, prosthesis, ergonomics, Medical
Therapy.
Piezo, thermo
electricity
Ultrasonic probe, MEMS sensors, TE refrigeration, Electrical
connectors.
Electromagnetic
Heating
Non conventional / Non Conduction heating: Laser, RF, Microwave
Battery Physics Solid Oxide, Lithium , Fuel Cell, Battery powered automobile

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Multiphysics Design:
Stethoscope
12
• Acoustics Performance
improvement
• Sound propagation
• Noise effects
• Material, Geometry
• Electromagnetic, electrostatic
=> acoustical energy

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Multiphysics Design:
Chest Belt
13
• Bio electrical signal
propagation in cardiac tissue
using the FitzHugh-Nagumo
equations and the Complex
Ginzburg-Landau equations.
• Electromagnetic physics to
model the electrical field
distribution on a realistic 3D
geometric model of the
heart and torso.
• Inverse problem solving for
smart chest belt.

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Multimaterial

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Composites
Multi
Material
Advanced
Materials
Noble Aluminum Steel
Multimaterial Product Design
15
• From “ All steel” ,
“All Aluminum ” All
Composites” To
Multimaterial
• Leverage the best of
material for product
performance.
• Challenges
• Fabrication
• Multiphysics
• Multifunctional High COST Low
HighWEIGHTLow
Performance: High

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Multiphysics Design of Materials
Structural Elastic constants Super structural
Thermal Thermal conductivity Superinsulation
Electromagnetic permeability and
permittivity Metamaterials
Acoustic Sound transmission
loss
Acoustic bandgaps
Transport
Diffusion
Permeability
Super flow
Design Extremel

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Multiphysics Design of Materials
Physics Governing Eqs* Constitute Eqs* Comments
Structural
Static:, Navier’s equation, Hooke’s law
for stress strain relation. F, volume
forces, σ,stress tensor, e, strain tensor,
D, stiffness matrix
Thermal
Heat Equation, Fourier’s law: ρ,density.
Cp, heat capacity, k, thermal
conductivity, Q,heat source.
Acoustic
Helmholtz eq: ω, angular freq, ρ0, fluid
density, cs, speed of sound, q, source,
Dtl, transmission-loss coefficient, Wi,
incident and Wt is the transmitted sound
power.
Diffusion Fick’s law, Diffusion Coeff. c is the
concentration, D is the diffusion
coefficient, and R is a reaction rate
Porous flow
Darcy’s law, Permeability, : v, velocity, μ,
dynamic viscosity, K, permeability and P,
Pressure.P
xv
K




* Equations from COMSOL documentation
c
N
Deff

 ave

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Metamaterial Simulation Results
18
Acoustic
Super lens
Ultrasonic
Meta Surfaces
Composite
cloaks
Electrostatic
resonance
Negative
refraction

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Multiscale

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Multiscale Modeling
• Multiscale model is a
mathematical model
formed by combining
partial model at different
length and time scales.
• Away from predicting
known properties towards
new materials with novel
properties.
• Products engineered from
Atomic scale
Multi scale modeling Framework

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Multiscale:
damage mechanism
21
Structure
Part
Laminate
Fiber
Matrix
Molecular
ATOMIC
0.3345 nm
0.142 nm
0.669 nm
c
ba

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Multi example

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Nano Foam
23
Engineers Quest is to
develop materials with
higher properties at lower
weight
Simulation based material
design for superior
properties
• Super specific stiffness
• Super insulation
Nano
Micro
Macro
After US 7838108
VfNormalizedProperty Air Material 2

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Multiscale Modeling Super Structural
24
• Engineer the pore size for
superior properties
• Example: Tooth enamel:
Bio polymer+ mineral
fillers
• Defect insensitive pore
size
• Nano to micro to macro
properties

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Multiscale Modeling Super Insulation
25
• Nanogel/ Aerogel : Thermal
conductivity lower than still
air to about 0.002 W/mK
• Nanoscale Knudsen effect,
Phonon scattering
• Conduction, convection and
Radiation = k
• U value for Fenestration
product performance
• Building Thermal Simulation
for annual Energy and Cost
Saving
(From:http://www.ameriluxinternational.com/html/archite
ctData/nanogel/documents/nanogelData.pdf)
2 pm

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Multiphysics Modelling
CAD Structural Elastic
constants
Super structural
Thermal Thermal
conductivity
Superinsulation
Electromagnetic permeability and
permittivity Metamaterials
Acoustic
Sound
transmission
loss
Acoustic bandgaps
Transport
Diffusion
Permeability
Super flow
CAM
CAE
3DPRINTING

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Fore more about
Multiphysics CAE
Visit:
www.atoa.com