How Are New CAE Innovations Improving Engineering Efficiency?

February 5, 2025
How Are New CAE Innovations Improving Engineering Efficiency?

In an ever-evolving engineering landscape, Computer-Aided Engineering (CAE) has become an essential tool, significantly enhancing precision, efficiency, and integration across various fields. The recent advancements in CAE technologies have revolutionized the way engineers tackle complex problems and streamline their workflows. This article delves into the latest innovations in casting process simulation, additive manufacturing, material simulation, high-performance computing (HPC), material flow simulations, and advanced calculation software, shedding light on how these developments are bolstering engineering efficiency like never before.

Advancements in Casting Process Simulation

Magma’s latest version 6.1 of its casting process simulation software, Magmasoft, introduces game-changing enhancements that elevate the modeling of low-pressure casting processes to new heights. A specialized process module for rheocasting and thixomolding vastly expands the software’s utility for die casters, opening up new possibilities for complex casting operations. Enhanced solver technologies underpin these improvements, offering unparalleled precision and efficiency in simulations. By leveraging new mesh generation capabilities with composite and TAG meshes, Magmasoft now provides an even more accurate representation of interfaces between cast materials, molds, and core materials.

One of the most intriguing features of Magmasoft 6.1 is the “Tracer” results, which deliver granular analyses of temperature, velocity, pressure, and path length within casting processes. This level of detail enables engineers to track melt movements and flows with unprecedented accuracy, reducing the trial and error typically associated with physical testing. Additionally, the introduction of the “Economis” perspective is a notable step towards sustainability, allowing users to quantify not only costs but also CO2 emissions associated with various decisions. These enhancements collectively drive down the time and cost of casting simulations, setting a new industry standard for efficiency in casting process modeling.

Streamlining Additive Manufacturing

Synera’s integration of Hexagon’s AM Studio Support technology marks a significant breakthrough in the field of additive manufacturing, particularly in the creation of metal parts. Traditionally, engineers invested considerable time and effort manually configuring component alignments and support structures, relying heavily on personal expertise rather than standardized methodologies. This labor-intensive process often led to inefficiencies and inconsistencies in production. By automating these tasks, Synera’s new integration promises to transform the workflow dramatically.

The integration introduces five distinct types of support structures—rod, line, block, tree, and adaptive cell—each optimized for build time and material efficiency. The automation facilitated by this technology extends to parametric design updates with CAD connectors, topology optimization, and support strategy implementation. Engineers can effortlessly apply build parameters and dispatch them directly to EOS machines, accelerating the entire production process. This not only minimizes manual interventions but also enhances precision, ensuring that parts are manufactured to exact specifications. The result is a significant leap forward in workflow efficiency, which translates to faster, more reliable production cycles in the realm of additive manufacturing.

Enhancing Material Simulation

J-Mat-Pro’s latest version, 15, has brought material simulation technology to a new level of sophistication, equipping engineers with tools to optimize both products and processes more effectively. This version incorporates several new features designed to reduce energy consumption while enhancing the precision of simulations. Notable additions include advanced hardness calculations for various steels, CCT and hardenability analysis, and high-temperature calculations for stainless steel. These features enable engineers to simulate material behavior and properties more accurately based on chemical composition and processing techniques.

Moreover, J-Mat-Pro 15 facilitates seamless export of material cards to a variety of CAE software solutions, ensuring smooth integration into broader simulation frameworks. This interoperability allows for direct incorporation of material data into simulations, enhancing the accuracy and reliability of predictions. By providing a more comprehensive understanding of material performance, the software helps engineers optimize their designs more effectively, reducing the need for extensive physical testing. The time saved and the increase in precision ultimately lead to more efficient development cycles and better-performing products.

Leveraging High-Performance Computing (HPC)

Altair has recently incorporated support for Nvidia’s cutting-edge Grace CPU and Grace Hopper superchip architectures within several products in its Hyperworks design and simulation platform, a move that promises monumental advancements in high-performance computing applications. Tailored for high-demand workloads in both computing and artificial intelligence, these architectures represent a leap in performance, efficiency, and scalability. Internal benchmarks have shown that the Nvidia Hopper GPU series can execute simulations up to twice as fast as its predecessors, offering unprecedented runtime reductions for Altair solvers.

These advancements significantly amplify Altair’s computational capabilities, allowing engineers to tackle more intricate simulations with enhanced accuracy and reduced computation times. By leveraging these next-generation computing resources, design and analysis processes become markedly streamlined. Engineers can now undertake more complex and computationally demanding projects that were previously untenable due to hardware limitations. This boost in computational power not only improves overall productivity but also results in more innovative and precise engineering solutions.

Optimizing Material Flow Simulations

Schnaithmann Maschinenbau GmbH has been leveraging Visual Components’ 3D simulation software to streamline project planning of complex automation systems for three years. This software enables users to simulate, validate, and optimize intricate automation projects with greater efficiency. Recently, Schnaithmann took a substantial step forward by integrating its standard product components into the Visual Components E-Catalog, which allows for more accurate and accessible simulations.

This integration benefits engineers particularly during the planning and design phases when detailed CAD files might not yet be available. By incorporating products like conveyors, lift transverse units, and vertical conveyors, the software enables proactive planning and optimization of material flow. This preemptive approach helps in identifying and mitigating potential errors early in the design cycle, thereby improving overall project efficiency. The ability to create reliable simulations without detours significantly enhances the planning and implementation phases of automation projects, reducing the likelihood of costly mistakes and project delays.

Advancements in Calculation Software

The latest release, R2024b, of the Matlab and Simulink product families has introduced numerous updates aimed at boosting workflow efficiency for engineering teams across various disciplines. One of the key enhancements is the expanded capabilities of the 5G Toolbox, which now supports 6G waveform exploration. Originally developed for the modeling, simulation, and verification of New Radio (NR) and 5G-Advanced systems, this tool now places engineers at the forefront of next-generation communication technologies.

The DSP HDL Toolbox has also seen significant improvements; it now includes hardware-capable Simulink blocks and subsystems for developing advanced signal processing applications. An interactive DSP HDL IP Designer app allows users to configure DSP algorithms and generate verification components more efficiently. Additionally, the System Composer tool now boasts improved features for specifying and analyzing architectures in model-based system development, streamlining software architecture modeling. Collectively, these updates enhance the overall capabilities of Matlab and Simulink, making them indispensable tools for engineers looking to improve precision and efficiency in their work.

Future Considerations and Technologies

In an ever-changing engineering landscape, Computer-Aided Engineering (CAE) has become a vital tool, greatly enhancing precision, efficiency, and integration across various fields. Recent advancements in CAE technologies have transformed the way engineers address complex problems and streamline their workflows. This article explores the latest breakthroughs in casting process simulation, additive manufacturing, material simulation, high-performance computing (HPC), material flow simulations, and advanced calculation software, highlighting how these advancements are boosting engineering efficiency like never before.

Casting process simulation has improved significantly, allowing engineers to predict and mitigate defects before actual production. Additive manufacturing, or 3D printing, has opened up new possibilities for creating intricate designs with unprecedented accuracy. Material simulation has also seen strides, helping engineers understand material behavior under different conditions. High-performance computing facilitates faster and more accurate simulations, even for highly complex systems. Material flow simulations ensure optimal use of resources, and advanced calculation software ties all these elements together, enabling more seamless and efficient engineering processes.

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