Ansys Solutions 05 2006

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Industry Spotlight

Oil and GasANSYS 11.0 brings together powerful enhancements to broaden the role of simulation in product development.

The Fiat Panda reached fuel efficiency goals through aerodynamic studies performed with ANSYS CFX.

ANSYS Mechanical performs real-time analysis for jet engine turbine components based on in-service usage.

ContentsIndustry Spotlight5 Oil and GasAdvanced simulation tools help meet growing worldwide needs for oil and gas as a critical resource for energy and materials in a wide range of products.

DepartmentsEditorialThe Spectacular Value of Being Right...............................

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Industry NewsAnnouncements and Upcoming Events.........................

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Simulation at Work

Features10 Expanded and Integrated

Development of an Innovative Snowthrower Steering System Meeting European Emissions for Trucks Meeting Market Requirements for Industrial Pumps Pressure Loss in Pipes with Sudden Contractions

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Solutions in ANSYS 11.0ANSYS 11.0 brings together powerful enhancements to broaden the role of simulation in product development.

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Technology UpdateNonlinear Stabilization Features..............................................

15 Latest Tools for Thermal

Analysis of Electronics

Tech FileGenerating Interpolated Data with Beam and Shell Elements..................................................................................

A wide range of ANSYS software is available to study cooling in electronics parts and systems.

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Tips and TechniquesANSYS Workbench Makes Simulating FSI Easier............................................................................................................

38 40

18 Simulation-Based Life-Cycle Cost ManagementANSYS Mechanical performs stress and thermal analysis for calculating as-flown fatigue life of critical jet engine turbine components.

Guest CommentaryRunning CAE Activities as a Lean Business..............

About the coverThe use of simulation plays a key role in enabling better exploration of new oil and gas fields, transportation of raw materials and transformation of this resource into everyday products. Read more in this issues Industry Spotlight article beginning on page 5.

21 CFD Helps Design an

Eco-Friendly Car

The Fiat Panda reached fuel efficiency goals through aerodynamic studies performed with ANSYS CFX.

For ANSYS, Inc. sales information, call 1.866.267.9724, or visit www.ansys.com. To subscribe to ANSYS Solutions, go to www.ansys.com/subscribe.Editorial Director John Krouse jkrouse@adelphia.net Managing Editor Fran Hensler fran.hensler@ansys.com Designers Miller Creative Group info@millercreativegroup.com Art Director Dan Hart dan.hart@ansys.com Ad Sales Manager Beth Mazurak beth.mazurak@ansys.com Circulation Manager Elaine Travers elaine.travers@ansys.com Editorial Advisor Kelly Wall kelly.wall@ansys.com Editorial Contributors Liz Marshall Chris Reeves emm@fluent.com chris.reeves@ansys.com

ANSYS Solutions is published for ANSYS, Inc. customers, partners and others interested in the field of design and analysis applications.Neither ANSYS, Inc. nor the editorial director nor Miller Creative Group guarantees or warrants accuracy or completeness of the material contained in this publication. ANSYS, ANSYS Workbench, CFX, AUTODYN, FLUENT and any and all ANSYS, Inc. brand, product, service and feature names, logos and slogans are registered trademarks or trademarks of ANSYS, Inc. or its subsidiaries in the United States or other countries. ICEM CFD is a trademark used under license. All other brand, product, service and feature names or trademarks are the property of their respective owners. POSTMASTER: Send change of address to ANSYS, Inc., Southpointe, 275 Technology Drive, Canonsburg, PA 15317 USA. 2006 ANSYS, Inc. All rights reserved.

www.ansys.com

ANSYS Solutions

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Volume 7, Issue 5 2006

Editorial

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The Spectacular Value of Being RightBy reducing hardware test cycles, engineering analysis helps avoid bottom-line penalties of being wrong regarding time, cost and quality on individual projects and product launches. But the greatest benefit of a systematic Simulation Driven Product Development approach is the sustainable business value of being right year after year with steady streams of design innovations that capture the imagination and dazzle the market.Save time, lower costs, maintain quality these are the benefits most companies go after with engineering simulation. For decades, thats been the name of the game: crank out products faster, cheaper, better than the competition. Using simulation, companies can spot and fix problems early By John Krouse in the cycle, thereby reducing Editorial Director the high cost and long delays ANSYS Solutions of going through numerous jkrouse@adelphia.net hardware tests. These proven benefits certainly are well documented. In one recent study, The Simulation-Driven Design Benchmark Report, the Aberdeen Group found that 100 percent of best-in-class manufacturers those meeting cost, revenue, quality and launch date targets 86 percent or more of the time use simulation in the design phase and average 1.6 fewer prototypes than all other manufacturers. With the help of simulation, these top performers, on average, were able to get the most complex products to market 158 days sooner with $1.9 million lower development costs. Manufacturers with the simplest products shortened launch times by 21 days and saved $21,000 in development costs. Most companies would jump at the chance to rack up these impressive numbers. Indeed, when it comes to time, cost and quality, failing to deliver on any one of these subtracts significantly from the bottom line. The penalty of being wrong is high, and the benefit of Simulation Driven Product Development in avoiding these deficiencies is unquestionable. But thats only part of the story and, certainly, no guarantee of market success. In fact, a well-designed, inexpensive, quality product launched incredibly fast can still be a total flop if its uninteresting and nobody wants to buy it. Thats why forward-thinking manufacturers aim for innovation continually capturing the imagination of the market with a steady stream of top-performing successful products. These companies listen to the voice of the customer, anticipate swiftly changing trends and know buyer expectations. Their products are innovative because they stand out from the crowd, and their development processes are innovative because these companies can quickly crank out successful designs one after another, year after year. In a recent study by Momentum Research Group, the number-one way for improving competitiveness cited by corporate decision makers was to increase the rate at which their organizations deliver product and service innovations. In another survey by The Boston Consulting Group in conjunction with BusinessWeek magazine, an overwhelming majority of senior executives named innovation as one of their top priorities. Unsurprisingly, Simulation Driven Product Development is at the foundation of many of these efforts in achieving repeatable and efficient design innovation. Instead of rushing to production, smart companies have learned that time saved by reducing the number of hardware tests near the end of development can be utilized early in the cycle to drive innovation. By using engineering analysis tools to evaluate alternative ideas, guide the design and refine concepts in the initial stages of product development, organizations front-load the process to cultivate the creativity and inventiveness necessary for true innovation. Leading-edge companies leveraging Simulation Driven Product Development know that the greatest value of the technology is that it enables them to pull ahead of competitors with innovative products and processes. They dont just avoid bottom-line penalties for being wrong; they get spectacular business value from being right adding money to top-line revenue streams, increasing brand recognition and sustaining ongoing profitability growth by hitting the bulls-eye, time after time, with unique and highly successful products.

www.ansys.com

ANSYS Solutions | Volume 7, Issue 5 2006

Industry News

Recent Announcements and Upcoming EventsTop-Performing Manufacturers Using Simulation in Design Phase A recent Aberdeen benchmark study examines when and how companies use simulation during product development and correlates this usage with their performance. The study found that 100 percent of best-in-class manufacturers reported using simulation in the design phase, while only three out of four of the poorest performers do the same. The report also discloses best practices in using simulation that lead to superior product development performance. Aberdeen Group, Inc. provides fact-based research and insights focused on the global, technology-driven value chain. The report was made available to the public through partial underwriting by ANSYS, Inc. Moldflow Plastics Insight 6.1 Offers New Capabilities Moldflow Corporation, a leading provider of designthrough-manufacturing solutions for the plastics injection molding industry, released the latest version of its powerful and widely used plastics design analysis software. Moldflow Plastics Insight (MPI) 6.1 delivers new technologies and key enhancements to help users investigate and solve potential