MECHANICAL CENTER OF EXCELLENCESupporting Different Domains :

Aero

Auto

Industrial

Medical

Consume Electronics

Hitech (Semi/Telecom)

Comprises of :

3

D o m a i n S p r e a d

Overview of CAE Group

Team composition

• 250+ team member

• More than 3.5 MN man hours

Composition :

Bachelor of Engineering : 90 +

Master of Engineering : 150 +

SME / PhD : 7

60% team members are placed in dedicated

ODC at HCL facility & customer place

40% of the team members are in common

pool.

Tools

• Abaqus

• STAR CCM+

• Fluent

• Icepak

• Flotherm

• Autoform

• Comsol

• Moldx3D

• Minitab

• CST

• Nastran

• Ls-Dyna

• Ansys

• MatLab

• Hypermesh

• CFX

• ICEM-CFD

• CF-Design

• Recurdyn

• Trace Pro

Consultant and collaborations

Consultants for:

• Applied mechanics

• Electrical and Magnetic

• Electrostatic

• Cryo mechanics

• Fluid dynamics

• Tissue Testing

• Automation

Common Pool Hardware

Workstations : 12core to 32

core (32 GB to 256 GB RAM)

HPC Serve : 60 Core with 5

Node, 64GB RAM each node

Altix Server (SGI) : 16 CPU,

128GB RAM, 6 node cluster

Hardware

Aerospace Industrial Hi-Tech Medical Automotive

• Structures• Engines• Systems

• Interiors & Exteriors• Safety systems• Powertrain• Engines• NVH & Durability• Crash & safety

• Heavy equipment• HVAC and Climate Control• Automation• Fire & Safety• Oil & Gas• Off-Highway Equipment

• Deposition systems• Electronic control equipment• Inspection systems• Implantation Devices• Wafer handling system• Gas delivery system

• Cardiovascular• Infusion Systems• Disposables• Orthopedic• Diagnostic Imaging• General Surgery

• Tablet • Laptop• Mobile Phone• Hand held printer• ATM machine• Home Appliances

CE&A

CAE Services : Simulation driven solutionFBD

Hand Calculation

1D Model

Feasibility Model (Simplified FE model)

Concept development support

Competitor product analysis

Material property extraction

Design direction

Test method validation support

Compliance Assessment

Design Rationale support

Process parameter Study

Mold qualification support

Metal forming

Casting

Root cause Analysis

Value Engineering

Material Solution

CAPA investigation

Finite element modelling

Analysis ( Structural / Thermal / CFD / Multiphysics etc..)

Verification based on standard (ISO / IEC / ASTM)

Material Selection & Testing

DoE

Sensitivity Analysis

Automation / Analytical solution

Package support

Concept Generation

Design Development

Sustenance Activity

Manufacturing

Quality & Regulatory

Market Support

Concept Generation

Design Development

Sustenance Activity

Manufacturing

Quality & Regulatory

Market Support

CAE Services : Simulation driven solution

FBD

Hand Calculation

1D Model

Feasibility Model (Simplified FE model)

Concept development support

Concept Generation

Design Development

Sustenance Activity

Manufacturing

Quality & Regulatory

Market Support

CAE Services : Simulation driven solution

Concept Generation

Design Development

Sustenance Activity

Manufacturing

Quality & Regulatory

Market Support

Finite Element Modelling

Analysis ( Structural / Thermal / CFD / Multiphysics etc..)

Verification based on Standard (ISO / IEC / ASTM)

Material Selection & Testing

DoE

Sensitivity Analysis

Automation / Analytical Solution

Package Support

Thermal Simulation

Vibro - Acoustic

CAE Services : Simulation driven solution

Drop Simulation Shock AnalysisStructural

Lighting Simulation

EMI/EMC

Concept Generation

Design Development

Sustenance Activity

Manufacturing

Quality & Regulatory

Market Support

Root cause Analysis

Value Engineering

Material Solution

CAPA investigation

CAE Services : Simulation driven solution

6%8.5%

Fabric Material Characterization

Field Failure

Value Engineering

Concept Generation

Design Development

Sustenance Activity

Manufacturing

Quality & Regulatory

Market Support

Process parameter Study

Mold qualification support

Metal forming

Casting

CAE Services : Simulation driven solution

Concept Generation

Design Development

Sustenance Activity

Manufacturing

Quality & Regulatory

Market Support

Test method validation

Compliance Assessment

Design Rationale support

CAE Services : Simulation driven solution

Concept Generation

Design Development

Sustenance Activity

Manufacturing

Quality & Regulatory

Market Support

Competitor product analysis

Material property extraction

Design direction

CAE Services : Simulation driven solution

Setup Box

Rugged Notebook

Peripheral

Display Module

Thermal Model

Sealed Thermal Management System

Drop Analysis

PCMC AssemblyScrew Loosening

Structural

Thermal

Drop analysis

Chassis optimization

Hinge analysis

Display module

Adhesive delamination

Screw fatigue

Processor Cooling solution

Fan Selection

Vent optimization

Heat spreader

Material Selection

ASHBY Technique

14

Feasibility simulation

Design & Improvements

Failure conditions

Thermal Management Structural Management

Modal Analysis

Shock & Random Analysis

Reliability Prediction

Solder Joint Lifetime

Under thermal cyclingUnder Vibration

Vibration StressThermal Stress

Server Storage Device

Continued…

15

XYZ

Fundamental frequency

Steinberg calculations for board components under Shock vibration excitation

Structural Management : Board Level Analysis

Steinberg Calculations

Continued…

16

Structural Management : Electronic package Analysis

Sub Model :Global Model :

Global Model results :

Sub Model results :

Cad Model

Stress plot

BGA Solder Joints life during thermal cycling scenario Lead Failure during Drop scenario

Continued…

17

Shock Strain Plot

Reliability Prediction : Sherlock software

Structural

CFD

Vibro Acoustic

Mold Flow

Process Parameter Optimization

Impact Test

Product development of Vacuum Cleaner

VAVETear Down AnalysisCost Modeling

Assembly Level Analysis

Structural

CFD

Optics

Metal Forming

VAVETear Down AnalysisCost Modeling

Sparking Food Cooking

Process parameter Optimization

Package Optimization

Mold Flow

Simulation Driven Design - OVEN

Voice Of Customer (VoC)

Inputs from Executives, Team, Stakeholders, Customers & Users

Conceptualize DesignDetailed Design & Analysis

Testing & Validation

Manufacturing

Substance & Post Market study Mold flow Analysis & Validations

Test & FEA Correlation

FSI simulation Erectile response studyFabric characterization

Failure Study of Needle

Buckling

Class III medical device implanted to treat penile prosthesis. HCL supported complete NPD program

Product Development of Penile Prosthesis Implant

Pressure Expansion StudyValve Design

Cost Reduction of Multi Functional Printer