PAMTALK - jp.esi-group.com · PAM-QUIKFORM for CATIA V5 2007 Hitachi gST Successfully Models...

PAMN E W S F R O M T H E V I R T U A L T R Y- O U T S P A C E

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Product News

PAM-QUIKFORM for CATIA V5 2007

Hitachi gST Successfully Models Oil-Air Interfaces in Fluid Dynamic Bearings of Hard Disk Drives with CFD-ACE+ from ESI group

Special report on CFD

Bombardier Transportation uses VA One, ESI Group’s vibro-acoustics simulation software to reduce

structure-borne noise transmission in trains

Success Story

ESI group CFD products are used extensively in the hard disk drive industry for modeling everything from the windage caused by the high-speed rotation of the disk pack, to the micro-capillary flows in

the critical fluid dynamic bearings.

790 AMD AD CAE.indd 1 3/5/07 15:42:04

editorial

Focusing on the CustomerFirst, I would like to thank all of our customers for your continued support and encouragement as well as for the extraordinary applications for which you utilize our solutions.

ESI Group has been listening. We have been listening to our customers, to the market, and to the recommendations of our advisory board.

The strong requirement and demand of industries across the world to have real world, multi-domain, realistic simulation solutions, which span multiple engineering disciplines, correlated with real world results, rather than physical prototyping and testing, and to have an open environment to manage multi-domain compute models, simulation processes and data, clearly defined our investments and our go-to-market model.

We have been listening and this is our response:

At the beginning of the year we started investing in three areas: sales and customer support, product development manpower, and the development of new products. In sales and customer support, we are substantially increasing our sales, support and consulting staff around the world to provide best-in-class service to our customers.

In the product development area, we are continuing to invest heavily to keep delivering leading state-of-the-art simulation solutions to our customers. The upcoming 2007 releases of our Virtual Performance, Virtual Manufacturing and Design & Analysis products not only includes new and unique capabilities, but also enhances performance, reliability and robustness to achieve Realistic Simulation faster and better.

The release of an open multi-domain environment compatible with customers’ present and future best practices –VisualDSS–, which is an end-to-end decision support system for CAE, is another step of our commitment to our customers to provide them with the essential solutions to enable them be more effective.

We are proud to offer these new advances to our customers. We hope that you will feel that we have, indeed, been listening.

We greatly appreciate our customers and are committed to providing world class, realistic simulation solutions and services to each and every one of you.

contents

Haluk Menderes

Executive Vice President Sales & Marketing, Worldwide Operations ESI Group

S p e c i a l r e p o r t o n c f d• Hitachi GST Successfully Models Oil-Air Interfaces in Fluid Dynamic

Bearings of Hard Disk Drives• Ballard: Flow Simulation Improves Robustness of Fuel Cell Design

S U c c e S S S t o r Y• Bombardier Transportation uses VA One, ESI Group’s vibro-acoustics

simulation software to reduce structure-borne noise transmission in trains

p r o d U c t n e W S• MIZUNO Corporation uses PAM-CRASH to improve sports

footwear performances• VISUALDSS, the End-to-End Decision Support System for CAE• PAM-QUIKFORM for CATIA V5 2007, a new Solution for the Composites

Simulation Value Chain• ESI Group releases VA One 2007, the One Simulation Environment

for Full-Frequency Vibro-Acoustic Analysis• ESI UK expands its consulting services• ESI Group metalforming solutions seminars for the manufacturing

industries

c a S t i n g• New Streamlined and Productive Environment for Casting Applications• Baosteel training• Modeling Continuous and Semi-Continuous Casting

p r o d U c t n e W S• Making Wind...

c o r p o r at e• 3 questions to Dominique Grolade,

Corporate Quality Manager, ESI Group• Publication: Simulation System Integration• 2006/07 annual sales: e66 M

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editorial

www.esi-group.com

PAMTALK is issued quarterly by ESI Group

Executive Editor: Nathalie David-FrancEditor-in-Chief: Rita Tronel

[email protected] Group MarketingPARC D’AFFAIRES SILIC99 RUE DES SOLETS - BP 8011294513 Rungis Cedex - FRANCE Tel: +33 (0) 1 41 73 58 00 - Fax: +33 (0) 1 46 87 72 02www.esi-group.com - [email protected]

Design: Agence TETRAKTYS

ISSN 1635-866XImpression : RIVET PRESSE EDITION

24, rue Claude-Henri-Gorceix - 87022 LimogesDépôt légal : Mai 07

All PAM and SYS products are trademarks of ESI Group. All other products, names and companies referenced are trademarks or registered trademarks of their respective owners. All text and images included in the articles are the copyright of the companies presenting their applications and simulation tasks.

Photo credits: AMD, Arcelor Group/Renault, Ballard Power Systems, Boeing, Bombardier Transportation, EC project IMPACT Consortium, Hitachi GST, HP, IfH University of Karlsruhe, Messe Düsseldorf, MIZUNO Corporation, Sim-Cast, Volkswagen Research

Cover Photography: Courtesy of Hitachi GST

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pam-talk #34 spring 2007

special report4

Special report SUcceSS StorY prodUct neWS caSting corporate

www.esi-group.com

Hitachi GST Successfully Models Oil-Air Interfaces in Fluid Dynamic Bearings of Hard Disk Drives

Special reporton CFD the challenge n ��Optimizing the design of fluid

dynamic bearings (FDBs) that are so small and inaccessible that it is difficult to see or measure them

n Building a scaled up physical model to validate a computational fluid dynamics (CFD) model

the Benefitsn The CFD model demonstrated the

ability to predict the performance of the scale-up model

n In the future, the CFD model can be scaled down and used to investigate alternative FDB designs


special report 5www.esi-group.com

difficult design challenge

FDBs are preferred over ball bearings in hard disk drives because the elimination of metal-to-metal contact greatly reduces non-repeatable runout due to surface imperfections. But ever since their introduction in the 1960s by prof. E. Muijderman for use in ultra-centrifuges, it has been well known that FDBs provide a very difficult design challenge. A few milligrams of oil must perform flawlessly in the FDB over the life of the HDD. The oil must not degrade, evaporate or atomize without oil changes or an oil filter.

The bearing surfaces in an FDB consist of a rotating (rotor) and stationary part (stator) with a thin layer of oil in between. Slanted grooves in either the rotor or stator generate oil film pressure to support the rotor. In FDB designs for high-speed server-class drives, the rotor usually moves around the shaft without contact, the shaft being rigidly supported at both ends.

The oil-air interface (OAI) occurs in the partial fill design of FDB’s when the oil covers the grooved areas only partially.

Controlling the OAI is often considered to be key to successful FDB design because gas/fluid interfaces strongly affect the rotordynamics. The OAIs must be stable, especially when located in the grooved section of the FDB, in order to avoid formation of bubbles. The challenge of analyzing FDBs is increased by the fact that FDBs are so small and inaccessible that the OAI cannot be easily observed or measured. For example, the radius of the shaft of the FDBs is a couple of millimeters and the clearance between rotor and stator is only a few microns.

Hardware scale-up model

Dr. Ferdinand Hendricks of Hitachi gST, has made major progress towards overcoming this obstacle by building an FDB that is scaled up by a factor of 1000, see Fig. 1. Dr. Hendriks selected the 1000X scale-up factor in order to achieve a minimum

1. (a)

1. (b)

2

scaled up bearing clearance of 3 mm, which is sufficient for measuring and observing. In order to reduce the size of bearing to a manageable level while keeping the 3 mm bearing clearance, he modified the design of the scaled-up hardware model so that it consists of a single inclined groove in the stator wrapped around itself, and a smooth cylindrical rotor.

cfd simulation

Simultaneously, Hitachi gST used CFD-ACE+ from ESI group to develop a CFD model of the scaled up bearing. The basic idea is that after validating the CFD model against the physical experiments, it should be possible to reduce the CFD model to the size of the actual FBD while maintaining its accuracy. Then Dr. Hendricks will be able to use the actual size simulation model to evaluate the effects of potential design changes and optimize FDB design.

The Volume of Fluid (VOF) model used to track the gas/fluid interface in CFD-ACE+ successfully identified all of the major features of the OAI dynamics. These include a difference in OAI deflection for the stator and rotor, unsteady flow in the grooves, fast revolution near the rotor and slow revolution near the stator. In order to save computational time a simplified “two-cell” VOF model is used. The two-cell model correctly predicts that the oil contact line C1 at the rotor is not drawn into the groove but continues its circumferential movement while adhering to the rotor. However, the simplified model predicted non-steady flow while steady flow is observed in the experiment. It was recently found that a slight increase in the wetting angle can suppress the unsteadiness.

In the near future Hitachi gST plans to use the model to incorporate complications such as modeling the effect of dissolved gases on cavitation behavior in FDBs, a common occurrence in many lubrication situations.

figure 1. (a) typical fdB herringbone bearing with 8 land/groove sections. to study a single land/groove pair shown in black, it was rolled up onto itself to form the tiny object at the center.

the final model figure 1. (b) is obtained after scaling up by a factor 1000. it is shown filled with silicone 350 cS oil and running at scale speed. the scaled up rotation time is approximately 7 seconds. c1 is the oil contact line on the inner, rotating cylinder, c2 is the deformed contact line on the outer grooved stator.

figure 2. computed average deflection of the oil air interface in the 1000X scale up model under 1g gravity. 1 cell discretization across the oil film. the average interface deflection agrees well with the deflection of the scale up experiment.

Hitachi Global Storage Technologies (Hitachi GST) was founded in 2003 as a result of the strategic combination of IBM and Hitachi’s storage technology businesses. Hitachi GST is positioned to immediately advance the role of hard disk drives beyond traditional computing environments to consumer electronics and other emerging applications. Hitachi GST offers a comprehensive product portfolio unsurpassed in the industry - including 1-inch, 1.8-inch, 2.5-inch, and 3.5-inch hard disk drive storage devices.

about Hitachi gSt




special report www.esi-group.com6

Flow Simulation Improves Robustness of Fuel Cell Design

the challenge n Improving the efficiency and life of

a fuel celln �Understanding the complex flow

inside the individual cells

the Benefitsn �Increase power generation

efficiencyn �Increase in life of celln �Engineering time savings

ELECTRIC CIRCUIT (40% - 60% Efficiency)

O2 (Oxygen) from Air

Heat (85°C) Water or Air Cooled

Air + Water Vapor

Flow Field PlateGas Diffusion Electrode (Cathode)Catalyst

Flow Field PlateGas Diffusion Electrode (Anode)

Catalyst

Used Fuel Recirculates

Fuel H2 (Hydrogen)

Proton Exchange Membrane

Ballard power Systems, Burnaby, British Columbia, is a leader in the design, development and manufacture of proton Exchange Membrance Fuel Cell (pEMFC). pEMFC is considered the most promising fuel cell technology for automobiles and automotive power supplies because of their high power density. Today, approximately 130 Ballard-powered fuel cell vehicles have accumulated more than 3.9 million kilometers on roads around the world, and have delivered more than 4.5 million people safely to their destinations.

Ballard’s pEMFCs use a complex design with a stack consisting of multiple cell rows, each cell row having multiple cell plates, and each cell plate having many channels. The extreme variation in scale, which is a key factor in the power density of the device, creates major design challenges. One of the key design goals is to provide a uniform flow distribution in the approximately 20 kilometers of total flow circuits in a stack because the stack performance is often limited by the unit cell with the worst performance.

Ballard uses the multi-physics environment of CFD-ACE+ including Proton exchange membrane fuel cell

Courtesy of Ballard Power Systems



special report 7www.esi-group.comSimulation matches experimental measurements of current density

Single channel cfd-ace+ model

cfd-ace+ used to optimize flow distribution in manifold

its pEMFC module to perform comprehensive 3D simulations of fuel cells. The full stack model is too large to run as one job so Ballard has created several different models that are used to optimize fuel cell performance at different scales.

optimizing manifold and headers

One key task is to design the manifold to balance mass flow between all cell rows and optimize pressure drops. This required a large-scale model that did not need to account for the details of the flow in the individual cells. First, manifold segments were optimized for pressure drop through CFD simulation. After optimizing the bends, CFD was used to analyze the complete manifold and ensure that mass flow is equally distributed between all cell rows.

The next step in the flow path is the headers which distribute gases to the individual cells. Optimizing the headers required a model that simplifies each cell flow field to an equivalent flow resistance to represent pressure drop in active cells.

The CFD-ACE+ model of the header showed that flow exiting the cells hit the outside wall of the header and formed two vortices. Flow separated towards the dead end of the inlet header leading to poor flow distribution for the last cells. Based on these insights, the header geometry in the model was changed several times and then the model was re-run until the flow field in the header was substantially improved.

optimizing cell plate geometry

The fuel cell must be modeled at even a smaller scale in order to optimize the cell plate geometry. A structured multi-block mesh was created to represent the bi-polar plates, the channels, and MEA layers. The model was verified by comparing simulation predictions with experimental results for key metrics

Ballard Power Systems (TSX: BLD; Nasdaq: BLDP) is recognized as a world leader in the design, development, manufacture and sale of zero-emission proton exchange membrane fuel cells. Ballard’s mission is to make fuel cells a commercial reality. To learn more about Ballard visit www.ballard.com.

about Ballard power Systems

including cell voltage vs. current density, plate current distribution, MEA water content, coolant temperature rise, and sensitivity to operating conditions and material properties. The simulations closely matched the experiments.

After verifying the model, Ballard analysts varied geometric parameters that affect transport including channel cross-section area, channel hydraulic diameter, channel length, and ratio of channel width to land area. They gained many insights such as that predicted cell performance increases with increasing gas channel width and channel pitch, which indicates that coupled transport in the gas diffusion layer is dictated by electrical conduction.

cfd-ace+ has become tool of first choice

“The net result was a substantial improvement in the robustness of our fuel cells designs,” Kumar concluded, lead simulation scientist at Ballard. “We are continuing to improve our modeling techniques in order to increase the accuracy of our models and reduce computation time. Other potential improvements include filament based models to communicate with porous media and using simple path length lookup tables to capture the shape of the channels. As a result of these advancements, CFD-ACE+ has become the tool of first choice for fuel cell designers at Ballard.”



success story www.esi-group.com8

Bombardier Transportation uses VA One, ESI Group’s vibro-acoustics simulation software to reduce structure-borne noise transmission in trains

Reducing noise and vibrations inside the structure of a modern train to ensure a high level of

passenger comfort is no easy task and requires detailed knowledge of transmission paths. Bombardier Transportation selected ESI group’s VA One software to perform the complex vibro-acoustic analysis needed.

Traditionally, Finite Elements (FE) and Statistical Energy Analysis (SEA) methods are used to predict noise and vibration transmission paths in train structures. However, it is often impossible to create system level models of the mid and high frequency response of large structures using Finite Elements. On the other hand, although SEA is computationally efficient and well suited to creating system level models of the high frequency response, it proves difficult to create detailed models of complex junctions and subsystems. The frequency range for which neither FE nor SEA models are applicable can be fairly wide and is often critical for practical design issues. The alternative of using separate software for different frequency ranges also results in loss of time and more delicate model management.

To overcome these modeling challenges, Bombardier Transportation chose the “Hybrid FE-SEA” module of VA One for their analysis, specifically because it implements a unique method for rigorously coupling FE and SEA in the same analysis. The method offers enhanced prediction capabilities including a widened frequency range coverage and reduced calculation times.

passenger trains systematically use floating floors to provide a good barrier to the transmission of air and structure-borne noise and vibration. Bombardier Transportation therefore focused their initial modeling efforts on the vibration reduction across the floating floor of a double-decker train.The study demonstrated that VA One could accurately predict the transmission of vibration across a floating floor design. It also identified the key physical parameters controlling the transmission across the floor, and enabled Bombardier Transportation to evaluate the efficiency of different isolation designs.

Further on, Bombardier Transportation used VA One to create a detailed system level model of a train structure. The model included structural excitation to account for track vibration. The analysis of the floor provided insights into the physical transmission paths and enabled the design of additional noise control treatments to be evaluated by simulation.

Finally, a series of design studies were performed to evaluate the radiation efficiency of heavily damped floor panels using the Hybrid FE-SEA module of VA One. The results from the analysis compared well with measured test data.

drawing and picture of double decker car structure

assembly of a complete coupled fe-Sea model of double-decker end section.

Vibration level of inner floor: prediction vs. experiment

Hybrid FE-SEA analysis is a real leap forward when it comes to acoustical modeling technologies and is likely to set the standard for industrial computational acoustics of large structures for the future. The innovative integration of FE and SEA methods within one model allows the user to solve problems that cannot be addressed by applying SEA or FE methods separately

Ulf orrenius, Senior Specialist: acoustics and Vibration. Bombardier transportation

BOMBARDIER



Bombardier Transportation is a global leader in the rail equipment manufacturing and servicing industry and serves a diversified customer base around the world. Its wide range of products includes passenger rail vehicles and total transit systems. It also manufactures locomotives, bogies, propulsion & controls and provides rail control solutions.

about Bombardier transportation

double decker trains in production plant

VAUC 2007 2nd European Vibro-Acoustics Users Conference

vi

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s A conference dedicated to vibro-acoustic simulation in major industries.

ESI Group is pleased to invite you to its 2nd European Vibro-Acoustic Users Conferencethe vauc 2007 will take place at the Hilton cologne Hotel, which is located in the heart of cologne, Germany.

the vauc 2007 is your chance to see how virtual prototyping solutions permits to find optimum design solutions, which meet noise and vibration specifications without adding extra cost and weight. among the speakers, the vauc 2007 will feature vibro-acoustic professionals from a wide cross-section of industries including Volkswagen AG, Faurecia, Alenia, EADS, Opel, and many others. Not only will vibro-acoustic users gather to hear and share industrial experiences, participants will also learn about the latest va one software developments by means of a “hands-on” training session supervised by the Esi va support Group, where participants will receive a one-week license of va one for use on their own computer to perform evaluations based on the training*.

VA One is the evolution of the AutoSEA2 and RAYON software, and combines state of the art FEa (Finite Element analysis), bEM (boundary Elements Method) and sEa (statistical Energy analysis) solvers in one easy-to-use environment for vibro-acoustic analysis and design.

Come and discover the latest simulation methods in vibro-acoustics!

In the course or this research project, Bombardier Transportation was able to validate the results from VA One by testing, and highlighted the benefits of using a Hybrid FE-SEA modeling approach. The use of VA One early in the design stage will help Bombardier Transportation to find optimum design solutions, meeting noise and vibration specifications without adding extra cost and weight. Since this successful experience, Bombardier Transportation has been applying this method as well to evaluate noise control measures from aircraft panels produced by the Bombardier Aerospace division.

Images courtesy of Bombardier Transportation

* Offer submitted to restrictions. As the number of places is limited, registration to the training is mandatory.

12 & 13 June 2007

Cologne, Germany

w w w . e s i - g r o u p . c o m / V A U C 2 0 0 7

courtesy of Volkswagen research

Messe Düsseldorf GmbHPostfach 1010 0640001 DüsseldorfGermanyTel. +49(0)211/45 60-01Fax +49(0)211/45 60-6 68www.messe-duesseldorf.de

11th InternationalFoundry Trade Fair withWFO TechnicalForum

www.gifa.com

2nd InternationalCastings Trade Fair withNewcast Forum

www.newcast.com

Come to where theprofessionals meet.

The GIFA and the NEWCAST 2007 present in world-wide contextthe technical cross-linking and the standard of performance of thecomplete value-added chain in the foundry sector.GIFA: Foundry technology from machinery to production process.NEWCAST: From waste-wax casting parts in medicine up to pre-finished, complex, large cast parts.

Welcome to Düsseldorf!

Düsseldorf

12 - 16June2007

GN_180x280_4c_INT.qxd 19.12.2006 13:28 Uhr Seite 1

success storywww.esi-group.com 11

MIZUNO Corporation uses PAM-CRASH to improve sports footwear performances

Through its extensive collaboration in academic and European projects and joint studies, ESI group’s

biomechanical activities have led to many capabilities in pAM-CrASH for modeling the human body, including active musculoskeletal models, as well as modeling of bone fracture and ligament injury. MIZUnO Corporation found it appropriate also for modeling inoffensive body impacts found in sport.

MIZUnO Corporation applies advanced technologies to superior quality sporting goods in order to design products with unique features that enhance athlete’s performances. Among its numerous studies on footwear development, MIZUnO Corp. has been using pAM-CrASH in their quest for improved results in numerous applications.

Soccer: improving Speed and control

Computer simulation reveals phenomena that cannot be measured with real-life testing. Using pAM-CrASH, MIZUnO Corporation has simulated the impact of a soccer player’s shoe on a soccer ball in order to improve both speed and control.

When a player kicks the ball, he needs to be able to deliver top speed. Therefore, a high reflection coefficient of the shoe’s upper (top of the shoe) is important. Furthermore, he needs to be able to control the soccer ball’s direction and spin. The longer the contact time between the upper and the soccer ball, the more control the player gets.

In order to provide the best compromise to its demanding customers, MIZUnO Corporation used pAM-CrASH to simulate the contact between the upper and the soccer ball (Fig.1), using various materials and geometries. The two parameters sought were the reflection coefficient of the upper and the contact time. The valuable output data allowed MIZUnO Corporation to choose optimal materials for the ‘shoot’ area (infront and instep kick areas) and the ‘pass’ area (inside kick area), as shown in Fig.2.

fig. 1 the simulation of the impact between the upper and the soccer ball



More support in side-stepping

In most sports such as soccer, volleyball, tennis and basketball, player movements are often made in cross directions. If the shoe upper is excessively deformable, the shoe will not sufficiently support the foot in the cross direction. Therefore, shoe design must be such that a sturdy material is set in a way that will not interfere with running, but will help the upper to support the foot. In order to identify the specific location of this reinforcement, MIZUnO Corporation has measured lateral movements of a professional athlete, and simulated the motion with pAM-CrASH. The Finite Elements Model (FEM) for the lower leg consisted of the bones, soft tissues, shoe upper and shoe sole (Fig.3). Through simulation, the value and direction of the stress in the upper were calculated (Fig.4). The highest stresses were revealed in the area of the fifth proximal phalanx in the upper, and a significant deformation of the upper appeared during sidesteps. In order to control deformation and reduce power loss, the shoe was reinforced at this specific location (Fig.5).

Through these two similar yet very different studies using ESI group’s human modeling capabilities, MIZUnO Corporation has been able to provide its demanding customers with yet more comfort and performance in high-end sporting footwear.

MIZUNO Corporation’s principal activities are the manufacture and

sale of golf, baseball and other sports equipment, sportswear and

footwear. The operations are carried out through two divisions

namely: Sporting Goods and Other. Sporting Goods division deals

in golf goods, other sports goods, sports wear and shoes. Other

operations include sports facilities such as management of track

fields, tennis courts, gyms, golf driving ranges and golf courses.

These products are also marketed in European and American

countries as well as in Asia.

about MiZUno corporation

fig. 2 the design of the upper

fig. 5 the volleyball shoe. the seam is embroidered

on the upper.

fig. 3 the feM lower leg model

fig. 4 Stress distribution and principal stress

directions on the upper

of the shoe

courtesy of eSi group

VisualDSS, the End-to-End Decision Support System for CAE

V isualDSS is an open environment specifically designed to build and manage simulation models for multi-domain usage, to automate processes & workflow, to manage simulation content and data, and to provide knowledge based decision support and automated reporting.

VisualDSS’ capabilities include unique and patented ways of building and maintaining the bi-directional link between CAD data stored in pLM systems and simulation domains. It also features a data persistency environment, which gathers the simulation data from the different applications used during the whole simulation lifecycle. VisualDSS’ ability to automate repetitive tasks in the engineer’s Simulation Based Design process improves day-to-day and long term effectiveness.

“VisualDSS is a unique solution on the market that provides users with an

extended coverage of their simulation practice, and helps to shorten development time cycles while enabling consistent collaboration between the engineering teams.

product news www.esi-group.com12

E SI group’s pAM-QUIKFOrM for CATIA V5 2007 was released in February 2007. Implemented within Dassault Systèmes’ Composite part Design (CpD) module, it allows decision-making early in the design process by eliminating design choices that would lead to manufacturing difficulties.

pAM-QUIKFOrM for CATIA V5 software is a simulation tool capable of predicting the deformation of the reinforcement of composite parts during manufacturing. It predicts in

a matter of seconds if a selected material can be used to form a part and it is the only solution on the market able to capture the specific deformation mechanisms occurring in unidirectional reinforcements draping, like intra-ply sliding, or the spreading of fibers.

Its ability to work directly from the laminate definition built in CATIA V5 CpD, with all its options, dramatically increases productivity.

PAM-QUIKFORM for CATIA V5 2007, a new Solution for the Composites Simulation Value Chain

This kind of step should accelerate the current efforts of aeronautics toward a simulation based design. patrick de luca, composites center of excellence Manager at eSi group.


draping of an aeronautical panel with associated flat patterns of 0° and 45° plies


I am confident, that it will bring a major competitive advantage to our customers”, says Vincent Chaillou, president product Operations and COO ESI group.

VisualDSS provide users a unique solution to manage simulation process and data

1- explore

2- automate

3- Query

4- consume

for more information, please visit www.esi-group.com

product newswww.esi-group.com 13


ESI Group releases VA One 2007, the One Simulation Environment for Full-Frequency Vibro-Acoustic Analysis

ESI Group, a pioneering company committed to delivering state-of-the-art predictive vibro-acoustic solutions, announced in June the official release of the new version of VA One: VA One 2007.

VA One is a complete solution for simulating the response of vibro-acoustic systems across the entire frequency spectrum. The release of VA One 2007 adds significant functionality to ESI group’s innovative solution for vibro-acoustic simulation, analysis, and design.

In December 2005, ESI group introduced VA One as a breakthrough product that significantly extended the types of vibro-acoustic problems that could be addressed through simulation, delivering low, mid and high frequency noise and vibration solutions. Based on AutoSEA2, the industry standard software for mid and high frequency noise and vibration design, and extended to include mid and low frequency methods using the rAYOn solver, VA One is the only simulation code on the market that covers the complete frequency spectrum of vibro-acoustic analysis in one common environment.

VA One is unique in its patented ability to rigorously couple the Finite Element Method (FEM), the Boundary Element Method (BEM) and Statistical Energy Analysis (SEA) in one environment. VA One can be used to find the optimum design solution for meeting noise and vibration specifications without adding extra cost and weight. This new version of VA One significantly extends the types of vibro-acoustic problems that can now be addressed with simulation.

VA One 2007 further extends ESI group’s leadership in vibro-acoustic simulation.

VA One is powered by AutoSEA2 & RAYON.

Highlights of the 2007 release are:

n Compatibility with the Microsoft Windows Vista® operating system.

n Acoustic cavities modeled with finite elements can now be coupled to SEA (statistical energy analysis) sources, sinks and cavities allowing for fast and accurate simulations of leaks and other small acoustic volumes.

n The Rayon 2006 BEM (Boundary Element Method) solver is included which reduces the computation time of BEM intermediate results by a factor of two to three.

n A Linux version of the batch VA One solver is now available.

courtesy of Boeing

courtesy of naSa


product news www.esi-group.com14


ESI UK expands its business activities

Although the focus has historically been in the metal forming and crash analysis activities of the automotive

sector, other industrial sectors such as aerospace, biomedical, oil and gas have become more proactive with Computer Aided Engineering (CAE). Their simulation needs now cover a number of additional disciplines, from resin transfer molding, welding assembly and continuous casting to comfort analysis, electromagnetics and Computational Fluid Dynamics (CFD).

“The ability to provide leading solutions in so many disciplines combined with our vision of an open virtual space gives us a unique edge over our competitors” says Alun rafique, UK Sales Manager.

ESI group has an unrivaled range of simulation products and expertise covering the Virtual Manufacturing, Virtual performance and Virtual Environment fields. To assist customers in attaining maximum value from these capabilities, ESI group has expanded the consulting services available in the UK to include high level technical simulation services and to work with customers to create innovative solutions to their specific technical business needs.

ESI UK offers technical simulation services in all areas of simulation technology – including CFD, crash and safety, stamping, casting, welding/heat treatment, composites design and manufacture, vibroacoustics/noise and vibration harshness (nVH) and electromagnetic compatibility (EMC).

By applying its full range of technical expertise and global resources, ESI group is helping customers find cost-effective solutions to improve products, streamline processes and automate operations in their design and manufacturing activities.

rolls royce consortium / partnership in process Modeling at the University of BirminghamIn February 2007, rolls royce (located in Derby UK) launched a strategic partnership with the University of Birmingham to expand the scope of the materials technology centre established there in 1991.

The process modeling partnership will involve collaboration between the University of Birmingham, rolls-royce and ESI group, with hardware partners IBM, OCF and AMD. These partners have agreed

to build a technical consortium to perform research in the simulation of manufacturing processes, with emphasis on welding, casting, heat treatment and forming operations, with the potential to include other manufacturing disciplines.

A new state-of-the-art computing and simulation laboratory has been set up in the Interdisciplinary research Centre (IrC) for net-Shape Manufacturing on the University’s campus. This activity, led by professor roger reed, will focus on modeling the structural behavior and properties of materials – both during processing and as finished components and assemblies.

engineering Simulation conference – June 26th 2007 iBM WarwickESI UK will be holding a simulation conference on June 26th 2007 at IBM Warwick.

This new event will comprise of parallel sessions covering a variety of CAE disciplines such as CFD, crash/safety simulation, vibro-acoustics, metallic and composite manufacture, tube hydroforming, casting, welding and workshop sessions.

This will be an opportunity to gain knowledge on a wide range of the latest engineering simulation tools, as well as features such as the chaining of simulations and ESI-group’s single CAE environment, known as Virtual Try Out Space (VTOS).

A complimentary breakfast and lunch will be provided to those attending.

eSi UK team

rolls royce consortium

For more information and registration, go to:http://www.esi-group.com/Seminars/Engineering_Simulation_Conference_uk.html

Or contact Stephanie Austin. Tel: 00 44 1865 338 007.E-mail: [email protected]

ESI Group has developed engineering simulation solutions since 1973. In the last 8 years, the

UK has provided dedicated technical support to key customers, such as Corus Automotive. In mid-

2005, ESI Group established a local subsidiary in the UK focusing on software licensing, consulting,

support and marketing. The rapidly growing UK team is tasked with covering all industries and

applications as well as the all encompassing Virtual Try Out Space (VTOS).

pam-talk #34 spring 2007When? October�23-25,�2007�•�Where? Les�Diablerets,�Switzerland

Learn more: www.esi-group.com/seminars/springback.html - Come join us!�[email protected]

ESI Group metalforming solutions seminars for the manufacturing industries

ESI group organized a series of seminars in Asia and in Europe including a ‘roadshow’ in China visiting

Beijing, Xian, Changdu, and Shanghai, unveiling to a large audience the benefits and key strengths of the latest version of its pAM-STAMp 2g, pAM-TUBE 2g and CATIA based stamping products.

pAM-STAMp 2g 2007’s advanced capabilities were demonstrated, including hot forming processes, progressive die, drawbead modelling, sub-structuring, advanced friction models, and follower lines for slip line prediction. The robustness of the pAM-QUIKSTAMp plus solver and the ease-of-use of pAM-DIEMAKEr illustrated ESI group’s determination to meet CAE users’ requirements. ESI group’s ability to position itself as a

key player in the product Lifecycle Management (pLM) and collaborative environment was highlighted with the presentation of pAM-DIEMAKEr and pAM-TFA for CATIA V5. pAM-TUBE 2g’s capacity to cover all steps needed in tube forming including meshing, pre-processing, simulation and post-processing of bending and hydroforming was also presented.

Sturdy customer relationships in the field of manufacturing were proven by industrial applications with, among others, the Korean and French steel manufacturers posco and Arcelor, or the French automotive manufacturer pSA peugeot Citroën, illustrating their application of pAM-STAMp 2g for high strength steels, die compensation for springback effects, and hemming processes.

Over the years, ESI group has a solid history with Hp, partner of both events, embodying the convergence between software and hardware technologies in order to provide customers with IT solutions to meet their specific needs.

Throughout the manufacturing industry, ESI group’s technology leadership in the metal forming field actively contributes to reducing the number of physical prototypes in stamping, tube bending and hydroforming areas.


Join our expert 3-day seminar on the springback phenomenon!

Courtesy of Arcelor Group / Renault

Spingback Prediction

Die Compensation

Verification

CADRe-construction

Get an insight into best practices to predict and control springback in sheetmetal stamping

Learn from a team of international experts:� n Professor Michel Brunet�(INSA)� n Alain Col�(President�of�IDDRG)� n Jean-Marc Devin�(Arcelor�Mittal)� n Joëlle Garabed�and�Anis Kanji Nanji�(PCA)� n Marian Gutierrez�(Tecnalia�Automoción�-�Labein)� n Andrew Heath�(ESI�Group)� n Professor Pavel Hora�(ETH)� n Daniel Pyzak�(Dassault�Systèmes)� n Professor François Rondé-Oustau�(Ecole�des�Mines�d’Albi)� n Dr. Henk Vegter�(Corus)� n Professor Fusahito Yoshida�(Hiroshima�University)� n Professor Koichi Ito�(Tohoku�University)

When? October�23-25,�2007�•�Where? Les�Diablerets,�SwitzerlandLearn more: www.esi-group.com/seminars/springback.html - Come join us!�[email protected]

Springbacks e m i n a rC

casting www.esi-group.com16

VisualCAST is the new post-processor of proCAST. It is a complete, productive and innovative post-processing

environment derived from the new state-of-the-art plotting and animation solution of ESI group. It presents the following key features:

n Windows look-and-feel intuitive interface

n Multi-model, multi-page, multi-plot environment

n Model manipulation toolsn Interactive slicing, scanning and X–ray

viewing modesn Contour, cut-off and vector display of

simulation resultsn results animationsn particle tracingn Curve plotting functionalitiesn results and geometry export

functionalitiesn Image and movie output for reporting

and communicationn Automatic report generation in pDF

and powerpoint formatn Support of session files

VisualcaSt User interface

Visualization – display Modes

Visualization – curve plotting tools

example of application with the main window divided in four:

a) snapshot of a filling with temperature scale b) slice (without background) with total displacement scalec) temperature curves d) particle tracing

On top of providing additional new visual features, a powerful particle tracing tool has been added to VisualCAST. This tool allows filling patterns to be understood and analyzed in a more precise way: Where does the fluid filling comes from? When did it enter into the part? What was its path? All these questions can now be answered precisely.

particle tracing applications

a) velocity plot c) flow lengthb) time to fill d) flow origin

a b

dc

ProCAST recent release offers a new post-processing tool fully integrated in the open collaborative engineering environment of ESI Group. This environment is an integrated suite of solutions providing an access to multiple applications in different simulation disciplines within a single environment. ESI Group casting solutions, ProCAST and QuikCAST, and also the appropriate geometrical tools, will therefore be part of this single unified environment allowing interoperability and chaining between both casting software and other simulation disciplines.

a b

dc

New Streamlined and Productive Environment for Casting Applications



castingwww.esi-group.com 17

S h a n g h a i B a o s t e e l group Corporation is one of the most profitable steel enterprises in the world with an annual production capacity of about 20 million tons. Baosteel aims to become the prime research and development base for new processes, new technologies and new materials in China’s iron and steel industry.

during the training

Beginning of 2007, Baosteel ordered the full suite of ESI group casting solutions specifically dedicated to continuous casting operations. philippe Thevoz, head of quality and support casting team at ESI group, trained Baosteel engineers during one week in Shanghai. The software is now fully operational in Baosteel.

ESI group strengthens its position as a leading supplier of foundry simulation solutions on the UK market. Following the success of the World Foundry Congress exhibition held in June 2006 in Harrogate and the Casting Seminar Days held in Derby in July, casting solutions gained new ground in UK. Since the beginning of 2007, six new major customers have decided to adopt the proCAST solution to optimize their process and to improve their casting quality.

Tritech, an industry active in the Investment casting field and Sim-Cast, a new consultancy dedicated to process improvement in the aeronautical sector (specializing in investment casting of single crystals) have both adopted proCAST for its clear and recognized supremacy in this sector.

JW Singer, a world-wide leader in manufacturing sprinklers, part of the

Tyco group, has chosen proCAST because of the capacity of the software to model the whole hpdc cycle (including shot piston) for Cu alloys.

Sheffield Forge Master, a recognized company for casting large Fe-based ingots (up to 400 tons!) has decided to use proCAST for coupling filling, solidification and deformation calculations. It appears that in this case the technology used by proCAST is the only one allowing this

coupling in a reasonable calculation time.

namtec, a center of technology dedicated to helping UK industries,

has decided to use proCAST because of the capacity of the software to model

a wide variety of processes from its three base modules.

Finally, the University of Sheffield has chosen

proCAST for its capacity to help in fundamental r&D projects

linked to various casting processes.

Baosteel training

Baosteel Headquarters

imag

es c

ourt

esy

of S

im-c

ast




casting www.esi-group.com18

Modeling Continuous and Semi-Continuous Casting

Continuous casting is the process whereby molten metal is solidified into a finished or semi-finished

product. Shapes are fairly simple, such as blooms, billets, rounds, slabs or beams. A schematic diagram of a typical vertical direct chill continuous casting is shown in Figure 1. The liquid metal is cast in a mould, having mainly a circular or a squared shape. In the mould the metal solidifies and is drawn out with certain velocity. In order to promote a fast removal of the heat from the ingot, which corresponds to a high productivity of the process, materials with a high thermal conductivity like copper and graphite are used for the mould. Additionally, water sprayed directly on the surface of the ingot is also often used to increase production efficiency. Although fairly simple in its principle, the continuous casting process involves several interplaying phenomena which finally render modeling approaches complex.

Modeling of continuous casting

The modeling of the casting process itself has often been reduced to the prediction of heat exchange during the primary cooling (within the mould) and the secondary cooling (water cooling). These models take into account conduction, convection and radiation when the metal is in contact with the mould, with air and with water jets. However, many parameters influence however heat exchange during the continuous casting process. The fluid flow has an influence due to forced convection and can potentially remelt the solid shell locally within the mould region. gap formation between the ingot and the mould plays an important role in reducing the heat transfer coefficient. Thus, the optimisation of the casting yield leads to innovative tapered moulds that compensate distortion of the mould and strand per ingot, in order to maintain a homogenous heat transfer.

Simultaneously, the entry nozzles are being improved with the same goals in mind. Clearly, these evolutions require the coupled modeling of fluid flow, thermal exchange, solidification and structure analysis. Whereas CFD softwares enable fluid flow and thermal analysis, they do not properly model solidification and structure analysis. reversely, FEA software model structure analysis, but no fluid flow.

ESI group has been developing for many years the solidification software CALCOSOFT that combines thermal analysis, fluid flow and metallurgical models for continuous casting. This already fills a gap left by the CFD and FEA codes. Simultaneously, proCAST has been developed for shape casting. In addition, as proCAST offers the possibility to couple the existing models with stress calculations, it has been decided to merge and further improve the capabilities of CALCOSOFT and proCAST in this particular field. This

figure 1: typical continuous casting process and schematic representation of its basic features and process related defects. on the right, typical calculated results within commercial code procaSt



castingwww.esi-group.com 19

results in the newly released version of proCAST 2006.1 allowing the unique modeling of steady state and non-steady state continuous casting process by predicting, in addition to the standard related solidification and fluid flow defects, the deformation of the ingot. In order to address continuous casting in a non-steady state way, a MiLE (Mixed Lagrangian-Eulerian) algorithm was developed and implemented into the commercial proCAST code. The principle of the MiLE algorithm is described in Figure 2.

direct chill casting application

The temperature evolution during the start-up phase of the continuous casting process is critical to the prediction of deformation and stress evolution during solidification. Deformation both limits the heat exchange with the mould and bottom block, and thus the production rate, and modifies the shape of the ingot. As shown schematically in Figure 1 and calculated in Figure 3, butt curl, butt swell and lateral faces pull-in making the final shape of the slab deviate from a parallelepiped. Stresses are also important as they induce hot cracking or even “cold” cracking in the ingot.

figure 2: Schematics of the Mile algorithm. the initial casting is divided in two domains (1 and 2). then, as the process goes on, a new domain (3) is created and is increasing in size in direction of the casting velocity

figure 3 shows a coupled thermal-flow-stress calculation using the new Mile algorithm during the transient start-up phase in a typical aluminium dc (direct chill) casting where one fourth of slab is represented

a) Inlet velocities

b) Velocity vectors c) Temperature Field d) Effective Stress e) Deformation (10x)

an application of steady-state calculation for a curved continuous casting is shown. the first picture is colored

by the temperature field while the second one shows the fraction of solid field

conclusions

Thanks to its recent and unique developments and by integrating all specific features of CALCOSOFT 3D, proCAST is now able to accurately address the whole continuous casting process including the modeling of the start-up phase. Thereby, the continuous casting industry now has a unique software solution combining several analysis methods for casting.


product news

Mean wind (10 min), gust wind (3-5 sec) and turbulence intensity profiles

Making Wind ...

from Botticelli’s Birth of Venus

Dynamic wind load simulation requires a numerical quantification of the properties of the natural

phenomenon called “wind”.

Wind. Wind is motion of air. Air moves on a global scale because of differential heating over the equator and over the poles. At a fixed height above ground, the pressure of warmer air near the equator is greater than the pressure of colder air near the poles. This global air pressure gradient tends to move air towards the poles. Coriolis forces tend to deviate the pole-ward air streams to the right on the northern hemisphere and to the left on the southern hemisphere (going with the air). Beside global wind patterns we experience regional winds such as Föhn, Mistral, Schirocco, hurricanes, typhoons, sea-land, mountain-valley wind systems and more.

High altitude winds become turbulent near the ground, where the motion of air is perturbed by surface roughness features and differential heating. Wind loads on structures can fluctuate due to natural wind turbulence, due to turbulence created by nearby objects, and due to turbulence induced by the considered structure itself. numerical simulation employs computational fluid dynamics (CFD) codes to evaluate dynamic wind loads. Computational structural dynamics (CSD) codes calculate the effects of these loads on structures. Coupled fluid-structure interaction (FSI) analysis can detect

aero-elastic instabilities when the structural deformations from wind loads interfere with the flow pattern. This article outlines the virtual design of structures under fluctuating wind loads.

Aero-elastic instability. Wind norms were developed which prescribe the static wind loads for the design of structures. The famous Tacoma Narrows Bridge experienced aero-elastic resonance under sustained winds, which made it fail spectacularly in 1940 a few months after its construction. This encouraged engineers to verify designs for aero-elastic instability.

failure of the tacoma bridge (Wikipedia)

While atmospheric wind tunnels can easily apply turbulent winds to reduced-scale rigid objects, they cannot be used easily when the building deformations interact with the aero-dynamic wind loads. This is because of conflicts of simultaneously modeling the aero-elastic similitude of both, the flow pattern and the structural vibrations at reduced scales. However, fluid-structure interaction simulation, can overcome this handicap.

Atmospheric wind tunnels. In so-called “atmospheric wind tunnels” natural wind conditions are synthesized by manipulating inflow obstructions in the shape of “spires” and by adjusting the “roughness elements” of a roughness stretch ahead of the analyzed object.

atmospheric wind tunnel (courtesy ifH)

atmospheric wind tunnel experiment (courtesy ifH University of Karlsruhe, prof. ruck)

In a dynamic CFD or FSI simulation, synthetic wind fields must be generated from known statistical wind data, such as local mean wind profiles, covariance functions, turbulence intensity profiles, wind power spectra and spatial flow coherence functions. These data can be derived from the individual local wind records supplied by meteorological stations.

Wind records. Wind velocity records, ui(t), can be transformed into a time-constant wind “mean” velocity, ūi, and a time-variable “fluctuation” gust wind velocity record ui’(t)

typical wind record with mean and standard

deviation

The duration for measuring the time-constant mean wind is often taken as 10 minutes. The fluctuations measure wind gusts of 3 - 5 second duration. Turbulence intensity is defined as the standard deviation divided by the mean.

Wind norm data include wind profiles and turbulence intensity profiles. These data are available at different sites from long standing series of wind recordings.

The vertical mean wind profiles, for example, are specified for different regions: urban, woodlands, seascapes.

As indicated in the following figure, the uniform wind velocity is reached fastest over smooth seascapes.

www.esi-group.com20

different mean wind profiles

ui(t)=ūi+ui’(t)



product newswww.esi-group.com 21

Synthetic wind field generationBased on statistical wind quantities, two methods for the numerical generation of synthetic wind fields, or input time series of wind fluctuations, have been implemented for pAM-FLOW. They approximate best the known statistical wind data of naturally turbulent wind processes, as defined for various regions and locations: (1) “Auto-regressive processes of order p” (Ar(p)), where a wind field depends on p past wind fields based on purely recursive and statistical considerations. (2) “Wave superposition techniques”, (using inverse FFT) where the atmospheric surface-layer turbulence is based on 3D spectral tensors. Once the turbulent fluctuations have been synthesized at the chosen inflow boundary grid points, the mean velocities must be added to obtain the total synthetic wind records, which can now be interpolated to the fluid mesh points at the inflow boundary:

Synthetic wind field from known mean profiles and calculated fluctuations

results The mean wind velocity profile and Snapshots of fluctuations obtained from a synthesized windfield using the Ar(p) method is shown in the following figure.

generated numerical wind profiles

Synthetic wind field A time snapshot of the velocity contours from the generated wind field is shown on different sections and at the flow domain boundaries, (d).

The overturning moment at the mast foot of

the umbrella is a principal design factor. This moment is plotted over time (e) and surface velocity and wind pressure loads

on the umbrella are plotted at times of large (f) and small (g) moments.Umbrella structure:

generated wind velocity field (time snapshot)

note that the turbulence seen over the umbrella surface stems from the umbrella itself, but also from the turbulent nature of the wind. The natural wind turbulence is now available in the CFD and FSI simulation packages.

flexible structuresFlexible structures are sensitive to wind loads, with possible aero-elastic instabilities, such as sustained edge flutter shown below.

If folded away, gusty winds may damage the flexible fabric, which calls for rigorous wind load design.

The expected spatial and temporal correlations of the generated flow pattern are recognized in the darker curves to the right, while random fluctuations (lighter curves) lack this correlation inherent to the wind.

Compiled by: Eberhard HaugWind implementation: Alexander MichalskiSimulations: pierre de Kermelpermissions: SL rasch gmbH / Liebherr Werke Ehingen / University Karlsruhe

d

e

f

g

applicationsThe Ar(p) scheme is applied to flexible umbrella structures. Owing to the Ar(p) scheme, the fluctuating mean wind profile can be applied instead of the conservative gust wind profile.A free-standing single umbrella that covers an area of approximately 29x29m (a) is modeled in pAM-SOLID (b) and in pAM-FLOW (c) and it is subjected to a synthetic wind field. The umbrella is made of a very high strength steel frame, which deploys a high-tech, UV-resistant, synthetic fabric (Teflon).

courtesy liebherr Werke ehingen

Umbrella structure: (a) in reality; (b) structural model; (c) cfd model

a

b

c

The methodology can be applied to the design of wind turbines:

Wind farm: potential application (Wikipedia)



questions to…

PAMTALK: eSi group’s iSo9001:2000 certification was renewed for the second time on december 2006.What are the benefits for the group?Dominique Grolade: Through the deployment of a process oriented approach, confirmed by this successful certification renewal, ESI group, a largely multi-cultural international company, has ensured a strong process management. From this basis, it can manage the operational steering of its processes, as well as facilitate its worldwide and multi-site interfaces.

management system within the company’s operation;n To broaden the perimeter of

the ISO9001 certification to our subsidiaries, establishing priorities according to market expectations;

n To harmonize and improve the overall set of internal processes worldwide.

development (R&D) sites in the US: Huntsville (AL), San Diego (CA) and Columbia (MD). A common understanding of the ISO9001 requirements was reached, to the purpose of harmonizing r&D processes within the group. An action plan was agreed to which spans over FY07.

n Meanwhile, the Quality teams of ESI group and ESI SW India have been working together in order to compare their respective r&D processes. An internal report on these exchanges will follow, describing how best to set up interactions of the different approaches into effective global r&D guidelines.

n In parallel, a workgroup was structured in February in MECAS ESI (Czech Republic) aiming at a progressive implementation of a Quality Management System throughout FY07, to be presented for ISO9001 certification at the beginning of FY08, right on time to meet the requirement of one of MECAS ESI’s strategic customers.

Dominique grolade, Corporate Quality Director,

ESI Group

PAMTALK: When can results be expected?Dominique Grolade: Quality is an ongoing process, in which the plan-Do-Check-Act (pDCA) cycle effectively leads us to everyday improvement. However, to specifically address the targets highlighted above, several actions have already been deployed:n In September 2006, a mission was

setup with our three research and

corporate www.esi-group.com22

3

ESI Group participates in the following events: date event place

June 12-14 2007 SAE Digital Human Modeling International forum on digital human modeling developments and applications Seattle, WA, USA

June 12-16 gIFA The 11th International Foundry Trade Fair Düsseldorf, germany

June 12-13 VAUC 2007 Vibro-Acoustic Users Conference 2007 Köln, germany

June 14-15 Fuel Cell 2007 Conference and Exhibition, Advancements in Applications and Technology rochester, nY

June 18-20 5th International Fuel Cell Science and Technology Conference on Cell Science and Technology new York, nY

June 25-28 37th AIAA Fluid Dynamics Conference and Exhibit CFD Show Miami, FL

June 26 Engineering Simulation ConferenceSeminars on Forming, Casting, Welding, Crash, Composites, nVH, CFD, Vibro-Acoustics and ESI group’s Open VTOS. Warwick, UK

July 17-19 Semicon West 2007 CFD Semiconductor Show San Francisco, CA

August 13-16 2007 Space & Missile Defense Conference and exhibition on Space & Missile Defense Huntsville, AL

August 28-31 Internoise 2007 global approaches to noise control Istanbul, Turkey

Sept. 10-13 CEAS 2007 Council of European Aerospace Societies germany

Sept. 17-19 Fan noise 2007 3rd International Symposium 2007 Lyon, France

Sept. 20-21 Wind Turbine noise 2007 2nd International conference in Lyon Lyon, France

PAMTALK: What are the next steps?Dominique Grolade: The next steps for ESI group should be:n To integrate the global quality



corporatewww.esi-group.com 23

A nnual sales for 2006/2007 totaled €66 M, yielding a growth of +6.2% compared to the previous financial year, and +7.6% on a constant exchange rate basis. This growth in activity integrates no changes in perimeter and can be analyzed as follows: • License sales (81% of total sales) registered a significant acceleration of +11.2% in volume terms over the 2006/07 financial year, versus +7.0% the previous year. This good performance illustrates the efficiency of the growth relays contributed by our emerging and innovative products.

• Services activity slipped by -5.6% over the financial year, although it was stable over the first half of the year and in strong recovery in the fourth quarter, following previous quarters impacted by unfavorable conjunctural factors.

The geographical split of global activity (America: 17%; Asia: 36%; Europe: 47%) confirms the remarkable surge of Asia, and validates ESI group’s positioning-strengthening strategy in this geographical zone where international OEMs are increasingly present. Indeed, license sales recorded in Asia were up +20.6% (+24.5% at constant exchange rates), essentially due to China, Korea and India, despite a slowdown in Japan which was further affected by the weakening Yen.

outlook

Alain de rouvray, ESI group’s Chairman and CEO, comments: “We are pleased with the growth in our licenses activity. Growth was buoyant in Asia, where emerging areas with substantial development potential also contributed to the sectorial diversification of our sales, in particular in the aeronautical sector. Although our services activity was significantly impacted by conjunctural events over the last year, its upturn towards the end of the year resulted from a substantial improvement in the economic climate and the development of certain new sectors such as electronuclear. Services should be further consolidated by the commercialization of a restructured offer and the launch of promising cofinanced and innovative projects.”

2006/07 annual sales: E66 M



“car to car” impact model with close to 9 million elements, in Visual-crash paM (Vcp) native version for Windows 64 bits

PUBLICATION

Simulation System Integration

E si group launches a multi-domain simulation platform, able to unify its numerous tools within a unique simulation environment. This represents a welcomed advantage for the group’s largely industrial customers which handles daily dozens of softwares and hundreds of models. What’s more, the platform benefits from the power of Windows 64 bits, managing over 4go of addressable memory, in order to work on models exceeding 10 million finite elements! Today, thanks to these excellent results, the engineers can use a unique model that covers the crash and safety simulation domain as a whole.

As pointed out by Jean-Louis Duval, Business Development Manager

“This platform is presently in its deployment phase. We have started with the integration of our crash, occupant safety, static model

analysis, and generally said vehicle structure dimensioning solutions. So far, it integrates our PAM-CRASH, PAM-MEDYSA and PAM-SAFE solvers, as well as complementary solutions such as NASTRAN, RADIOSS, LS-DYNA or MADYMO. A second phase will follow, integrating manufacturing oriented software for casting, welding and metal stamping as well as electromagnetic and CFD simulations, and finally specific client applications.»

Based on this platform, VisualDSS is a unique End-to-End Decision Support System for CAE, specifically designed to manage Multi-Domain Compute Model, process & Workflow, Simulation Content & Data and Decision Support & reporting as well as a module to standardize and capture the users’ complex procedures.

the Benefitsn �The simulation platform provides a

unified graphical interface.n It shares a single set of models,

avoiding hazardous data files manipulation from one application to another, and making sure that a given model update is used in all simulations.

n It welcomes other simulation solutions, be they customer specific or third-party. A development tool is provided for customers to personalize their solutions and integrate new programs.”

Source: cad.magazine- N°136- February-March 2007; interview with Jean-Louis Duval, Business Development Manager ESI Group.

HP helps you not only achieve your goals, but exceed them.HP CAE solutions deliver optimal performance, unprecedentedreliability, and collaboration with experienced partners.Innovation: HP develops integrated SMP server and DMP cluster solutionsthat ensure superior results for CAE applications. Examples includeHP-MPI, the industry's standard commercial high performance MPI, andHP's new c-Class BladesSystems, a groundbreaking product that reducesenergy consumption by dynamically adjusting power and cooling.Choice: Only HP offers the full range of industry-standard microprocessors,operating environments, middleware, interconnects, and integrationservices—ensuring the optimal solution for your CAE applications.Performance: The collaborative partnership between HP and ESI Group produces highly scalable andreliable clusters for exceptional PAM-CRASH and CFD-ACE+ results—on time and on budget.

© 2007 Hewlett-Packard Development Company, L.P. The information contained herein is subject to change without notice. The only warranties for HP products and services are set forthin the express warranty statements accompanying such products and services.

HP Information: www.hp.com/go/CAEContact HP: www.hp.com/country/us/en/wwcontactPartner Information: www.esi-group.com

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