Automotive Simulation Solutions

Automotive developers use Ansys FEA and CFD engineering analysis software solutions to develop engines that burn fuels more efficiently, rely on alternative energy sources, or incorporate next-generation emissions control devices.

By delivering multiphysics capabilities in a single platform, Ansys solutions make it easier for your engineering team to examine the complex issues surrounding engine performance and outputs.

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Design ElementsChallengesSimulation Benefits
  • Resolve pressure distribution around the vehicle
  • Minimize vehicle drag (to improve fuel economy)
  • Assess vehicle handling and stability (side forces, lift)
  • High-end turbulence models
  • Sophisticated and accurate numerics
  • Highly efficient transient solvers
  • Mesh-adapt-on-the-fly ability
  • Industry-leading parallel scalability
  • Noise propagation for external and internal flows
  • Qualify acoustic sources
  • Determine dominant frequencies and sound pressure level (SPL)
  • Understand effect of modifications to local geometric features on SPL and frequency
  • High-end turbulence models
  • Highly efficient transient solvers
  • Highly accurate numerics
  • Built-in acoustics-specific tools
  • Industry-fastest turnaround times
Airbag Inflators
  • Optimize inflator design from the aspect of gas flow delivery in the airbag
  • Gas flow data are input for crash simulations
  • Need detailed characterization of the gas flow inside and/or outside the inflator
  • Robust explicit solver able to deal with highly compressible, unsteady, flows and propagating pressure waves
  • Species transport model
Brakes & Wheels
  • Design brakes and wheels that are durable and can sustain variable loads
  • Predict stress and fatigue
  • Predict local temperature distributions and thermal loads
  • Optimize brake venting
  • Flow and structural solution from the same CAE vendor
  • Easy and seamless transfer of CFD and FEA data between applications
Climate Control System
  • Design HVAC system able to provide thermal comfort to passengers over a wide range of driving and ambient conditions
  • Deliver appropriate cabin airflow for clearing windshield and windows as required by safety regulations
  • Optimize performance of HVAC components
  • Hexcore technology for efficient meshing
  • Robust and accurate solver regardless of mesh type
  • Deicing and defogging models
  • Solar load model
  • Design components capable of sustaining harsh operating environments
  • Proper thermal management is crucial for reliability and durability
  • Accelerated failure mechanism in materials
  • Packaging constraints
  • Vibrations
  • Variety of products targeted for electronics, from full-feature applications to highly application-focused and automated vertical tools
  • Easy and seamless transfer of flow and structural data between CFD and FEA
FSI Simulations
  • Capture the flow-induced structural deformations (one-way coupling)
  • Capture the alterations of the fluid flow due to structural deformations (two-way coupling)
  • Both 1-way and 2-way FSI simulations can be performed entirely within the Ansys Workbench environment
  • A single environment with a consistent graphical user interface, making it easier to learn and use
  • Simulation process completely streamlined
  • Automated mesh morphing
  • Both CFD and FEA results can be simultaneously post-processed in the Ansys CFX post-processor
Headlights & Lamp Housing
  • New polymer materials have lower thermal resilience than glass
  • Thermal stresses caused by absorption of emitted light
  • Condensation is visible in case of clear panes
  • Flow distribution needs to be optimized for proper ventilation
  • Complete solution: CFD and FEA
  • Choice of several radiation models
  • Condensation model
  • Material nonlinearity
  • Easy mapping of CFD data onto FEA
Underhood Thermal Management
  • Predict cooling system performance (e.g. air flow distribution in heat exchangers, top hose temperature, fan-off temperature…)
  • Minimize simulation turnaround time while meeting accuracy targets
  • Preprocessing: Complexity of the geometry, number of parts (in hundreds), dirty CAD data, etc.
  • Powerful pre-processing tools (e.g. TGrid, Ansys ICEM CFD)
  • Full suite of physical models (e.g. radiation, buoyancy, shell conduction, fan model, heat exchanger model)
  • Robust and accurate numerics
  • Fully parallelized calculations for fast turnaround
  • Fully coupled solution with major 1-D fluid system (e.g. Flowmaster) and engine simulation codes (e.g. GT-Power and WAVE)
  • Analyze the mechanisms of complex assemblies involving many parts
  • Determine forces experienced at the joints
  • Predict stresses in critical regions
  • Rapid modeling of mechanisms and optimizing the design
  • Automatic joint detection for complex assemblies
  • Quickly switch simulation from fully- rigid to flexible in the same environment
Body in White
  • NVH and point mobility analysis of full BIW structures
  • Accurately model spot welds
  • Crash simulation of structure
  • Feature rich surface meshing tools including variable thickness
  • Auto creation of spot welds from weld data
  • Ability to export the model from static to crash analysis
Chassis and Suspension
  • Full system model of a chassis or suspension
  • Connection of all the parts in the assembly
  • Meshing the entire assembly
  • Include joints and mechanism
  • Advance preprocessing tools allow for geometry cleanup, mid surfacing in a single environment
  • Automatic contact detection
  • Contact easily defined between sheets and solids
Hyperelastic Seals
  • Predict leakages and failure of seals
  • Highly non-linear material and load behavior
  • Complex physics involving self-contact
  • Ability to model non-linear materials
  • Easy to set up self-contact
  • Easy to model 2-D as well as 3-D solutions
  • Advanced diagnostic tools to help convergence
Fuel Cells
  • Channel design that optimizes distribution of oxygen (hydrogen) to the cathode (anode)
  • Water management
  • Thermal stresses and cooling plate design
    • Materials
    • High costs
  • Property variation
  • Space limitations
  • Probabilistic design in virtual prototypes
    • Design for Six Sigma
  • Minimize costly physical prototypes using analysis based on first principle physics (electrochemistry, fluid flow, heat and mass transfer, structural mechanics)
Battery Packs
  • Increase power capability, while avoiding hot spots that cause premature failure
  • Insure proper thermal management of the battery pack for performance and reliability
  • Battery pack performance impacted by performance of individual cells and modules
  • Capture heat transfer of the actual cell or module (case, terminal posts, connectors, interconnects, relief valves, seals, etc.)
  • Multiphysics modeling capabilities (electro/thermal, CFD, FEA) all in a single CAE package