CAE & Simulations

With a wealth of experience exceeding 10 years, APPL Global Infotech brings expertise in Finite Element Methods (FEA), Computational Fluid Dynamics (CFD), and Multibody System Dynamics (MBD) to the table. This extensive knowledge is at your service for the design, analysis, and enhancement of your products. Our strong emphasis on strength assessment includes proprietary software development.

True to our guiding principle of 'Innovation by Simulation,' we deliver premium engineering services across various domains, including mechanical engineering, plant engineering, traffic engineering, automotive engineering, aerospace engineering, polymer and composite engineering, civil engineering, medical engineering, and sports equipment technology.

Using the latest software technologies, we are able to shorten the timespan between the conception of a product idea and the production readiness considerably. Computer simulations serve as a virtual testbed and reduce the number of actual prototypes as well as the development time, reducing costs in both sectors.

Structural Simulation

At APPL Global, we have cultivated specialized proficiency in various types of finite element analysis, catering to clients in India and globally, whether it's structural, crash, or durability analysis. The following are the areas in which APPL Global provides finite element analysis services and solutions.

In various mechanical systems, such as automobiles, aircraft, and washing machines, predicting the complex loads generated by moving parts is challenging. Analysing the interaction of multiple moving parts is crucial for effective product design. Motion analysis encompasses kinematics, vehicular cornering, vibration, and durability, among others. Its applications in suspension systems, aircraft landing gear, and robotic manipulators illustrate its significance.
Simulation of car crashes is among the most critical aspects of Vehicle Integration in the development cycle. Meeting crash requirements in accordance with various Vehicle Safety Standards (FMVSS, NCAP, EC, Japanese- NCAP) is essential to ensure compliance and deliver a safe vehicle to end customers. Crash simulations include full frontal, side, rear, rollover at the vehicle level, as well as system-level simulations like Crash Management System (CMS), seating, and interior crashes. Other applications include drop testing, forming simulation, and analysis of shock loads.
Noise and vibrations are undesirable outcomes of dynamic loadings, and failures due to vibrations can be severe in terms of product warranty. NVH (Noise, Vibration, and Harshness) aspects are critical for user comfort and ergonomic perspectives. NVH simulations, including cyclic vibrations (FRF), random vibrations (PSD/RLD), and transfer path analysis, help reduce NVH effects during the Product Development phase.
Predicting structural failure under varying load cycles or dynamic loads is challenging due to the numerous parameters associated with such failures. Fatigue and Durability analysis assist designers in determining the life expectancy, number of duty cycles, and maintenance schedule during operations. Different types of durability simulations, such as High Cycle Fatigue (HCF), Low Cycle Fatigue (LCF), and cumulative life prediction using Miner’s rule, require a thorough understanding of material behaviour and load definition. Proper implementation of durability simulations provides designers with an advanced understanding of the overall product life.
CFD Simulation

Our commitment to 'Innovation by Simulation' is evident in the premium services we offer across diverse sectors such as mechanical engineering, plant engineering, automotive engineering, aerospace engineering, polymer and composite engineering, civil engineering, medical engineering, and sports equipment technology.

Computational Fluid Dynamics (CFD) consulting services play a crucial role in the design and development phases, ranging from the aerodynamics of sports cars to the ventilation of data centers. Various fluids, such as air, water, and oil, are involved in different systems, necessitating different types of flow simulations in product development. To obtain reliable results in flow simulations, engineers must possess a thorough understanding of fluid dynamics and implement appropriate turbulence models. With extensive experience in flow simulations, APPL Global has developed wide-ranging expertise in delivering efficient products with fluid systems. Turbulence flow prediction is a complex analysis, and the utilization of machine learning in sub-grid-scale (SGS) for Large Eddy Simulation, combined with existing CFD tools, enhances SGS calculations, opening new perspectives in this domain.
Heat transfer is a common element in multi-physics systems, whether in engines, batteries, or solar systems. The performance of batteries and power electronics components heavily depends on thermal conditions. Designers must consider thermal aspects like cooling and heat dissipation to develop efficient products. Thermal simulations are often coupled with flow simulations (Conjugate Heat Transfer, CHT), and the results of thermal simulations are mapped onto structural simulation models to simulate thermo-mechanical systems. APPL Global has expertise in complex heat transfer simulations, such as thermal simulation of a battery pack. In this case study, the challenge was extremely narrow cooling passages in the battery pack, requiring massive computational models (100+ million cells). Leveraging a multi-core High-Performance Computing (HPC) cluster, we not only simulated the battery pack but also delivered an optimized variant based on the simulation.
CFD can be applied to predict and optimize noise levels resulting from fluid flows. Aeroacoustics involves identifying noise sources and understanding the propagation of sound waves. Special mathematical models are used for aeroacoustics. In electric vehicles (EVs), where engine noise is absent, noise from HVAC systems becomes a focus for designers, and EV HVAC systems need to be highly optimized for aeroacoustics.
Changes in the structure impact flow conditions, and vice versa. FSI is implemented to simulate structures and fluids simultaneously. Applications of FSI include predicting the airspeed at which a wind turbine will start rotating and simulating the sloshing of fluids during transport in a container. Vibrations due to fluid reactions on the structure are critical from a durability perspective. FSI is crucial in fuel cell vehicles, where studying the behaviour of hydrogen in the storage tank is required for operational safety
1D Simulation

1D system simulation, or 1D simulation, is a highly effective method for obtaining fundamental inputs essential for system design during the conceptual stage of product development. This approach enables the rapid simulation of various operating parameters, providing crucial inputs for subsequent 3D simulations. APPL Global is actively engaged in diverse 1D system simulations, and a few examples are outlined below.

Enhancing engine performance, optimizing fuel consumption, and minimizing pollutant emissions pose significant challenges. The engine control unit can be programmed to adjust parameters using various sensors such as temperature and throttle position sensors to achieve the desired performance. Simulation plays a crucial role in developing suitable control strategies. Performance evaluation scenarios for the engine include after-treatment systems, turbocharging, predictive combustion and knock, and exhaust acoustics.
1D simulation offers a cost-effective and faster alternative to chassis dynamometer testing. It provides a comprehensive model with predictive combustion and turbocharging for a chosen drive cycle, allowing for the virtual simulation of different road profiles.
Virtual integration of a battery pack into the entire drivetrain enables the prediction of operating modes under specified drive conditions. Component-level optimization is essential for optimum performance, and this can be predicted through 1D simulations.
Process Simulation

In today's complex product landscape, intricate product designs demand advanced manufacturing techniques. Achieving optimal manufacturing parameters is crucial, and manufacturing process simulation provides a virtual platform for designers to design and refine these parameters efficiently. This simulation approach minimizes wastage, ensuring that products are manufactured precisely as per the design specifications.

Industries such as consumer appliances, aeronautics, automotive, and packaging rely extensively on sheet metal forming simulation for component design. Forming simulation involves parameters like press forces and tool geometry. It provides valuable insights for process engineers, revealing aspects like Flow Line Diagram (FLD), thinning and thickening of sheet metal parts during forming, and regions prone to wrinkles.
The results from forming simulation offer valuable information for process optimization, especially in the case of multi-step forming. Residual stresses and strains arising from manufacturing processes are crucial for designers, particularly in terms of durability considerations. Understanding thinning and thickening regions of significant Body-in-White (BIW) components plays a pivotal role in crash simulations.
As the trend shifts towards converting metal parts to plastic for weight reduction, the complexity of plastic part topologies increases. Designers face the challenge of ensuring proper manufacturability of these parts. Moldflow simulations play a crucial role in simulating the injection moulding process, evaluating and optimizing riser and gate systems, and ensuring uniform flow distribution of molten plastics in the cavity.
The use of Moldflow simulations allows for a quicker assessment of digital designs, identifying issues such as warping and other manufacturing defects through virtual injection trials. This early-stage simulation provides insights into factors like suitable wall thickness, weld lines, inlet cooling, and the placement of cavity degassing.
In the case of glass fibre plastics, the orientation of the fibres is determined through Moldflow simulations. This fibre orientation information is then integrated into structural simulation models to simulate orthotropic behaviour.
In today's manufacturing landscape, efficiency in workflow, minimal inventory, and reduced maintenance are essential requirements for production units. The intricacies of manufacturing systems arise from factors such as multiple subassemblies, numerous manufacturing steps, and complex equipment, leading to increased preventive maintenance needs and downtime. To address these challenges, discrete simulation models are essential for managing complex manufacturing systems.
Robotic simulations in Body-in-White (BIW) assemblies offer a comprehensive virtual overview of a manufacturing unit well in advance. This approach benefits plant designers by providing insights for optimizing plant layouts, allowing for enhanced efficiency and minimized operational disruptions.
In the quest to eliminate physical prototypes while ensuring top-notch quality and durability against corrosion, paint simulation becomes crucial. Various processes, including electrodeposition painting, dipping, and spraying with electrostatic coating, can be effectively simulated. For instance, issues like non-uniform thickness due to geometrical factors such as sink at edges, door grip, etc., in typical spray-painting processes can be addressed.
With the continuous rise in production volume at each paint shop, the time available for the Body-in-White (BIW) to pass through the e-coat process is diminishing. Predicting challenges like gas bubbles and liquid carry-over during dip in/out processes is challenging in actual testing. Moreover, using the same paint shop line for multiple vehicle programs adds complexity. Paint Plant Simulation methods offer solutions to these challenges by aiding plant designers in areas such as Dip-in Process Simulation, Dip-Out Process Simulation, and Oven Baking.
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