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ATOA Scientific Technologies | Multiphysics CAE | Engineering Apps | 3D printing
Dr Raj C Thiagarajan
ATOA Scientific Technologies Pvt Ltd
Multiphysics CAE for Engineering Innovation
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Why are we here?
• Mythology
• Theologist
• Philosopher
• Scientist
– Physics, Chemistry, Biology, Mathematics….
• Engineers
– Civil, Mechanical, Electrical, Chemical…
• Multidisciplinary
– Nano, Bio, Info, Cognitive
• Multiphysics CAE for Engineering Innovation
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Engineering Innovations
• Shelter, Tools, Pottery, Textile..
• Wheel
• Arch Bridge
• Gun powder
• Mariners Compass
• Paper Making
• Printing Press
• New paper
• Arc lamp, Stem locomotive, Automobiles
• Polymer: Jet Engine: Composites: www:
• Mobile Phones : 3D printing
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Industrial Engineering Innovation Cycle
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• Wealth creation cycle
• Contributions for overall economic growth
• Long cycle and low Success Rate
• Simulation based product design for acceleration of Engineering innovation
Basic Research
Applied Research
Industrial Research
Innovation/ Product
development
Commercialization
Wealth Creation
ACADEMICINDUSTRY
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Simulation Based Product Design
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• Simulation is considered third pillar of Science & Technology
• Simulations has No Cost constraints, harsh/unrealistic parameter range, EHS concerns.
• Reliable, efficient and affordability is the key driver for Concurrent Product Development and Innovation
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Design Change Cost in product development
• Cost of fixing = Stages X Times
• Cost of Design changes increases exponentially with product development cycle.
• 80% of the product cost is determined or committed at the concept design stage
• Management influence reduces over time
• CAE for first time right product development
Product Planning
Concept Design
Final Design
Pilot Production
Mass production
HIGH
LowA
ctiv
ity,
Infl
uen
ce In
dex
, D
esig
n c
han
ge C
ost
NPI Activity
@
Part
1X
@
Sub assembly
10 X
@
Final Assembly 100 X
@
Dealer
1000 X
@
Customer
10000 X
6
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CAE for Engineering Innovation
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Engineering Innovation
Multiscale Multiphysics
Multimaterial
Engineering is Conversion of Material into Useful Product
Industrial Drivers: Cost, Weight and Performance
CAX (CAD, CAE, CAM) product development for first time right
Multiphysics, Multimaterial and Multiscale for Innovative Design
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Multiphysics Modeling
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• Product Design is Multiphysics but are Designed for Dominant Physics
• Technology adaptation trend vs industry
• Current Technology and maturity level Enables Affordable and Reliable Multiphysics Product Design
• Multiphysics Design for First time right cost effective, faster product development.
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Multiphysics Modeling
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Constitutes more than
one component with
governing equation.
• Coupling at Bulk, interface level:
– Magneto hydrodynamics , Reaction transport
– Fluid structure, aero elasticity, laser heating
• Coupling at time and length Scale (multiscale):
– atomistic to continuum Damage mechanics
• Coupling at Material Scale (multimaterial):
– Homogenization from nano, micro, macro
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Multiphysics ExamplesMultiphysics
Stru
ctu
ral
The
rmal
Flo
w
Aco
ust
ics
Dyn
amic
s
EM/O
pti
cs
Ch
em
ical
Bio
-Me
dic
al
Par
ticl
e
Industrial Examples
Aero elasticity Aircraft wing, wind turbine, helicopter blades, micro turbines, long bridges,
Fluid Structure Offshore foundations, Sloshing, actuators, compressors, Induction
Conjugate Heat transfer
Racing car, offshore pipes. Gas turbine, forming, welding, electronic packaging,
NVH, aero acoustics Acoustic panels, sound barrier, sonar, Automobile, aero engine, speakers
Chemical Transport Composite cure, reactive polymer flow, adhesive, Biomedical
Biomechanics BioCAE
Medical Imaging, Orthosis, prosthesis, ergonomics, Medical Therapy.
Piezo, thermo electricity
Ultrasonic probe, MEMS sensors, TE refrigeration, Electrical connectors.
Electromagnetic Heating
Non conventional / Non Conduction heating: Laser, RF, Microwave
Battery Physics Solid Oxide, Lithium , Fuel Cell, Battery powered automobile
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Multiphysics Design: Stethoscope
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• Acoustics Performance improvement
• Sound propagation
• Noise effects
• Material, Geometry
• Electromagnetic, electrostatic => acoustical energy
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Multiphysics Design: Chest Belt
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• Bio electrical signal propagation in cardiac tissue using the FitzHugh-Nagumo equations and the Complex Ginzburg-Landau equations.
• Electromagnetic physics to model the electrical field distribution on a realistic 3D geometric model of the heart and torso.
• Inverse problem solving for smart chest belt.
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CompositesMulti
Material
AdvancedMaterials
Noble Aluminum Steel
Multimaterial Product Design
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• From “ All steel” , “All Aluminum ” All Composites” To Multimaterial
• Leverage the best of material for product performance.
• Challenges
• Fabrication
• Multiphysics
• Multifunctional High COST Low
Hig
hW
EIG
HT
Low
Performance: High
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Multiphysics Design of Materials
Structural Elastic constants Super structural
Thermal Thermal conductivity Superinsulation
Electromagnetic permeability and permittivity
Metamaterials
Acoustic Sound transmission loss
Acoustic bandgaps
TransportDiffusion
PermeabilitySuper flow
Design Extremel
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Multiphysics Design of Materials
Physics Governing Eqs* Constitute Eqs* Comments
StructuralStatic:, Navier’s equation, Hooke’s law
for stress strain relation. F, volume
forces, σ,stress tensor, e, strain tensor,
D, stiffness matrix
ThermalHeat Equation, Fourier’s law: ρ,density.
Cp, heat capacity, k, thermal
conductivity, Q,heat source.
AcousticHelmholtz eq: ω, angular freq, ρ0, fluid
density, cs, speed of sound, q, source,
Dtl, transmission-loss coefficient, Wi,
incident and Wt is the transmitted sound
power.
DiffusionFick’s law, Diffusion Coeff. c is the
concentration, D is the diffusion
coefficient, and R is a reaction rate
Porous flowDarcy’s law, Permeability, : v, velocity, μ,
dynamic viscosity, K, permeability and P,
Pressure.P
xvK
* Equations from COMSOL documentation
c
NDeff
ave
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Metamaterial Simulation Results
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Acoustic Super lens
Ultrasonic Meta Surfaces
Composite cloaks
Electrostatic resonance
Negative refraction
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Multiscale Modeling
• Multiscale model is a mathematical model formed by combining partial model at different length and time scales.
• Away from predicting known properties towards new materials with novel properties.
• Products engineered from Atomic scale
Multi scale modeling Framework
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Multiscale: damage mechanism
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Structure
Part
Laminate
Fiber
Matrix
Molecular
ATOMIC0.3345 nm
0.142 nm
0.669 nm
c
ba
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Nano Foam
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Engineers Quest is to develop materials with higher properties at lower weight
Simulation based material design for superior properties
• Super specific stiffness
• Super insulation
Nano
Micro
Macro
After US 7838108
VfN
orm
aliz
ed P
rop
erty
Air Material 2
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Multiscale Modeling Super Structural
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• Engineer the pore size for superior properties
• Example: Tooth enamel: Bio polymer+ mineral fillers
• Defect insensitive pore size
• Nano to micro to macro properties
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Multiscale Modeling Super Insulation
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• Nanogel/ Aerogel : Thermal conductivity lower than still air to about 0.002 W/mK
• Nanoscale Knudsen effect, Phonon scattering
• Conduction, convection and Radiation = k
• U value for Fenestration product performance
• Building Thermal Simulation for annual Energy and Cost Saving
(From:http://www.ameriluxinternational.com/html/architectData/nanogel/documents/nanogelData.pdf)
2 pm
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Multiphysics Modelling
CA
DStructural Elastic
constantsSuper structural
Thermal Thermal conductivity
Superinsulation
Electromagnetic permeability and permittivity Metamaterials
AcousticSound transmission loss
Acoustic bandgaps
TransportDiffusion
PermeabilitySuper flow
CA
M
CAE
3D
PR
INTIN
G
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Fore more about
Multiphysics CAE
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www.atoa.com