Find out how our simulation tools are helping the automotive industry discover better designs, faster
STAR-CCM+ STAR-CCM+ is a multidisciplinary simulation platform that allows you to represent all of the the real world physics your vehicle will encounter.
HEEDS HEEDS MDO automates the design exploration process allowing you to uncover new design concepts that improve products and significantly reduce development costs.
STAR-CD STAR-CD offers the world’s most comprehensive toolkit for simulating the performance and behavior of internal combustion engines from intake to after-treatment.
Battery Design Studio Battery Design Studio provides a complete simulation environment for the analysis and design of the electrochemical system and detailed geometry of individual battery cells.
Find out how multidisciplinary simulation and design exploration can help to solve the toughest challenges that the automotive industry has to offer.
STAR-CCM+ is the only simulation tool that allows you to make a complete digital twin of your proposed vehicle design, and predict exactly how it will behave under a full range of operating conditions
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Our tools are the most used in the industry for simulating the full thermal environment of the vehicle including component temperatures and full three dimensional modeling of coolant and lubricant networks. STAR-CCM+ is the only tool that lets you represent the full complexity of your vehicle underhood and underfloor systems.
By optimizing the aerodynamic performance of your vehicle from early in the design process, you can minimize the amount of fuel required to overcome aerodynamic resistance, and also reduce the impact of its acoustic signature on passengers and pedestrians. STAR-CCM+ has adjoint and morphing capabilities that guide you through making intelligent design decisions.
Design exploration using STAR-CCM+ and HEEDS allows you to ensure that passengers in your vehicle remain comfortable across a complete range of environmental conditions. Our bio-regulated mannequins allow you to predict how a passenger would feel in a given scenario. Defrost and demist models ensure that visibility is consistently maintained.
STAR-CCM+ allows you to protect passengers and sensitive components from the thermal radiation emitted from hot gases in the vehicle exhaust system.
Together, STAR-CD and STAR-CCM+ offer the world’s most comprehensive toolkit for simulating the performance and behavior of internal combustion engines from intake to after-treatment, allowing you to design clean and efficient engines that don’t compromise performance.
Automotive Industry in Crisis: Traditional Design Methods Fail to Deliver Performance Improvements
Automotive Manufacturers Turn to Simulation to Meet Sustainability Targets
The pressure on automotive manufacturers to deliver more cost-effective and efficient vehicles intensifies every year. Growing concerns about global pollution have led to increasingly tighter regulations that reduce vehicle emissions and improve fuel efficiency. As a result, manufacturers are having to respond rapidly and constantly – and often there is significant variation between geographical territories.
As regulations change, the burden on vehicle and engine designers increases. Examples of these changes can be reduced weight, downsizing of engines, improved aerodynamic performance, reducing frictional losses in components and the engine as a whole. With all these changes, there is also demand for higher output. Designing vehicles with both higher output and lower weight engines is a difficult engineering challenge.
Innovation through simulation
Simulation is the key tool in meeting these challenges. From aerodynamics to acoustics, from intake to after-treatment, automotive engineers have pioneered the use of simulation in industry, producing bigger and more realistic simulations than are present in almost any other sector. Alongside finite element analysis for structural testing, an engineer might also turn to fluid dynamics to check the flow of oil, air or coolant around an engine, or combustion cycle analysis to assess the behavior of fuel.
However, even in this most progressive of industries, the way in which vehicle manufacturers use simulation software is rapidly evolving.
“Initially, we dealt mainly with stress analysis; for example, the stress on the intake/exhaust valves during operation,” says Siemens’ Fred Ross, a 30-year veteran of automotive simulation. “Computational fluid dynamics (CFD) for air flow and coolant flow was added to the mix around 20 years ago, looking at flow into the combustion chamber, plus the path of the coolant flow around the cylinders. Today, we are looking at simulating complete systems of components, including stress, thermal and flow in a single simulation. Identification of thermal stresses is very important, and simulation helps to identify where potential cracks may occur within the engine structure and guide the modification of the design accordingly. Often the worst thermal stresses occur under non-standard operating conditions, so our simulation tools need to be able to account for the full range of possible use scenarios.”
Better designs, faster
The reasons why simulation software is used have not changed, however – it saves vast amounts of time and money.
“Our customers, such as GM, Jaguar and Volkswagen,” continues Ross, “are moving towards virtual prototypes, replacing expensive physical prototypes with numerical simulation, which is advantageous both in terms of cost and in the fact that virtual prototypes can be deployed much earlier in the design process, helping OEMs to identify and correct potential problems before they occur. For example, simulation helps them to predict the performance of an engine over a wide range of operating conditions, such as driving up a hill or towing a trailer. Using simulation, they can also model the performance of the engine over a complex drive cycle, such as stop-and-go city driving."
Together, STAR-CCM+ and STAR-CD are the most widely utilized multidisciplinary simulation tools in the automotive sector, used by 14 of the 15 largest automotive OEMs.