The traditional engineering design process applies engineering simulation at the detailed engineering stage to verify designs. This involves using software tools to model the design and simulate its performance under various conditions. Any modifications or optimisations are typically limited to areas that do not meet the design criteria. This approach, while effective, often leads to extended timelines and increased costs as issues are identified and resolved late in the design process. However, by integrating engineering design and simulation early and throughout the project, significant improvements in efficiency and outcomes can be achieved.
The Benefits of an Integrated Approach
An integrated approach uses simulation earlier in the design process, during the concept development and preliminary design stages. This approach, known as virtual prototyping, allows for refining and optimising designs before reaching the detailed engineering phase. Applying advanced analysis throughout the design process delivers multiple benefits to projects, including:
- Reducing project timelines – By eliminating the need for post-design analysis, projects can progress more quickly. Simulation during concept development helps identify and solve potential issues early, reducing the time required for subsequent design phases.
- Reducing project costs – Ensuring final designs do not need to be ‘de-featured’ for analysis helps maintain the integrity and functionality of the design while controlling costs. Early detection of issues prevents costly redesigns and modifications.
- Full optimisation – All aspects of the design can be fully optimised while meeting design criteria. This leads to more efficient and effective designs that perform better and are more reliable.
- Early verification – Designs can be optimised and verified during the concept development phase rather than during detailed engineering. This early verification ensures that designs are feasible and meet all requirements before extensive resources are committed.
- Speeding up final delivery – By reducing real-life prototyping requirements through rigorous testing in a virtual environment, the overall project timeline is shortened. This accelerates the final delivery of the project, getting products to market faster.
Using simulation at the concept development stage reduces the overall project timeline and operating costs. By rigorously testing, optimising, and verifying designs in a virtual environment during concept development, real-life prototyping requirements are reduced, and project delivery is accelerated, thus reducing timeline and cost.
Analysis-Driven Design
Avesta Consulting offers a uniquely integrated approach to engineering design, an approach we call “analysis-driven design.” We use simulation tools to drive the engineering design process from start to finish, rather than as an afterthought for design verification only. Simulation techniques are applied in the development of new designs, during testing, and for verification compliance of existing designs.
We specialise in the provision of the following simulation techniques to the engineering design process:
- Finite element analysis (FEA).
- Computational fluid dynamics (CFD).
- Discrete element modelling (DEM).
- Pipe network stress and fluid flow analysis, process modelling, and specialised engineering simulation and calculation software tools.
Finite Element Analysis (FEA)
FEA is applicable to a wide range of mechanical, civil, and structural applications. Our capabilities include:
- Linear and nonlinear analysis including deflection, material and contact.
- Static and dynamic structural analysis including natural frequency, harmonic (vibration), spectral response (seismic) and transient (shock, impact and blast).
- Steady state and transient heat transfer analysis.
- Fatigue life assessment (stress and strain life).
- Time dependent high temperature creep failure assessment.
- Staged construction sequencing.
Computational Fluid Dynamics (CFD)
CFD analysis is applicable to the most complex industrial flow problems. Our capabilities include:
- Laminar and turbulent steady state and transient flow.
- Incompressible and compressible flow.
- Heat transfer analysis including solid conjugate heat transfer (CHT).
- Stationary and rotating domains (fluid, solid and porous representations).
- Multi-component and multi-phase fluid flow modelling.
- Chemical reactions and discrete particle models (DPM).
Discrete Element Modelling (DEM)
DEM is applicable to a wide range of bulk solid (granular) material flow problems. Our capabilities include:
- Transient particle flow analysis considering particle-particle and particle-wall interaction, internal/wall friction and energy loss.
- Spherical and non-spherical (shaped) particles of variable density and particle size distribution (PSD).
- Particle cohesion and arching (sticky particles).
- Static, moving (translating/rotating) and vibrating boundaries.
- Particle breakage.
- Calibrated DEM simulation models (from physical test data).
- Determination of particle motion/interaction, velocity and wall pressure/shear stress.
The Role of AI & Machine Learning in Integrated Design & Simulation
Artificial Intelligence (AI) and Machine Learning (ML) are revolutionising the field of integrated design and simulation. These technologies enhance traditional simulation techniques by enabling more sophisticated analysis and optimisation. Here are some key benefits of integrating AI and ML into the engineering design process:
- Predictive analytics – AI and ML algorithms can analyse vast amounts of data to predict the performance and potential issues of designs before they are physically tested. This predictive capability allows for proactive adjustments, significantly reducing the risk of failure.
- Automated optimisation – Machine learning algorithms can automatically optimise design parameters to achieve the best performance. This reduces the need for manual adjustments and accelerates the design process.
- Improved accuracy – AI enhances the accuracy of simulations by learning from historical data and continuously improving its models. This results in more reliable predictions and better-informed design decisions.
- Enhanced efficiency – AI can handle complex calculations and simulations faster than traditional methods, significantly speeding up the design process and reducing time-to-market.
- Innovative solutions – By leveraging AI and ML, engineers can explore innovative solutions that might not be apparent through conventional analysis. This fosters creativity and leads to breakthrough designs.
Integrating AI and ML into engineering design and simulation not only improves efficiency and accuracy but also opens new avenues for innovation and optimisation.
Conclusion
Integrating engineering design with simulation from the earliest stages of a project transforms the traditional design process, offering substantial benefits in terms of time, cost, and performance. By adopting an analysis-driven design approach, Avesta Consulting leverages advanced simulation techniques to ensure that designs are optimised and verified throughout the development process. This proactive strategy not only enhances the efficiency and effectiveness of engineering projects but also fosters innovation and collaboration among multidisciplinary teams.
Moreover, the incorporation of AI and machine learning into the design and simulation processes brings a new dimension to engineering. These technologies enable more accurate predictions, automated optimisations, and innovative solutions, further enhancing the value of an integrated approach. As industries continue to evolve and the demand for more sophisticated and reliable designs grows, the role of integrated engineering design and simulation will become increasingly crucial, driving the future of engineering toward greater heights of achievement and excellence.
The synergy of traditional simulation techniques with AI and ML capabilities ensures that engineering designs are not only robust and efficient but also cutting-edge and forward-thinking. This integrated approach positions organisations to meet the challenges of the modern engineering landscape, delivering superior products and solutions that meet the highest standards of quality and performance.
