Manufacturers! How Effectively Are You Using CAD Software to Test Designs?

Much was written in the press about Toyota's misery recently, and some errors have been caused by CAD software (computer assistance design) and PLM (product lifecycle management). Obviously this problem is in a basic understanding of the function and environment of the operation, as well as testing involved, not the actual use of CAD.

In general, both simulation testing through virtual analysis (including analysis of the element to, the dynamics of FEA fluid and computing, CFD) and physical testing depend on deep understanding of what can happen. Only once do we understand what we are looking for, can we resolve the problem specifically in the context of testing. Limited (Express) FEA and CFDs are freely available in embedded in most CAD software, which is a danger for non-experienced users and may have contributed to this problem.

The challenge with any tool is to cut both ways and sharper tools, the more damage can be done when used incorrectly. If you don't know what you are looking for, any simulation is useless. If you do not have the experience or knowledge needed to interpret the data correctly, the incorrect results are generated. Even worse, if you don't know the underlying software limits, improper extrapolation will be made, especially with the express version of FEA software. Default virtual simulation software allows designers to use tools without paying contributions needed to understand technology. Unfortunately, because of the nature of the software, they might not even realize that they use CFD or FEA!

FEA and CFD are a great tool if used with clear goals, by analysts who meet the requirements and in a limited context. The actual physical testing of a product ensures an important reality inspection is made. But combining FEA into the design process can dramatically reduce the time and development costs. But it is a total package understanding of device functions and the operation environment, combined with the correct application of virtual simulations and physical testing, which provides confidence to go to production.

Here are some clear phases needed in developing any product, but note that product design and development is an iterative process. These phases must be understood at the top level for coherence, but usually different people and different sets of skills that produce the results needed:

1. Product vision (including development plans and overall direction)

2. Virtual modeling (conceptual development for marketing purchases)

3. Design for manufacture (including detailed modeling, calculations, production drawing and process development)

4. Virtual testing (including tolerance, interference checks, stress, bend, resonant and dynamic analysis & / or flow analysis)

5. Physical testing (including static loads applied, impact load, exhausted load and environmental testing etc.)

6. Production development (how it was made, what, where and whom)?)

7. Product release (including customer feedback monitoring and guarantee problems management)

8. Product life cycle management (including the development and development of ongoing products and the development of product replacement strategies)

After being produced, it is monitoring ongoing products, awareness of warranty problems and rapid response to known problems that will avoid product withdrawal. Because as we have seen, product withdrawals can paralyze even the most powerful manufacturer!