With a team of 15+ years of industry experience, we can provide meshing and model building, CAE passive safety analysis, NVH analysis, fatigue durability analysis, CFD fluid analysis, multi-body dynamics analysis, product drop analysis, structural rigidity and strength analysis, stamping and mold design, etc. for the automotive industry, white goods industry, general machinery and other industries. The details are as follows:

Multi-condition collision simulation covering the entire vehicle and key components, including frontal 100% overlapping rigid barrier collision, frontal 50% overlapping moving progressively deformable barrier (MPDB) collision, 40% offset deformable barrier collision, small offset collision, deformable moving barrier side collision, side pillar collision, rear-end collision, pedestrian protection, etc. LS-DYA is used in combination with the high-precision material GISSMO model to achieve accurate predictions of body structure deformation, intrusion, and acceleration curves, and complete the calibration and benchmarking of self-developed frontal and side barriers. Supports battery pack extrusion/acupuncture/thermal runaway simulation, meeting national standards, ECE, C-NCAP, E-NCAP, C-IASI and other regulatory requirements.

For new energy vehicles, a "battery pack-body" collaborative protection system is developed. Through Ls-TaSC, Ls-Opt topology optimization and multi-objective optimization algorithms, it can achieve lightweight while meeting collision safety.

Simulation analysis of frontal restraint system

Simulation analysis of side restraint system

Side pillar impact simulation analysis

Low speed collision simulation analysis

Top cover strength analysis

Battery pack extrusion strength optimization

Completed the calibration and benchmarking work of self-developed a-PLI leg type, Flex-PLI leg type, children's head shape, and adult head shape.

Benchmark analysis of pedestrian protection head

Dynawe a-PLI leg type simulation analysis

Covers vibration and noise simulation of the entire vehicle and key components, including body modal analysis (10-2000Hz), acoustic cavity modal analysis, transmission path analysis (TPA), powertrain suspension system optimization, road noise/wind noise prediction, etc. The LS-DYNA software is used in combination with test data (such as modal tests and hammer percussion tests) to calibrate the model to achieve the goal of interior noise (NVH) ≤ 38dB(A) (idling condition).

In order to solve the problem of wind noise, the CFD and acoustic simulation coupling method was used to optimize the shape of the rearview mirror and the structure of the A-pillar guide channel. The aerodynamic noise of the entire vehicle was reduced by 5dB(A), and the interior noise (120km/h) was reduced from 65dB(A) to 58dB(A). The NVH problem solving cycle is shortened by 60%, and the test verification cost is reduced by 40%.

Based on the multi-axis fatigue theory (Miner's law, rain flow counting method), the fatigue life prediction of key components (such as frame, suspension, transmission shaft, welded structure) is realized. Supports road spectrum load collection (through six-component force sensors and strain gauges), load spectrum editing and accelerated fatigue test simulation. The ANSYS nCode DesignLife solver is used, combined with the material S-N curve and E-N curve, to predict the fatigue life of components under different working conditions (such as urban roads, highways, and off-road conditions).

Aiming at the durability requirement of 1 million kilometers for commercial vehicle frames, ANSYS multi-body dynamics and finite element coupling analysis were used to optimize the frame welding process (such as welding sequence, welding leg size) and material selection (upgrading from Q345 steel to Q690 steel). In the frame simulation of a certain heavy truck model, the fatigue life was increased from 800,000 kilometers to 1.2 million kilometers and passed relevant certifications. The number of physical prototype tests is reduced by 50%, the after-sales failure rate is reduced by 30%, and R&D costs are saved by 20 million yuan per model.

Covers vehicle aerodynamic performance, thermal management system, engine cylinder flow field, battery pack thermal runaway and other fluid simulations. ANSYS Fluent solver is used, based on the RANS/LES turbulence model, to achieve quasi-simulation of aerodynamic drag coefficient (CD value), lift coefficient (CL value), flow field distribution, and temperature field distribution. Supports battery pack liquid cooling/air cooling system optimization, and the temperature difference is controlled within 5°C.

In response to the demand for increasing the cruising range of new energy vehicles, the "aerodynamic-thermal management" collaborative optimization plan was developed. Through topology optimization of the aerodynamic shape of the vehicle (such as streamlined front design, flattening of the chassis, and adjustment of the rear wing angle), the CD value of a pure electric model was reduced from 0.28 to 0.23, and the cruising range was increased by 12%. For battery pack thermal management, the serpentine flow channel and manifold liquid inlet design are used to reduce the cell temperature difference from 8°C to 4°C and increase the cycle life by 20%.

Wind tunnel test costs are reduced by 60%, battery pack heat dissipation efficiency is increased by 15-20%, and vehicle energy consumption is reduced by 5-8%. After a new power car company applied it, the comprehensive cruising range of pure electric models was increased from 500km to 580km.

Vehicle water wading analysis

Calculation of drag coefficient and partial pressure coefficient

Based on the finite element method, the static strength, stiffness, modal, buckling and stability analysis of key components are carried out. The ANSYS/LS-DYNA solver is used to support multiple material models such as metal, composite materials, and plastics to achieve accurate prediction of the stress distribution, deformation, and natural frequency of the structure under different working conditions (such as full load, braking, turning, and bumping). Supports structural optimization algorithms such as topology optimization, shape optimization, and size optimization.

Industry plan: For aero-engine blades, develop a "strength-vibration" collaborative optimization plan. Through composite material layup optimization (such as carbon fiber T800/resin system, layup angle [0°/±45°/90°]), while meeting the strength requirements (maximum stress <800MPa), the first-order natural frequency is increased from 200Hz to 250Hz to avoid the risk of resonance. In the structural strength analysis of a commercial vehicle frame, the bending stiffness was increased by 25% through the optimization of the cross-sectional shape of the longitudinal beam (changed from U-shaped to hat-shaped). Structural redundancy is reduced by 20-30%, material costs are saved by 15-20%, and structural reliability is increased to 99%.

Through the ANSYS active safety module, a scene library covering 100,000+ scenarios is built, and through the three-level verification system of MIL (model-in-the-loop), SIL (software-in-the-loop), and HIL (hardware-in-the-loop), rapid iteration of active safety functions is achieved. For example, in the AEB function simulation of a certain car model, through the optimization of the data fusion algorithm of the forward-looking camera and millimeter-wave radar, the recognition distance of pedestrian crossing scenes was increased from 50m to 70m, and the collision avoidance speed was increased from 40km/h to 50km/h.

The actual vehicle test mileage is reduced by 80%, the function development cycle is shortened by 50%, and the active safety performance meets the requirements of C-NCAP 2025 "GSR" (Global Safety Regulations).

Focusing on the "motion-force-energy" coupling behavior of mechanical systems, it supports rigid-flexible coupling modeling (MotionSolve+ANSYS joint simulation), kinematic analysis of complex mechanisms, and vibration and noise control (modal superposition method). Equipped with an industry-specific template library (car chassis K&C analysis, robot gait planning), it can quickly build multi-body system models (including 1000+ degrees of freedom), and output dynamic response curves (displacement/velocity/acceleration) and optimization plans.

For the automotive industry, it provides chassis system dynamics analysis (such as suspension K&C characteristics: roll stiffness, steering return), and controls the front wheel positioning parameter deviation within ±0.5° through multi-body optimization; for engineering machinery, it simulates the multi-axis linkage of excavator buckets, optimizes hydraulic system flow distribution, and improves operating efficiency by 15%. A new energy motor project identified the second-order resonance point (2800rpm) through modal analysis, adjusted the rotor imbalance to 0.5g·mm, and reduced the bearing vibration acceleration from 12m/s² to 4.5m/s². The number of physical prototype tests is reduced by 60%, and the dynamic performance optimization cycle is shortened by 40%. After a car company applied it, the chassis handling and stability development cycle was shortened from 12 months to 8 months.

"Integrated analysis of "impact process-structural damage-protection optimization" covering scenarios such as electronic equipment, packaging, and medical equipment. Supports multi-working condition simulation: free fall (0.5~2m height), directional impact (30°~90° angle), transportation bumps (ISTA 3A standard), uses LS-DYNA solver and high-precision constitutive models such as *MAT_024 (elastoplasticity), *MAT_106 (foam material) to predict impact acceleration, stress distribution, and failure modes.

For the smartphone drop scenario, a 1.5m hexahedral drop (6 directions) was simulated, and the display dynamics algorithm was used to capture the screen rupture risk area (the deviation compared with the actual drop test was <3%); when optimizing the packaging structure, the DOE method was used to iteratively buffer the foam density gradient, reducing the transportation impact acceleration of a certain home appliance product from 1500g to 800g, and reducing packaging costs by 20%. A medical device project used drop simulation to reduce the thickness of the ABS material of the shell from 2mm to 1.5mm, reducing the weight by 25% and meeting the IEC 60601 impact standard. On average, the number of physical prototype tests is reduced by 60%, the product development cycle is shortened by 30%, and the after-sales breakage rate is reduced by 50%.

Based on the JStamp/LS-DYNA platform, it provides a full-process solution from product formability evaluation to mold life prediction. Core functions include: Forming Limit Diagram (FLD) analysis (locating the risk of cracking within 10 minutes), die surface engineering design (automatic generation of draw beads/process supplementary surfaces), springback compensation technology (incremental method + static implicit algorithm, prediction error <10%). Equipped with 2000+ material database (DC06/DP590/aluminum alloy 6061), supporting multi-objective optimization (thinning rate <20%, springback <1mm).

In the field of automotive panels, the fender of a certain model has been optimized with drawbead layout, reducing the corner thinning rate from 28% to 18%, and the number of mold trials reduced from 5 to 2; in the field of home appliances, the washing machine inner barrel project has improved the material utilization rate from 65% to 78% through layout optimization, reducing annual costs by 1.2 million yuan. For the power battery casing, the "segmented control of blank holder force (500-2000kN) + intelligent matching of friction coefficient (0.08-0.15)" solution was adopted, and the forming pass rate was increased from 62% to 95%. The mold development cycle is shortened by 40%, material costs are saved by 15-20%, and the dimensional accuracy of stamping parts (flatness ±0.3mm) is increased to 98%.

Please consult our engineering service department and team for details.