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Mechanical Engineering and Product Design Services

CAE Services for Industrial Machinery

CAD (Computer-Aided Design) is software used to create 2D or 3D models of products or parts. These models can be used to visualize, simulate, and analyze the product design before it is physically created. Likewise, CAE (Computer-Aided Engineering) is software used to analyze and simulate the behaviour of products or parts under various conditions, such as stress, heat, fluid flow, and motion. CAE is used to evaluate the design and identify potential problems or weaknesses before the product is built. Both CAD and CAE have become essential tools in many industries to improve the design, reduce costs, and increase efficiency of product development. They are widely used in industries such as automotive, aerospace, defence, architecture and manufacturing for the benefits they offer.

Industrial Machinery
The terms ‘industry machines’ or ‘industrial machinery’ refers to the machines and equipment used in various industrial applications to produce goods and services. These machines are designed to perform specific tasks such as cutting, shaping, drilling, welding, assembling, and packaging of raw materials or finished products. These machines are typically larger, more complex, and more powerful than machines used for household or personal use. They are designed to handle heavy workloads, operate for long periods of time, and often require specialized training to operate safely and efficiently. Industrial machines can be categorized based on their application, such as manufacturing, construction, mining, agriculture, and transportation. Each industry has its specific set of machines that are designed to meet the demands of that industry. A few examples of industrial machinery from various sectors include CNC (Computer Numerical Control) machines, excavators, cranes, oil rigs, loaders, and haul trucks. Industrial machines are also designed to meet specific industrial requirements, such as precision, speed, durability, and safety. They may incorporate advanced technologies, such as computer controls, automation, and robotics, to improve their performance and efficiency.  

CAE of Industrial Machinery
Even if you do not have an engineering background, you would have realized by now that designing of industrial machinery is a demanding task. A simple analogy should suffice to highlight this point - it requires relatively less efforts to design a single security cabin as opposed to designing an apartment complex with 2, 3 and 4 BHK and amenities like swimming pools, multi-level parking, and so on. To design complex industrial machinery, engineers need to be familiar with and be able to bring together motor control theory, kinematics, dynamics, electronics, simulation, programming and machine design, apply interdisciplinary knowledge and deal with practical application issues.

The design process involved in developing industrial machines typically follows a set of steps, including: identifying the specific need the machine will address, the research and development needed to determine the best design and technology to meet the identified need, conceptual design (which involves CAD) and prototyping (which involves CAE, simulation and modelling), manufacturing, installation, maintenance and product refinement.

CAE (Computer-Aided Engineering) is a powerful tool that can be used in designing and developing industrial machines. It enables engineers to simulate and analyze the performance of machines before they are built, which can help identify design flaws and optimize the machine's performance.

Here are some ways that CAE can be useful in designing and developing industrial machines:
  • Finite Element Analysis (FEA): FEA is a CAE technique that enables engineers to simulate the structural behaviour of machines under various loads and conditions. By using FEA, engineers can optimize the design of a machine to ensure that it can withstand the loads and stresses that it will be subjected to during operation. This can help reduce the risk of machine failure, increase safety, and improve performance.
  • Computational Fluid Dynamics (CFD): CFD is a CAE technique that enables engineers to simulate the flow of fluids (such as air, water, or oil) through a machine. By using CFD, engineers can optimize the design of a machine to ensure that it has the right flow characteristics to achieve the desired performance. For example, CFD can be used to optimize the design of a pump or a heat exchanger to ensure that it has the right flow rate and heat transfer characteristics.
  • Kinematic and Dynamic Analysis: CAE can also be used to simulate the motion of a machine and its components. Kinematic and dynamic analysis can help engineers optimize the design of a machine to ensure that it moves correctly and operates smoothly. This can help reduce wear and tear on the machine, increase its lifespan, and improve its performance.
  • Design Optimization: CAE can be used to optimize the design of a machine by evaluating different design alternatives and selecting the best one based on specific criteria such as performance, cost, or weight. Design optimization can help engineers improve the efficiency and reliability of a machine while reducing manufacturing costs.
  • Multibody Analysis: is the engineering involved in the motion of complex mechanical systems under the application of mechanical forces. It involves analysis of kinematic and dynamic motion of the various components of a complex system in relation to each other. CAE enables the efficient calculation of the dynamic behaviour of multibody systems using simulation software

CAE Services for Industrial Machinery
Needless to say, more complex the machinery, more the sophistication required in its design. As computers became main-stream equipment through the inexpensive availability of electronics and microprocessors, CAE has become an indispensible tool in the design of industrial machinery. There are many software tools available for CAE today for the job. The choice of software depends on the specific application and requirements of the engineering project. CAE software helps engineers to model, simulate, and analyze different engineering designs and systems, enabling them to optimize the designs and improve the overall performance of the products.However, it is challenging for most manufacturers – especially small and medium scaled enterprises (SMEs) - to possess all the skill sets needed to develop a complex industrial machine. They therefore prefer to outsource the task to competent engineering companies that provide CAE services, and have a rich experience in diverse industrial domains. These engineering consulting companies can help manufacturers optimize their design faster, reduce risks, and accelerate the overall development process using the right CAE tools.

Industrial machines play a key role in the economy, especially for countries like India. With proper CAE analysis, industrial machines can help to reduce labour costs and improve the quality of goods and services produced. This in turn can help a nation be self-reliant and achieve industrial progress.