Once you implement CAD and CAM tools in your shop, you will not only work better but also interact more effectively with your customers and vendors. Now, it may be time for Step 2—assimilating computer-aided engineering (CAE) tools into your workflow—a move that will further boost productivity while making the most of your processes.

CAE manufacturing applications whip processes into shape by simulating and analyzing them so you can optimize the use of materials, tools, shape and time.

Many companies are discovering that CAE can slash production time and prevent costly rework. As a result, CAE has grown in importance, no longer consigned to the end stages of the design and manufacturing process.

CAE is advancing in two areas. First, many design and manufacturing organizations are using CAE tools earlier in the product development process, with some even utilizing them in the conceptual phase—the initial stage of design. Second, software vendors are doing a better job of integrating CAE into their CAD and CAM tools. Additionally, falling computer prices are helping CAE's cause—especially since some tools need immense processing power when tackling big assemblies or extremely precise engineering constraints.

A major hurdle remains, however. Many shops are reluctant to embrace CAE because they believe only highly paid analysis specialists can grasp and apply CAE tools. They are actually mistaken. While some of the high-end tools for complex analyses do call for specialists, many available CAE tools only require individuals to undergo some basic training and practice.

While a technical mind is certainly a prerequisite for using all CAE tools, a doctorate in mathematics is no longer a must for many types of analysis and simulation. What's more important is becoming familiar with the interface of a CAE tool for generating and loading digital models, and then studying and interpreting the results.

Of the various types of CAE-related manufacturing applications, FEA (finite element analysis) for designed parts and tooling is probably the most widely used. It's a numerical technique for determining the strength and behavior of structures. With FEA, you can figure out deflection, stress, vibration, buckling and other behaviors. It's useful for say, lowering a part's weight and/or boosting its strength.

In FEA, structures are broken down into tiny, clear-cut units, called elements. The behavior of individual elements can be explained with a comparatively simple set of equations, while the behavior of a complex structure will require a large set of simultaneous equations. When the equations are worked out, the computer and FEA tool show the physical behavior of the structure based on its separate elements.

Mechanical designs can be optimized using FEA tools. The optimization process involves design improvements that produce the best physical properties at the lowest cost. But it is no easy feat. Optimization with FEA tools is time-consuming, entailing design variations that each requires lengthy evaluation. As a result, FEA can be better for innovation than optimization. With FEA, you can uncover novel and unique approaches to mechanical design.

Before implementing any CAE tool, verify that it's compatible with your current CAD and CAM tools, the kinds of parts and assemblies you design, and your overall workflow. Remember that no single tool will meet everyone's needs. Some in your organization will be concerned with fluid flow, others with structural mechanical properties, or perhaps thermal issues. Consult with the groups that will likely be positively affected by CAE tools.

When choosing between CAE tools, review them with your models, not solely with models provided by a vendor. This will allow you to objectively assess the various CAE tools that fit your needs, without being unduly influenced by a vendor's presentation.

Finally, set realistic expectations. CAE tools won't fix every glitch in all of your parts. And keep in mind that return on investment will be difficult to calculate. In fact, figuring out the ROI of using CAE tools can be as complex as analyzing complicated assemblies. You can, however, probably expect payback from such things as a truncated design process, reduced material costs, diminished need for physical prototypes and perhaps a sharp decline in the number of product liability lawsuits.

CAE is not a magic cure—people still have to do a lot of the work—but used properly, it will likely enhance your workflow and deliver concrete benefits in no time.

Source: Advanced Design Insights
Jeffrey Rowe
Advanced Manufacturing, March/April 2003
http://www.advancedmanufacturing.com