Introduction
In recent years, advanced simulation technology has played a pivotal role in transforming the automotive and aerospace/defense sectors accelerating product innovation and development processes, hence, enhancing competitiveness. From finite element analysis to computational fluid dynamics, simulations are becoming more accessible and powerful, enabling engineers to optimize designs and predict performance.
Role of advanced simulation:
Identify and fix issues in product development cycle:
Simulation encompasses a set of technological tools and methods for successfully implementing digital manufacturing. It facilitates information exchange during real-time product development cycle. It can identify issues within the product design, reducing prototyping costs and a lot of trials, as a result, reducing time.
In todays’ manufacturing environment, simulation has been used in product design, it helps connect bridges between setup planning, scheduling, machining, and many more areas.
Simulation offers better customization when the product development process is inherently complex, and products become more versatile and complicated and require mass customization. Secondly, with the prior assessment of the product, simulation allows reducing design flaws and helps fixing issues from the root.
Enhance Product Testing and Validation, and Derive New Product Insights:
Simulation modeling and analysis are conducted to gain insight into complex systems, to develop and test new concepts or systems that live up to the expectations of modern manufacturing, before implementing them in real-time.
To gather information and knowledge without disturbing the actual system, advanced simulation tools, for instance, digital-twin play a vital role to derive new product insight.
Cut costs and time to market
Simulations save costs by minimizing the need for physical prototypes, reducing material wastage, and mitigating risks early in the design process. They optimize resource allocation, streamline processes, and enable predictive maintenance, preventing costly downtime. Additionally, simulations facilitate market testing, ensuring investments are targeted effectively, leading to higher returns on investment.
Research suggests $30mn revenues are linked to successful product development making it an essential part of big industries Aerospace and Defense, Automotive, and others.
Value Drivers of Advanced Simulation Technology
Trends in Adoption:
Adoption Trends in the Automotive Sector
The automotive industry has been at the forefront of leveraging advanced simulation technology to enhance product design, prototyping, and testing processes. Specific use cases in the automotive sector include crash simulations, aerodynamics studies, virtual testing of components, and optimization of fuel efficiency.
Increasing Adoption: Surveys show a 20% year-over-year increase in the use of engineering simulations in the automotive sector.
Diverse Applications: Simulations are now used for 70% of crash testing, 60% of aerodynamics analysis, and 50% of structural integrity assessments in vehicle design.
Integration into Development Cycle: 80% of automotive manufacturers integrate simulations into their product development cycle, reducing time-to-market by up to 30%.
Cost Reduction: Virtual testing saves an average of $1 million per vehicle model by minimizing physical prototype iterations and test expenses.
Focus Areas: Simulations play a crucial role in electric vehicle (EV) development, with a 40% increase in simulation usage for battery optimization and range estimation.
Adoption Trends in the Aerospace/Defense Sector
In the aerospace and defense sectors, advanced simulation technology plays a crucial role in various critical areas such as aircraft design, propulsion systems analysis, structural integrity assessment, and sensor integration. The application of simulation technology in these sectors has led to significant improvements in product reliability, safety, and performance.
Increasing Adoption: Aerospace and defense industries witness a 15% annual rise in the utilization of engineering simulations.
Diverse Applications: Simulations are integral for 80% of aerodynamic analysis, 70% of structural integrity assessments, and 60% of propulsion system optimization in aerospace and defense projects.
Integration into Development Cycle: 90% of aerospace and defense contractors incorporate simulations into their product development, reducing time-to-market by up to 25%.
Cost Reduction: Virtual testing saves an average of $2 million per aircraft model by minimizing physical prototype iterations and test flights.
Focus Areas: Simulations are pivotal in unmanned aerial vehicle (UAV) design, with a 50% increase in simulation usage for autonomy testing and mission planning.
Figures are drawn from a combination of industry reports, market analysis studies, and trends observed within the aerospace and defense sectors
Technological disruption in Simulation:
Cloud based simulation platform:
Cloud-based simulation platforms are disrupting the simulation technology by leveraging benefits of Parallel computing, Distributed computing, and Grid computing. These platforms provide an alternative to traditional workstation-based infrastructure and offer benefits such as unlimited storage and computing capabilities. Users can access resources anytime, anywhere, and benefit from enhanced resource sharing.
Data safety concerns are addressed through dedicated technicians and safety methods. Cost savings are achieved by eliminating the need for hardware investment and system maintenance. Developers can focus on innovation with platform-as-a-service offerings. Rapid development and deployment are facilitated, accelerating the innovation process and enabling organizations to bring their simulations to fruition quickly. Cloud-based simulation platforms offer unparalleled advantages, including access to resources, enhanced data safety, cost savings, and streamlined development processes.
AI – ML for Simulation:
Although traditional simulation methods, including finite element analysis, computation fluid dynamics, and multibody simulation, are still widely used. With recent advancements in AI, machine learning, and cloud HPC-based simulations, these are emerging as game changers in modeling and simulation.
AI and ML simulation technologies provide enhanced capabilities, such as advanced optimization, accelerated modeling processes, and more accurate predictions. With quicker access to higher computing power and real-time collaboration, cloud HPC is democratizing access to simulation. These new AI and ML-based simulations can revolutionize product development and innovation across various industries, including aerospace, automotive, medicine, and manufacturing.
Areas of applications: scheduling and optimization, fault detection, predictive analysis, and many more.
Quantum Algorithms for Engineering Simulation:
Quantum algorithms are revolutionizing engineering simulation by harnessing the principles of quantum information processing. These algorithms have demonstrated the ability to solve complex coupled simulation problems that were previously considered unsolvable. By offering innovative approaches to explore diverse and more precise solutions, they contribute to improved product development and faster time to market, addressing two crucial drivers of adoption in industries.
The adaptability of quantum algorithms to both classical and quantum computers is paving the way for innovation to meet future demands, including sustainability, product innovation, and accelerated time to market. The faster information processing capability enables engineers to evaluate and modify existing solutions more swiftly than would have been possible using classical computers alone, presenting an exciting prospect for expediting engineering processes and enhancing overall productivity.
Areas of applications: CFD (Computational Fluid Dynamics), Optimization, QML (Quantum Machine Learning), and many more.
Future Roadmap of Simulation:
A new generation of software based on cloud platforms and powered by advanced algorithms is set to redefine how businesses operate, offering various capabilities including increased computational power, for intensive data sets and tackling innovations enabling additive manufacturing, lightweighting, complex Multiphysics among others.
Increased Computational Power: Advancements in computing technology will enable simulations to handle larger and more complex models with greater speed and accuracy.
Intensive Datasets Integration: Simulations will harness big data analytics, machine learning, and artificial intelligence to integrate extensive datasets for more precise predictions and insights.
Digital Twins Evolution: Digital twins will become more sophisticated, replicating real-world systems with unprecedented fidelity. They'll enable real-time monitoring, optimization, and predictive maintenance across various industries.
Additive Manufacturing Optimization: Simulations will play a crucial role in optimizing additive manufacturing processes, enhancing part quality, reducing material waste, and accelerating production cycles.
Lightweighting and Structural Integrity: Simulations will continue to advance lightweighting strategies while ensuring structural integrity. They'll enable the design of lighter, stronger materials and structures, leading to improved performance and fuel efficiency in transportation and aerospace industries.
Multi-Physics Simulation Integration: Simulations will increasingly integrate multiple physics phenomena, such as fluid dynamics, electromagnetics, and thermal analysis, providing holistic insights into complex systems and processes.
Augmented Reality Integration: Simulations will merge with augmented reality (AR) technologies, allowing engineers and operators to visualize and interact with simulated models in real-time, enhancing collaboration, training, and decision-making.
Conclusion
By understanding the value drivers, adoption trends, applications, challenges, and future prospects associated with simulation technology, organizations can unlock new opportunities for growth and advancement. Continued investment, collaboration, and integration of advanced technologies are crucial for further advancing the capabilities and applications of simulation technology to drive industry progress and innovation.
Resources:
1.“Unveiling the next frontier of engineering simulation” https://www.mckinsey.com/capabilities/operations/our-insights/unveiling-the-next-frontier-of-engineering-simulation
2. Parekh, Rhea, et al. "Quantum algorithms and simulation for parallel and distributed quantum computing." 2021 IEEE/ACM Second International Workshop on Quantum Computing Software (QCS). IEEE, 2021