What is Computer Aided Engineering (CAE)? A thorough explanation, from the basics to examples of use.

Computer Aided Engineering (CAE) is a technology that uses computers to perform various analyses and simulations in the design and manufacturing processes. In recent years, CAE has become indispensable in the advancement of the manufacturing industry and manufacturing DX (Digital Transformation). This article provides a detailed explanation of the basic concepts of CAE, specific examples of its use, the benefits of its introduction and future prospects.

What is CAE? Basic concepts

CAE is a technology that virtually verifies the performance, strength and operating characteristics of a product on a computer at the design stage. This allows problems to be identified theoretically without the need for repeated prototyping.

CAE can be divided into three main processes

　　modelling

1. 

   • 3D models of products and components are created in CAD (Computer Aided Design).

     Simplification and mesh division (subdivision used in the finite element method) are carried out for analysis.

     
     

     Analysis and simulation

   

   • Load, thermal, fluid and other conditions are given to the created model and calculations are carried out on the computer.

     A wide variety of analyses are possible, including structural analysis (strength and stiffness), thermal analysis (temperature distribution) and fluid analysis (flow velocity and pressure).

     
     

     Result evaluation and design improvement

   

   • Based on the analysis results, the validity of the design is assessed and, if necessary, the shape and materials are improved.

     Traditionally, product development required a great deal of cost and time due to repeated prototyping and experimentation; CAE significantly reduces these costs and realises an efficient and highly reliable design process.

     
     

     Typical analysis methods of CAE

     
     

     There is a wide range of analysis methods used in CAE. Some of the most common are introduced below.

• Structural analysis (stress and deformation analysis)

  
  

  Predicts stress and deformation for forces and pressures applied to products.

  Used to check the strength of automotive components and building structures.

  
  
  
  

  Thermal analysis

  
  

  Calculates heat generation, heat dissipation and temperature distribution.

  Useful for countermeasures against thermal deformation of electronic equipment and molds.

  
  

  Flow and fluid analysis

  
  

  Analyses the flow and pressure distribution of resins and fluids.

  Used to study aerodynamic characteristics and cooling performance.

  
  

  Vibration analysis

  
  

  Evaluates the vibrations and natural frequencies to which products are subjected.

  Reduces the risk of resonance in mechanical and electronic equipment.

  
  

  Topology optimisation analysis

  
  

  Analysis that leads to an optimum shape by eliminating unnecessary parts.

  
  

  By combining these, complex simulations close to the actual operating environment are possible.

  Application examples of CAE

  CAE is widely used in various industries.

  
  

  Automotive industry

• Crash simulation to improve crash safety.

  
  

  Improved fuel economy through aerodynamic analysis.

  
  

  Aerospace industry

• Structural design for light weight and high strength.

  
  

  Thermal and vibration evaluation in high-altitude environments.

  Household appliances and electronic equipment.

  Heat dissipation design in component layout.

  Analysis of failure mechanisms due to micro-deformation.

  
  

  Architecture and civil engineering

  Seismic and wind resistance verification against earthquake and wind pressure.

  
  

  Long-term durability evaluation of structures.

  
  

  Resin moulding

• Resin flow analysis in the mold for quicker delivery and higher quality.

  
  

  Optimisation of degassing and weld line positions.

  
  

  These examples are important factors directly linked to shortened product development, reduced costs and improved quality.

  
  

  Benefits of introducing CAE

  The following benefits can be achieved by introducing CAE

  
  

  Reduced number of prototypes and costs

  Reduced number of prototypes as performance can be predicted before the actual prototype is made.

  
  

  Shorter development times

  Allows early detection and correction of defects.

  
  

  Improved design quality

  Optimum design supported by objective numerical data.

  
  

  Reduced risk

  Minimised occurrence of defects after product release.

  
  

  Innovation promotion

  Virtual verification makes it easier to realise challenging designs.

  
  

  Key points and cautions for using CAE

  CAE is a very effective tool, but there are some points to be aware of.

  
  

  Accuracy of the analysis model

  Inappropriate setting conditions and mesh quality can lead to erroneous results.

  
  

  Interpretation of results

  Simulation is a theoretical calculation, so deviations from reality must also be considered.

  
  

  Human resources

  Appropriate training and know-how are important.

  
  

  Computational resources

  High-precision analysis may require a large computing environment.

  The key to success is to operate with an understanding of the scope of application of CAE in light of these factors.

  
  

  CAE and future prospects

  
  

  In recent years, development of “next-generation CAE” combining cloud technology and artificial intelligence (AI) has been progressing.

  
  

  Cloud CAE

  Running large-scale analyses in the cloud reduces infrastructure costs.

  
  

  Optimisation by AI

  Learns analysis results and automatically proposes optimum designs.

  
  

  Digital twin

  Reproduces the same behaviour as real-world products digitally, with real-time monitoring and control.

  
  

  With these advancements, CAE will become increasingly popular as a fundamental technology supporting rapid and advanced product development.

  
  

  Conclusion.

  
  

  Computer Aided Engineering (CAE) is a powerful analysis technology that uses computers to support product design and development. Simulation at the design stage can reduce prototype costs and simultaneously increase development speed and quality.