CAE Examples

These are just some of the projects we have worked on

Click on the images for an animation or on the titles for more information

  • 3D Subaru Engine and Transmission Scan

    For this project, we scanned a Subaru EJ20 engine and 5 speed transmission as an accompaniment to our 2WD conversion kit. Using the same processes as we use to engineer chassis and roll cage designs, the powertrain was first 3D scanned using Artec scanners. Artec uses structured light scanning technology to take thousands of images and stitch them together into a “point cloud” image of the engine. This usually takes a few hours to get good model resolution. The raw data points from the scan are then meticulously positioned and any low-quality images filtered. Once

  • Forensic Crash and Failure Analysis

    Our Finite Element Analysis (FEA) software can be used to simulate vehicle crashes and structural failures in order to determine the initial conditions that preceded the crash or failure. Typical questions are "what speed was the vehicle travelling at when it hit the structure?" or "could some operating cases be sufficient to cause failure of the structure?” Prosolve are a New Zealand based forensic engineering firm who carry out investigations into air, sea, road accidents and industrial failures. Bremar has collaborated with Prosolve on various projects, supplying FEA analysis which allows the comparison of simulated loading

  • 4 Bar Rear Suspension

    Cartech recently approached us to provide some guidelines on triangulated 4 bar rear suspension systems, particularly around the strength of the arms and the loads that go into the chassis. This was not an analysis of a specific suspension kit, but more of a general analysis to see which parameters the 4 bar linkage was sensitive to and what to look out for when assessing these type of systems. The triangulated 4 bar is a suspension system for a solid rear axle, more commonly seen on older cars. The upper links are

  • Falling Concrete Impact

    Bremar recently completed a project which involved simulating the impact of wet concrete falling 150m into a hopper in an underground mine. The objective of the analysis was to assess the strength of the hopper and determine whether it could withstand the proposed impact of the falling cement, which is travelling at nearly 200km/h when it hits the hopper. For this analysis, we used Altair Radioss to perform a Finite Element Analysis (FEA), and a simulation technique called Smooth Particle Hydrodynamics (SPH) to represent the wet cement. SPH basically represents incompressible fluids as multiple smooth spheres

  • Excavator Arm Extension FEA

    RK Findlay Engineering approached us to assist them with a design modification to an excavator arm, extending the reach of the machine from 14m to 29m. The 100T Komatsu excavator needed to have the reach extended to be used for shaping the underwater floor profile of reclaimed shipping berths in Port Kembla's outer harbour. The image below shows another excavator in action performing similar works. The original boom, and a dipper arm from a CAT330 machine had the centre sections cut out and replaced with newly fabricated longer sections. We used FEA to

  • Security Barrier Crash Analysis

    We were recently commissioned by Magnetic Automation to perform a crash simulation on one of their rising step barriers, using Finite Element Analysis (FEA). The rising step barrier is installed at site entry roads to prevent unauthorized vehicular access, and must be able to withstand the impact of a vehicle hitting the barrier at speed. Magnetic wanted to assess how their barrier design would perform to PAS68:2010, which is a standard test specification for impact testing of vehicle security barriers. In this case, the test involved a 7.5T

  • Crusher Stand Vibration Analysis

    We've recently completed a project in conjunction with RK Findlay Engineering, Global Crushers and Quarry Products Newcastle, assessing the dynamic and vibration response of a rock crusher stand using Finite Element Analysis (FEA). The stand is around 4m high, and supports a rock crusher weighing 27T, driven by an electric motor weighing around 2T. We used a range of FEA techniques including modal analysis and frequency response analysis to gain an understanding of how the structure responds to dynamic imbalance and vibration loads at the crusher and motor.

  • Vehicle Handling Simulation

    Using our Multi Body Dynamics (MBD) software, Altair MotionSolve, we are able to simulate full vehicle models performing a range of vehicle dynamics tasks and maneuvers. We have worked with vehicles ranging from lightweight sports cars, through to heavy vehicles such as semi trailers and truck and dog combinations. We are continually developing our capabilities in this area and have some interesting projects on the horizon in this field. (click here for front view of this animation) Whilst there are a range of tools available to predict vehicle handling characteristics with

  • VSB14 Suspension Assessment

    V6 Conversions approached us to perform an assessment on their front end kit for early model FX-HR model Holdens. The subframe, suspension and steering systems were all assessed to VSB14 regulations, which sets out guidelines for the loads that various components should be able to withstand, and the desired suspension geometry changes as the wheel moves through its travel. We used various analysis methods including FEA and MBD to simulate the front end assembly. Springs, bumpstops and even flexible Nolathane bushes were modelled to achieve a high degree of accuracy. Various bump, cornering and braking

  • Drill Rig Stress Analysis

    Our client, R.K. Findlay Consulting Engineers, had a customer whose drill rigs were showing signs of cracking around the main base pivot. Rather than perform basic stress calculations in house, R.K. Findlay engaged us to perform an FEA analysis on the rig, due to the complexity of the structure and loadings. We worked with R.K. Findlay to review a number of loadcases covering various conditions from transport and installation, through to drilling torque and drill bit pull out loads. Our analysis showed up hot spots exactly where the issues were occurring and we proposed various changes to the rig to

  • Stabiliser Bar Optimisation

    In a race car, an adjustable stabiliser bar allows the driver to alter the roll stiffness of the car from the cockpit, greatly affecting the car’s handling. In this example, the driver was complaining of very little change in roll stiffness from the first few notches of adjustment, then a huge increase in stiffness from the last two notches, effectively giving him an all or nothing adjustment range. As illustrated on below, flexible ‘blades’ on either end of the stabiliser bar rotate through 90° to provide the adjustment that governs the overall stiffness of the stabiliser bar and ultimately the

  • Seat Adjust Mechanism

    In this example, the adjustment mechanism of an automotive seat was simulated to calculate various parameters such as torque required at the height adjustment handwheels for different occupant loads, and the range of motion of the occupant's hip joint. The analysis was also used to determine loads between various components and to calculate stresses in the leaf return spring. MBD was the ideal tool of choice for this stress analysis, as it provides accurate input loads without having to make any simplifying assumptions to represent the loading.

  • Roll Over Protection

    In this example, the roll over protection structure (ROPS) of a race car was modeled and subjected to various load cases to determine whether it would meet the required regulations. A non linear material model was used to evaluate plastic deformations and stresses within the structure. Loads and displacements at various points on the structure were plotted to better understand how the loads were being transmitted. This example highlights the benefits of virtual testing. Without the use of simulation, a sample ROPS would have to be constructed and physically tested, destroying the ROPS

  • Front Suspension Simulation

    In this example, the front suspension of a race car was modeled and put through its motions. Pre defined templates calculate and plot important suspension characteristics such as camber curves, toe curves and roll centre position throughout the suspension travel. The analysis can also determine loads in the system which can then be used as inputs to FEA analysis to calculate stresses in various components. The optimisation capability of the software adds further to the analysis by determining ideal locations for suspension hardpoints, along with sensitivity

  • Chassis Torsional Stiffness

    In this example, finite element analysis was used to calculate the torsional stiffness of a Formula Ford chassis and determine the effect of changing various parameters such as floor material and gearbox bellhousing thickness. The chassis was modelled using 2d shell elements, while engine, bellhousing and gearbox were modelled with 3d elements. These components were included since they form a structural part of the chassis. Suspension members were also modelled because constraints were applied to the front wheel hubs as per the actual physical test that was being replicated. Loads