Ensuring Sustainable, High Performance and Quieter Machines with Simulation

Industrial Equipment manufacturers make some of the most complex products in the world. Products are specialized with demanding design and production requirements. Today, manufacturers face the challenges of creating products that meet not only performance and safety requirements of the customers but also sustainability requirements while improving cycle times and reducing costs

Now – as we enter the next epoch marked by a focus on sustainability, better citizen experiences, and higher performance at lower costs – it is important to reimagine how we design and develop industrial equipment for the future. Simulation has a wider role to play here, allowing engineers and manufacturers to accurately predict complex real-word behavior of component parts, large-scale structures, and complete systems thereby ensuring sustainable, high performance and quieter machines.


Join the Simulation Nation Episode 3 was titled “Smart, Safe and Connected Machines” with sustainable, high performance, and quiet equipment as the key themes. This follows the previous two episodes on Simulation Reveals the Real World and The Road Ahead: Powering the EV Revolution.

In Episode 3 of “Join the Simulation Nation,” viewers get to witness how simulation on 3DEXPERIENCE® platform is helping produce quieter machines with higher efficiency and thermal management of the gentle giants ensuring the safety of employees who work on the heavy machinery while increasing machine longevity.

Benefits of Simulation for the Industrial Equipment Sector

How Simulation Helps Manufacturers Optimize Design and Deliver Better Results

The major benefit of simulation for manufacturers, as discussed during this episode is that they can predict complex and non-linear machine behavior with less dependence on physical testing. This was explained in detail by Mark BOHM, Senior Director, Technical Sales, SIMULIA at Dassault Systèmes. “SIMULIA helps in accelerating product development while also improving product quality. It’s not just about the simulation technology that we deliver, but it is also about applying that technology to develop sustainable products,” he added.

Suyog SHINDE from Larson & Toubro was present at the episode, talking about how SIMULIA apps on the 3DEXPERIENCE Platform had helped unlock a more agile product development process. Sharing his experience, Shinde said, “We are able to do simulations in a much-advanced manner to handle more non-linearity, be it the material non-linearity or complex contact related non-linearities, which has helped us. Besides, we are also able to perform forming simulations. Also, the cloud computing aspect in simulation is definitely going to change the whole way we work.”

Simulation makes it possible to deliver equipment without rework once the final fabrication is ready. It also aids in maintenance operations towards the end of life of machinery, making it easier for the upgradation team to perform analysis to maximize an equipment’s lifetime.

Other key participants included, Shripad TOKEKAR, Industry Process Consultant, Senior Manager, SIMULIA at Dassault Systèmes, Emlin VATHSALAN, Industry Process Consultant, SIMULIA Fluids, at Dassault Systèmes, and Sureshkumar MUTHUKUTTY, Customer Process Experience – Industry Process Consultant, SIMULIA at Dassault Systèmes.


Simulation for Thermal Management

The episode highlighted how SIMULIA’s thermal management feature lets users evaluate thermal performance at a very early stage so that the internal design can be optimized with minimal costs and delays.

There are three issues with heat – the comfort level of the operator will have issues if the machine gets heated up and the second aspect is safety of the operator with chances of fire. Third aspect is that there are a lot of systems running like HVAC, Air conditioning, the engines and cooling etc. If there is more heat being produced, these systems need more power and more energy to absorb the heat. So it boils down to fuel efficiency, and overall cost of operation.Therefore it is very important to manage thermal aspects effectively using the simulation .


Simulation for Noise Reduction and Regulatory Compliance

During the webinar, our speakers mentioned how the lockdown provided a glimpse into the impact of industrial equipment on communities and citizen life. When there is a construction project ongoing within one’s proximity, it is typical to generate (and expect) consistency and loud noise. Equipment manufacturers need to tackle the challenge of undesirable noise for both better experiences as well as regulatory compliance.

The SIMULIA application on the 3DEXPERIENCE Platform helps understand the source of noise and pinpoint the machine part responsible. It also visualizes how the noise propagates to the human ear and predicts its aerodynamic movement to help achieve noise targets from day one of the design phase. The simulation solution has true rotating geometries enabled, and patented technology for flow-induced noise detection to help any noise control engineer or acoustic engineer. This is one of the many possibilities enabled by cutting-edge simulation technology.


Shripad TOKEKAR, Industry Process Consultant, Senior Manager, SIMULIA at Dassault Systèmes highlighted “Considering the noise aspects in the early stage of design is very important. If we do this at the later stage of design cycle, we may have a lot of issues in terms of changing the design, associated costs, rework etc. Therefore today a lot of companies are looking at digital simulations as it is key for noise mitigation”


Emlin VATHSALAN, Industry Process Consultant, SIMULIA Fluids, at Dassault Systèmes “Government has come up with stringent regulatory requirements when it comes to community noise. This forces an equipment manufacturer to meet regulations before even the machinery is in the production phase. A shift in the industrial equipment is that they have now shifted to a totally digital test environment by reducing or even replacing the traditional experimental testing. SIMULIA has got the world leading best-in-class transient flow solver which also has the acoustic solver”


Simulation for Tire Industry

Tire manufacturers are constantly looking at innovation. We provide Smart Tyre industry solution experience to break the silos and provide digital continuity in the entire tire manufacturing process. Tire engineering is one of the engineering Industry Process that concentrates on design and engineering aspects.


In addition to this, simulation has also helped customers in the tire industry. Advanced simulations like Slip tests, Inflation analysis, footprint analysis, Impact analysis etc. can be done using the SIMULIA application on the 3DEXPERIENCE platform. Speaking about how SIMULIA is helping the tire industry meet the regulatory standards, Sureshkumar Muthukutty, from Dassault Systèmes, said, “The Plunger test offered on our 3DEXPERIENCE Platform helps our customers understand the strength of the cap of the tire from the safety point of view and to choose the right materials and design so that their product works seamlessly in the environment.”

Key Takeaways


In Episode 3, our experts explained:

  • The need for better machines in sectors ranging from manufacturing and construction to agriculture and mining
  • How to develop a well-defined and validated simulation process
  • How to improve machine variables like weight and performance while meeting safety and durability requirements
  • The benefits of SIMULIA with respect to noise mitigation, thermal management etc. in the industrial equipment space
  • How advanced simulation offered by the SIMULIA apps on the 3DEXPERIENCE platform helps Tire manufacturers

Simulation provides teams with the freedom and tools they need to engineer superior industrial equipment. The SIMULIA application on the 3DEXPERIENCE Platform makes it possible to manufacture collaboratively using a business platform that drives digital continuity.

Know how SIMULIA provides realistic simulation solutions that address a multitude of engineering challenges for industrial equipment manufacturers: https://www.3ds.com/products-services/simulia/solutions/industrial-equipment/

With real-world examples from SIMULIA experts and customers, this episode will leave you with important insights and takeaways. You can watch the full session here: Episode 3: Smart, Safe, and Connected Machines