Thermal Analyses of Materials and Structures by Use of Computer-aided Engineering Simulations.

The importance of thermal simulations in engineering

Thermal simulations are not only an optimisation tool but, also a key process in terms of meeting strict standards and technical specifications. CAE technology makes it possible to precisely depict the equipment operating conditions and analyse potential problems that could affect its operation.

Examples of thermal simulation applications

The most common applications of thermal simulations are:

• simulation of assembly thermal expansion – aims to explain how temperature changes affect the dimensions of parts and structural assemblies; helps to avoid problems with thermal deformations;
• estimation of the heat transfer coefficient – to identify places with high thermal energy losses and enable better selection of thermal insulation materials and develop better design of heat penetrated walls and their connections;
• analysis of powertrain cooling – has an impact on the reliability and efficiency of cooling systems thus, positively affecting the safety and efficiency of the designed vehicles;
• thermo-mechanical analyses of components – used to predict how temperature change will affect the strength and durability of the structural parts under investigation;
• identification of areas at risk of overheating – indicating critical points of electronic and mechanical systems from the overheating point of view allows to avoid damage, disruptions, or loss of functionality.

The role of thermal simulations in various industries

Thermal simulations support design processes in many industries, help to optimise designs and to reduce risks of failure. Here are examples of applications in individual sectors:

Automotive Industry

During the design of a car, thermal analysis is used in the creation of cooling systems for combustion, electric and hybrid propulsion. These simulations allow for the optimisation of heat management systems, which translates into greater vehicle efficiency, reduced fuel consumption and better performance. Application examples:

• analysis of battery cooling in electric cars.
• efficiency optimisation of air conditioning and cabin heating systems (HVAC).

Bus Design

In the design of commercial vehicles and buses, flow and thermal simulations play an important role in the design of HVAC (heating, ventilation, air conditioning) systems. They enable system development for comfortable passenger traveling and minimum energy consumption. These simulations are also being used to analyse the thermal management of drive systems and electronic components.

Heat flow analyses in Rail Transport

Rail vehicles such as trains and trams require reliable cooling systems for their drive and electrical systems. In the design of rail vehicles, thermal simulations support the design of components that are resistant to changing operating conditions and to the high temperatures generated during braking. These analyses also help to improve passenger comfort by optimising ventilation systems. HVAC is also standard in Rail cars and locos today.

Heavy Working Machinery and Agricultural Machinery

In the design of working machines and the design of agricultural machines, thermal simulations support the design of cooling systems that must operate reliably under difficult working conditions. Optimisation of cooling systems, engines and hydraulic systems is the key to extending the lifespan of machines and improving their efficiency. HVAC is today standard in the personnel cabins.

CAE Thermal Analyses – Summary

Thermal simulations which use CAE technology are an important tool in the design process of modern equipment. These analyses allow for the identification of potential problems, and system optimisation for increased efficiency and safety.

Why choose Endego to be your partner for thermal simulations?

Endego offers comprehensive services in the field of computer-aided engineering simulations. Our team consists of experienced experts who successfully carry out even the most demanding projects and have application feedback, verification and experience.

Our offer includes, among others:

• industrial design – tailored to specific customer requirements
• design of vehicle bodies – structures that meet the highest safety standards
• services of CAE engineering simulations – precise analyses that support each stage of the project

Endego carries out comprehensive thermal analyses, supporting various industries, such as automotive, public transport and railway by use of the most modern tools and the wide experience of its specialists. Choosing Endego to be your partner, you get access to advanced technologies and wide knowledge of the expert team who successfully carry out even the most complex tasks. Contact us to learn more about our services and opportunities for cooperation!