Simulation and Analysis Drive Transmission Development

Vicura AB, Trollhättan, Sweden, and SpaceClaim Corp., Concord, Massachusetts

Vicura is a developer of manual transmissions and dry dual clutch transmissions, as well as powertrain integration in a large number of front wheel drive and all wheel drive applications. The company’s engineers are responsible for a broad range of complex simulation and analysis testing including system, structure, and fluid mechanics. The team performs critical simulation and analysis to ascertain the strength, stiffness, thermal, and dynamic behaviors of all possible transmission assemblies and components (housings, shafts, gears, synchronizers, clutches, etc.).

Figure 1. The **Original Design** fulfills the requirements, but as much mass as possible had to be reduced.

Designs created in CAD software are sent for simulation and analysis. Before importing the designs into a meshing program, the geometry has to be simplified, and this process was difficult and time-consuming. Often, files would have to be sent back and forth to CAD experts, losing time — usually days for each iteration.

The company starting using SpaceClaim^®’s 3D Direct Modeler more than a year ago, and found that it solved many simulation and analysis challenges. When designers send CAD models, SpaceClaim is used to sort out what to include in the analysis, saving time and improving the simulation process.

For each design, the CAD data is opened in SpaceClaim, which removes features that would complicate the mesh, such as rounds, small holes, and geometry outside the region that needs to be analyzed. When performing CFD, SpaceClaim extracts volumes to be analyzed. Once ready, a Parasolid file is sent to SimLab or to HyperMesh to create a mesh and add couplings, contact information, and boundary conditions. Finally, the mesh is saved as an Abaqus input file, the preprocessing is completed, and the simulation is run in Abaqus.

Once results are obtained, SpaceClaim is used to modify the geometry; for example, adding material, fillets, and bolts until there is confidence that the concept will address issues discovered in the simulation. When the design is optimized, the CAD team is sent a version of the model in which they can reconcile the changes in the detailed model.

Figure 2. A rendered image of the **Final Design** using SpaceClaim and KeyShot.

Vicura offers customers design and optimization services to ascertain durability, noise, and vibration issues and efficiency. The company focuses on analysis to optimize structures for manufacturing feasibility, stress analysis, and casting optimization. Prior to SpaceClaim, if the team found that concept work had to be done on the model, it would be sent back to the designer. SpaceClaim provides more flexibility and can conduct a quick simulation, identify high-stress areas, and make design changes.

Customer communications have been vastly improved, leveraging SpaceClaim with KeyShot to create realistic renderings. This approach is used in the bidding process and when presenting design proposals to the customer. For cross-section views of large assemblies SpaceClaim enables clarity for discussions with the designers.

This work was done by Vicura using software by SpaceClaim. For more information, Click Here .