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CAEbay

Typical budget: $3,000-$10,000
Located in Brisbane City, QLD, Australia

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What we do?

1/ Finite Element Analysis (FEA):

  • Predict product behavior through linear, nonlinear, thermal, and dynamic analyses
  • Estimate fatigue life and fracture propagation of product
  • Analyse weld fatigue, vibration fatigue, low/high cycle fatigue, and composite fatigue
  • Optimise designs and validate product performance before production

2/ Computational Fluid Dynamics (CFD):

  • Inspect fluid flow, air flow, free surface flows (multiphase)
  • Analyse thermal management and heat transfer
  • Turbomachinery, turbulence and combustion
  • Fluid-Structure Interaction (FSI) and thermal FSI
  • Make faster and better decisions in the product development process

3/ Discrete Element Methods (DEM)

  • Virtual test for equipment that handles bulk materials
  • Heavy equipment: truck bodies, backhoe and excavator buckets, spreaders, tillers, and harvesters
  • Mining and metal: conveyors, feed chutes, reclaimers, crushers, and grinding mills
  • Process manufacturing: powder mixers, tablet coaters, milling machines, and dryers
  • Investigate new designs at an affordable cost.

4/ Multibody Dynamics (MBD)

  • Virtual prototypes of mechanical systems
  • Rigid and flexible multibody system
  • Dynamics of an engine and parts
  • Durability of machine/system components
  • Large deformation of plastic materials
  • Vibration analysis over various terrain
  • Kinematics and kinetics
  • Loads and displacements
  • Affordable budget with a fraction of the time and cost required for physical testing.

5/ Injection moulding and RTM

  • Predict fill pattern
  • Optimise gating & runner
  • Predict volumetric shrinkage
  • Avoid air traps
  • Determine fiber orientation
  • 3D resin transfer moulding (RTM)
  • Find cause of warpage.

6/ Consulting Services:

  • Provide specialised solutions to engineering problems ranging from basic to complex analyses in the areas of structural analysis and fluid dynamics, applied mechanics and heat transfer.
  • Additional services include design verification/auditing, new product R&D, physics calculations.

Why choose us?

Our qualified services are the result of years of scientific study and international working experiences. The owner and experienced engineer, Tri Tien (Tri is pronounced as Tree), has more than 10 years in simulation and manufacturing industries, both in Australia and overseas. Before starting his CAE sole trading business, Tri had previously performed various roles as technical engineer, production & development engineer, and engineering head for many companies covering a range of industries including mechanical simulation, composite manufacturing, wood machining and fitness equipment manufacturing.

Tri holds a Bachelor of Automotive and Engine Engineering from Ho Chi Minh City University of Technology, a Masters of Science from Konkuk University South Korea, and a PhD in Computational Engineering from University of Southern Queensland. Tri has published more than 15 peer-reviewed international journal articles and conference papers in the area of computational engineering.

"CAE only delivers meaningful results if the engineer driving the computer fully understands the theory behind the simulation."

What clients say?

“I have complete confidence in Tri’s Finite Element Simulations because they are based on Tri’s deep understanding of the engineering fundamentals – unlike the work of some FEA practitioners whose simulations are really no more than computer games!” Director Cliff Walker, Vacmobiles.com ltd., New Zealand.

“We encountered some serious failure problems that halted our sales. Tri quickly identified the cause of the failures and invented a fail-safe substitution that allowed us to resume sales.” Thomas R. Anthony Ph.D, NAE., America.

“With a very tenacious and robust problem solving ability, Tri was able to apply a deep technical knowledge into an array of projects to improve both existing systems along with the research into new areas of possible business.” David Pring, Managing Director, Timber and Laminate Services Pty Ltd., Australia.

Using finite element simulations to optimise metal machining

As confirmed by experimental results obtained from published literature, our FEM simulations accurately predict chip form and allow the effects of parameters influencing chip formation to be studied. Given the material properties of the workpiece, adjusting the cutting conditions in the simulation (e.g. depth of cut, cutting speed, and tool rake angle) enables prediction of the resultant chip form. It is therefore possible to predetermine the cutting parameters required to produce the serrated chip form preferred for automated machining. In our simulations, the Johnson-Cook model is used in combination with the Johnson-Cook damage initiation model as well as the Hillerborge damage evolution criteria. These FEM simulation methods may also be used for cost effectively investigating other damage situations such as impact test, car crash, torsional crush, and armor-bullet impact.

In addition to the physical characteristics of chip formation and similar damage processes, parameters such as stress, strain, strain rate and temperature rise, can be determined by finite element simulation. Especially with processes taking place within very short or very long time intervals, such parameters may be difficult, impractical or expensive to measure experimentally.

When detailed information about a physical process is required, but is difficult or expensive to obtain from actual testing, the feasibility of simulating the process using the finite element method should be considered.

Open file Using finite element simulations to optimise metal machining.pdf

The majority of metal-cutting operations involve the creation of chips from the workpiece. Prediction of chip form is important because chip form directly influences surface finish and may lead to damage of the machined surface, the cutting tool or the machine. The finite element method (FEM) may be used to simulate chip formation quite precisely and this note shows how the method maybe applied. The mathematics involved is outlined in Appendices, which may look complex. If maths is not your thing, you may want to review the simulation results only.

Depending on the workpiece material and the cutting conditions, you will see that three type of chips (continuous, serrated, and discontinuous) may be produced during metal machining. As the simulations will demonstrate, the type of chip is influenced by tool rake angles, cutting speeds, and depth of cut. The numerical results obtained in our simulation are compared with experimental data collected from literature wherever possible. You will read that good overall agreement is found.

The full paper can be downloaded in the attachment.

Safety factor and fatigue life – effective design measure

As shown in the analyses, both pedal axle and body are unsafe for use and their fatigue life is too short. The following improvements are suggested: • For the axle, the flange needs to be thickened and the axle diameter (after the hex) needs to be increased. • For the pedal body, the connecting arms should be strengthened. This could be achieved by increasing their diameter and by providing a more gradual transition between the arm and the body. • Incorporate radius fillets wherever a sharp shape transition intensifies the stress. Through this real life* example, we can see how SF and fatigue life computations can be used to identify weak points and thus improve designs. A similar approach can be applied to more complicated applications and designs.

  • Pedal failure could result in serious injury or death, especially with mountain and stand-up bikes. Even a best case injury after a pedal failure is likely to be very sore testicles for a male cyclist. Avoid the pain, use CAE!
Open file Safety factor and fatigue life - effective design measures.pdf

Many catastrophic failures have resulted from underestimation of design safety and/or fatigue of structures. Failure examples of engineered structures can be seen in many applications such as wind turbines, bridges, engines, and bicycles.

To ensure the structure’s ability to carry a load, safety factor and fatigue life are often calculated using detailed analyses, especially when comprehensive testing is costly and time-consuming or impractical. This note will provide a typical example of how the safety factor and fatigue life of a product are effectively calculated using CAE approaches and it will show the design can be improved. We will begin with a review of the two factors to see why they are important in product design.

The full analysis paper can be found in the attachment.

Structural analyses on bicycle pedal

Press play to watch to Structural analyses on bicycle pedal.wmv

Demonstrations of safety factor and fatigue life analyses

Chip Formation Processes

Press play to watch to Chip Formation Processes.wmv

Since the development of finite element method (FEM) in the early 1970s, numerical simulation of this process has become increasingly more popular due to its ability to provide detailed insight into the process. FEM has been widely used to evaluate chip formation processes in relation to operating parameters, tool settings, and material properties. Such simulations have reduced costly experimental tests and prototyping used in tool and process designs.

Casec 1 Blade Coating without Reservoir

Open external link https://www.youtube.com/watch?v=Ex2EF9xWThY&t=18s

Case 1 Blade Coating without Reservoir

Case 2 Blade Coating with Reservoir

Open external link https://www.youtube.com/watch?v=XGdsgipkM1g&t=25s

Case 2 Blade Coating with Reservoir

Blade Coating Moving Mesh Demonstrations

Open external link https://www.youtube.com/watch?v=fDL6eIxxuu0

Blade Coating Moving Mesh Demonstrations

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