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Chairman’s Message Drive innovation with Simulation-Based Design The past year has seen remarkable achievements as our leading customers have expanded the boundaries of realistic numerical simulation and taken up ambitious new projects. In their own words, some have achieved ‘quantum leaps’ while others have attained ‘revolutionary results’, thanks to ESI’s Simulation-Based Design (SBD) solutions.
The great industrial challenge: innovate faster and better with virtual development The major breakthrough in Product Lifecycle Management (PLM) is the use of numerical simulation for early evaluation and improvement of physical prototypes’ performance and manufacturing processes. Thanks to virtual prototyping, powered by increasingly realistic physics, numerical simulation is poised to support the entire product lifecycle; from preliminary design to manufacturing.
That said, the traditional approach of Simulation-Driven Design is based on a ‘hybrid’ prototyping process, in which the numerical model is calibrated against real prototypes. Simulation is used to explain the physical prototypes’ malfunctions, thus bringing about lengthy and costly iterations. With Simulation-Based Design, ESI proposes to further promote innovation. Now simulation starts immediately, at the preliminary design phase, and continues through the detailed design to validate step by step the performance of the complete digital model well before the first real prototype. This approach of ‘intrinsic’ simulation – in which preliminary calibrations of the physics at work are performed on elementary and generic sub models – allows one to make key decisions upstream, providing significant gains in reliability, productivity and innovation, to get to a real prototype ‘right the first time’.
This new era of Simulation-Based Design, as illustrated by the remarkable projects featured in this brochure, is already at work. We are therefore especially pleased to showcase our customers’ successes, enhanced by our global partnerships, software solutions and advanced engineering services. Together we work steadfastly to fulfill your expectations, to support your methodological evolution towards Simulation-Based Design, and to empower your success through cost control and innovation.
Alain de ROUVRAY, Chairman & CEO
Company Profile and Strategy Strategy
Profile
ESI, empowering Simulation-Based Design to drive innovation
ESI is a world-leading supplier and pioneer of software that enables the realistic simulation of prototypes and manufacturing processes by properly representing the physics of materials.
ESI’s solutions simulate the Product Lifecycle: how a product is designed to function, how it is manufactured, and how it fails at the limits of performance. We deliver industry-specific solutions that accelerate our customers’ innovation and allow them to capture and automate best practices.
ESI has developed an extensive suite of coherent, industryoriented applications: to realistically simulate a product’s behavior during testing and real life use; to refine manufacturing processes for desired product performance; and to evaluate the effect of the environment in which the product is deployed.
ESI’s scalable Simulation-Based Design solution
ESI’s products represent a unique collaborative and open environment for Simulation-Based Design, enabling virtual prototypes to be improved in a continuous and collaborative manner while eliminating the need for physical prototypes during product development.
ESI’s technologies are flexible and span disciplines. Our open, easily integrated software platforms allow for compute model management across multiple domains and processes.
Wherever you are on the engineering spectrum, ESI Engineering Services are available to support you as you move along the path to Simulation-Based Design.
1G Physics:
Manage realistic physics per simulation model.
2G Processes:
Manage processes and best practices per design domain for a given component.
The company employs over 750 high-level specialists worldwide covering more than 30 countries. ESI Group is qualified as an “innovative company” by the French Innovation agency, OSEO. To meet our customers’ expectations for quality products and services, ESI Group is ISO 9001 certified, guaranteeing full conformity with ISO 9001 international standards.
3G Decisions:
Manage End-to-End Virtual Prototyping, spanning a complete range of domains, processes and systems, and synchronize within the PLM process.
Software & Services for Simulation-Based Design
Solutions Virtual Performance Solution A highly versatile solution addressing market needs for scalable simulation solutions and Multi-Domain Optimization
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ESI has achieved a quantum leap in the field of simulations. By being able to utilize a unique mathematical model for both crash and load testing, we’re improving our development efficiency at several stages of a project. Given the ever-shortening development cycles in the automobile sector, this gives us a decisive competitive edge.
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Dr. Ralph Sundermeier, Head of Functional Calculation and Methods, Volkswagen
Optimized body structure by Virtual Performance Solution for different crash scenario Courtesy: Volkswagen AG
VisualDSS A unique end-to-end decision support system for CAE
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With the Visual-Process module in VisualDSS, developed automation tools on FMVSS 210 Seatbelt Anchorage Analysis gave us not only immediate return on investment but also the confidence to leverage these tools to increase repeatability and reproducibility with substantial lead time and labor cost reduction.
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Example of process automation with Visual-Process in VisualDSS Courtesy: Nissan Technical Center, NA
Daniel Kim, Nissan Technical Center, NA
Vdot™ A lean project and process management tool adding an essential component to ESI’s solutions for Simulation Systems Integration
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Vdot™ takes the Program Management effort to a new level, one that offers time saving options. It’s very nice to have a quick look at who owes you what so you can get started with a task, and conversely to whom you owe output.
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Vdot™ Workbench 5.0
James Owens, Design Engineer Aerospace, Qualis Corporation
Vdot™ at NASA and Qualis Corporation improves performance on Rover robotics study
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Vdot™ supports management’s ability to quickly assess problem areas and greatly reduces the uncertainty of who is directly responsible for work accomplished at any point in the project life cycle. Vdot™ was invaluable in managing a development project with a very distributed engineering team, spread across several disciplines and development tools.
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Roger Herdy, Program Manager for NASA Marshall Space Flight Center, Qualis Corporation
Talon robot rover arm was redesigned for lunar mission from original terrestrial environment
Services Pursuing a sales strategy designed to give momentum to our Services activity, Fiscal Year 2007/2008 performance confirms the increasing market appeal of realistic simulation solutions dedicated to helping industry leaders shorten their time-to-market.
Engineering Services The increase in Services is primarily due to the increase in new high value-added engineering studies. The growth in innovative industrial projects reflects raised industry focus on the need for ever-increasing productivity and flexibility in today’s global economy. The new trend for all major OEMs and Tier 1 suppliers is to apply a complete SimulationBased Design process.
RADAR Cross Section (RCS) of a jet aircraft
CFD Services The addition of the Mindware Engineering team to ESI brings a large global team with over 20 years of experience in Computational Fluid Dynamics (CFD) engineering services. The group provides innovative solutions to complex CFD simulation challenges ranging from automotive to aerospace and defense applications such as vehicle aerodynamics, climate control for passenger thermal comfort, vehicle thermal management, powertrain, brake cooling, in-cylinder flows, etc. ESI delivers in-depth expertise, global presence and the abitlity to provide a comprehensive CFD solutions package.
Support and Training Services ESI’s engineering teams offer immediate and expert support to help you achieve better and faster results with Simulation-Based Design. We train your engineers to become proficient users thanks to our rapid and effective method of knowledge transfer. ESI’s training classes can be taught at our learning centers, on client-site, or live on-line by an instructor.
Special Projects Industrial consortia are co-financed by industry partners and aim at sharing the members’ technological expertise for specific product development. ESI Group actively contributes to industrial consortia in order to assure that we bring the most advanced practices and technology to Simulation-Based Design. Barrier Consortium: Enhancement of crash barrier models to improve vehicles’ behavior to crash tests
Interior cabin climate control analysis
Automotive, Transportation ESI’s products and services are employed in a wide variety of industries and used by leading companies worldwide. Below we highlight some of our customers’ application of ESI’s technologies in their product development.
Škoda Auto relies on ESI’s solutions and services to design each new car model.
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In 1996 PAM-CRASH was introduced in Škoda Auto… Since then it has been used for the design of each Škoda car model. The long-term profitable collaboration with ESI backed with local services and engineering simulation software has helped Škoda reach new international standards in design and production with the recently launched Roomster the first Škoda’s car to score 5 star rating at EuroNCAP.
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Courtesy: Škoda Auto
Milos Safr, Head of FEM Simulations Škoda Auto a.s.
Using PAM-STAMP 2G, FAURECIA reduces the tooling time to design seat components by 20%.
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Thanks to PAM-STAMP 2G, we have been able to predict with accuracy the stamping process of slider rails and flange. We’ve used it to predict and manage the thickness distribution, stress, strain and cracks apparition during forming and distortion after springback. Simulation results being identical to the real parts, PAM-STAMP 2G helped us modify tool design and achieve high quality for die tooling and seat components.
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Vincent Retaillaud, Tracks Product Line Bending Process manufacturing Engineering Manager, Faurecia
Courtesy: Faurecia
Successful ‘full spectrum’ VA solution coming from the integration of Straco & VASci acquisitions
BOMBARDIER
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Hybrid FE-SEA analysis is a real leap forward when it comes to acoustical modelling technologies and is likely to set the standard for industrial computational acoustics of large structures for the future. The innovative integration of FE and SEA methods within one model allows the user to solve problems that cannot be addressed by applying SEA or FE methods separately.
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Ulf Orrenius, Senior Specialist: Acoustics and Vibration, Bombardier Transportation
Courtesy: Bombardier
Aeronautics / Aerospace Composite materials solution described as revolutionary Chengdu Aircraft Industrial Group Company
Shenyang Aircraft Corporation, Ltd.
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ESI’s virtual solution for composite parts manufacturing engineering is really revolutionary. It changes the entire thinking and process of composite design and manufacturing at Chengdu Aircraft and enables us to know well in advance as early as in the preliminary design phase what kind of defects might occur in the composite parts due to the different methods or processes in manufacturing, against the design requirement of aircraft performance.
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Hafel Aviation Industry Co., Ltd
Courtesy: Boeing
Yougi Wen, Chief Manufacturing Engineer, Chengdu Aircraft Industry Corp
Vibro-Acoustic simulation helps predict the harsh environments encountered during launch and liftoff
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Ensuring that our structures survive the harsh environments encountered during launch and liftoff is essential to our missions. Using VA One we can now predict the dynamic stress, strain and force in key components. This will help us ensure that our structures are qualified for the acoustic and vibrational environments encountered during launch and liftoff.
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Ben Tsoi, Senior Dynamics Environmental Engineer, NASA Jet Propulsion Laboratories
Von Mises stress response computed using VA One Courtesy: MDA Corporation
Airbus benefits from ESI’s Integration of Resin Transfer Molding (RTM) simulation in the CATIA V5 working environment
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With this application, Airbus is introducing the numerical simulation of manufacturing liquid composite molding processes. It is seen as a major breakthrough that will help us remain at the cutting edge of the technology in the composite material field. Gilles Debril, Airbus Concurrent Engineering, Composite Project Manager
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Courtesy: Airbus
Heavy Industry, Energy ProCAST casting simulation tool proves to be essential to the forging design cycle
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We have strengthened our modeling capabilities with the use of ProCAST. Its usage across our melting and foundry divisions has proved to be essential for our design cycle.
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Dr. Jesus Talamantes-Silva, Sheffield Forgemasters International
Courtesy: Vulcan SFM, a company of the Sheffield Forgemasters Group
CFD simulation improves the design and reliability of fuel cells
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Simulation has helped us significantly increase the efficiency and life of proton exchange membrane fuel cells (PEMFCs), and thus CFD-ACE+ has become the tool of first choice for fuel cell designers at Ballard. Sanjiv Kumar, Ballard Power Systems
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Optimization of flow distribution in manifold Courtesy: Ballard
ESI Engineering Services help demonstrate the conformity of French nuclear equipment
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COMEX NUCLEAIRE (CxN) completed in collaboration with ESI Group the Behavior Analysis Report for Replacement Steam Generators (RSG) provided by Mitsubishi Heavy Industries, Ltd. (MHI) for EDF French nuclear power plants. This notable work was carried out with a high level of quality using innovative approaches, such as SYSTUS functionalities allowing to complete 3D numerical models with as few hypotheses as possible. These studies include both complex thermo-hydraulic and thermo-mechanic analyses in order to demonstrate the equipment’s full conformity with French nuclear regulation.
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Dr. François Billon, Technical Director and Director of the MHI - CxN Partnership
3D Mesh of a Steam Generator’s bottom part Courtesy: Comex Nucléaire
Electronics, Consumer Goods MIZUNO Corporation uses PAM-CRASH to improve sports footwear performances MIZUNO Corporation applies advanced technologies to superior quality sporting goods in order to design products with unique features that enhance athletes’ performances. MIZUNO Corporation found PAM-CRASH appropriate for modeling inoffensive body impacts found in sport. Through different studies using ESI’s human modeling capabilities, MIZUNO Corporation has been able to provide its demanding customers with yet more comfort and performance in high-end sporting footwear.
The design of the upper The simulation of the impact between the upper and the soccer ball Courtesy: MIZUNO Corporation
Advanced multi-physics modeling reduces cost of ownership of LED production equipment
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AIXTRON has used CFD-ACE+ for more than ten years for our modeling needs. The advanced multiphysics modeling capability of CFD-ACE+ helps evaluate the impact of key process and reactor design parameters on performance criteria… Virtual prototyping with CFD-ACE+ delivers accurate results reliably and leads to performance improvements, yield enhancements and significant cost savings. Martin Dauelsberg, AIXTRON
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Example of architectural lighting with white LEDs
Hitachi GST successfully models oil-air interfaces in fluid dynamic bearings of hard disk drives with CFD-ACE+
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We have probably achieved the first validated simulation of oil-air interfaces (OAI) in a high-speed fluid dynamic bearing (FDB). FDB’s are so tiny that the OAI is extremely hard to observe or measure. Simulations of the OAI have contributed to a much improved understanding of the behavior of FDB under extreme circumstances. Dr. Ferdinand Hendricks, Hitachi Global Storage Technologies (Hitachi GST)
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Deflection of the oil air interface Courtesy: Hitachi GST
International Strategic Partnerships ESI values its partnerships with hardware suppliers, software solution providers and leading industrial players. Alliances are deeply rooted in our business strategy to further facilitate the adoption of Simulation-Based Design.
ESI Group accepted into the IBM Service-Oriented Architecture (SOA) specialty
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Service-Oriented Architecture is an increasingly important business requirement for organizations because of the business flexibility it enables. ESI’s commitment to SOA provides their customers with a powerful way to reduce development costs by rapidly deploying process simulation applications across their manufacturing organization. Sandy Carter, Vice President of IBM SOA and WebSphere
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ESI Group joins Dassault Systèmes’ PLM MarketPlace
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This program creates business synergy and is an integral part of our company strategy to facilitate value channel network selling. Referenced on the PLM MarketPlace, ESI’s specialized simulation applications built on top of our CATIA platform solutions are well positioned and directly accessible by Dassault Systèmes’ worldwide reseller network.
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Thierry Collet, Vice President, Global Field Marketing, Dassault Systèmes
Audi works with ESI Group and HP to advance Auto safety standards with Auto industry’s fastest supercomputer
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Providing Audi with a high-performance computing solution helps them design better and safer cars while reducing their power consumption and costs. HP has a long history of knowledge and expertise in providing automotive customers high-performance computing that fosters innovation.
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Paul Perez, Vice President, Scalable Datacenter Infrastructure, HP Enterprise Storage and Servers, Technology Solutions Group
ESI adopts Oracle to power ESI Group Decision Support System enterprise solutions ESI is working with Oracle to meet the growing demand for enterprise based computeraided engineering (CAE) and analysis in the PLM environment. ESI will empower its VisualDSS solution with the latest technologies and product architectures from Oracle in order to optimize its answer for simulation process and data management.
An expert worldwide distribution network ESI provides services and support to its international industrial customer base. With subsidiaries, agents and distributors established in more than 30 countries, ESI Group employs over 750 professionals worldwide.
Headquarters Subsidiaries Offices Agents and distributors
Bologna, Italy
Madrid, Spain
Tokyo, Japan
S達o Paulo, Brazil
Paris, France
Lausanne, Switzerland
Pilsen, Czech Republic
Beijing, China
San Diego, CA, USA
Eschborn, Germany
Oxford, United Kingdom
Bangalore, India
Seoul, Korea
Detroit, MI, USA
ESI HEADQUARTERS 100-102 Avenue de Suffren 75015 Paris - France Phone: +33 (0)1 53 65 14 14 Fax: +33 (0)1 53 65 14 12
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