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Realities of Virtual Prototyping
- 1. Realities of Virtual Prototyping Jonathan Prince
- 2. What are we talking about? • What is virtual prototyping from an engineering perspective? • Why perform virtual prototyping? • Time to market • Accuracy of design • Risk mitigation • Real life examples of the difference virtual prototyping can make…
- 3. What is virtual prototyping? • Understanding the build process • Simulating Loads and working conditions • Simulating fatigue- long term loads • Simulating the component manufacture • Understanding the manufacturing/ assembly process
- 4. Virtual prototyping? Nah, I’ll just whip one up! • Stress Analysis • Understand loads / forces early • Remove unnecessary weight / material • Flow Analysis • Will the mould fill? • Will the part last? • CAM – Machining • Can the mould/ part be made?! • Rapid Prototyping • Visualisation • Check fits Embrace Technology
- 5. Why is virtual prototyping important? • Time to market • Crucial to product profitability • Accuracy of design • Crucial to the brand, the product and success of the company • Mitigating risk
- 6. Why is virtual prototyping important? Time to market
- 7. Late to Market Lost revenue 1 2 3 4 5 Volumes/ Sales Time Time to market
- 8. Time to market • “Products that come to market six months late but on budget will earn 33% less profit over five years… • In contrast, coming out on time and 50% over budget cuts profits by only 4%”. • - McKinsey and Company
- 9. Why is virtual prototyping important? Mitigating risk www.latimes.com
- 10. Risky? Really?! Risk: The probability of something happening multiplied by the resulting cost ($$ or life) if it does.
- 11. Case study: Life changing!
- 12. Why is virtual prototyping important? Accuracy of design
- 13. Fit for Purpose? • Can it take the loads? • What are the loads? • Can it handle the environmental conditions? • What are the long term, ongoing scenarios? • How might this be used & abused? • Rubbish in = rubbish2 out
- 14. Case study: How hard can it be? • Feller/De-limber • $150k per unit • Failing in the field • Analysed for failure • And then we checked it in the field!
- 15. Case study: Lucky?! • $1/4M prototype • 25 Year life • 10 Million cycles • 3 month test cycle
- 16. Analysis process • Progressive
- 17. Analysis process • Progressive • Conservative railpictures.net image © phil cotterill
- 18. Analysis process • Progressive • Conservative • Controlled
- 19. Analysis process • Progressive • Conservative • Controlled • Validated
- 20. Case study: Lucky?! • $1/4M prototype • 25 Year life • 10 Million cycles • 3 month test cycle • Right first time! Get it right, before you cut steel!
- 21. Over the Top? Design without analysis is like pilots without instruments; they know they’re flying, but they might not know exactly where they are!
- 22. Summary • Build virtual prototyping into your development process • Don’t skimp on the engineering • Rubbish in = rubbish2 out • Develop a virtual prototyping methodology • Get it right before you cut steel