1. SARNATH
CORPORATE PROFILE
CAE

2. CLIENTS WORKED WITH
 PARAMETRIC TECHNOLOGY CORPORATION (FORTUNE
500)
 M/s. ASHOK LEYLAND LTD.,
 M/s. TITAN INDUSTRIES.,
 M/s.UCAL SYSTEMS (MINICA SERVICES).
 M/s. HYUNDAI ENGG. CO. LTD.,
 M/s. DURR INDIA LTD.,
 M/s. RANE STEERING SYSTEMS.,
 M/s. ABAN CONSTRUCTION COMPANY.,
 M/s. F.F.E MINERALS.,
 M/s. THAR TECHNOLOGIES.,
 M/s. JAPS TECH ENGINEERS PVT. LTD.,
 M/s. NATIONAL INSTITUTE OF OCEAN TECHNOLOGY.
 M/s. I.I.T. CHENNAI.,
 M/s. GULF ENGINEERING INDUSTRIES.,

3. DOMAIN EXPERTISE
1. Customization/Design Process Automation
2. FEA, CFD & MBD
3. Stacker Reclaimer Design
4. Ship Unloader Design
5. Wind Turbine (Structures Design and Value
Engineering)
6. Lean & Kaizen
7. Product Development
8. Reverse Engineering

4. Sub Domain Expertise
 Crash Analysis.
 CFD Analysis.
 Fatigue Life Estimation.
 Multi Body Contact Analysis.
 Vibration Analysis of Motor/Engine, Automotive and
Aerospace component.
 Spring Back Simulation during forming operations.
 Non Linear - Transient - Casting Solidification
Simulation.
 Coupled Field (Fluid-Structure Interaction, Thermal–
Struct., CFD-THERMAL).
 Non Linear Explicit Dynamic and Transient Problems

5. CAE PROJECTS
Project Description Client Type
Team
Size
Man
Days
FEA & CFD of Water Pump UCAL (Minica Services) FEA & CFD 2 100
CO2 pump Analysis Thar Technologies Structural FEA 2 120
Pipe Seal Analysis ChangePond
Non Linear
Rubber 1 50
Door Seal Analysis Five Element
Non Linear
Rubber 1 80
CFD Analysis of Helical Port ASHOKLEYLAND CFD 2 120
CHASSIS REDESIGN ASHOKLEYLAND FEA 3 180
CFD Analysis of CAR Body Borgwarner CFD 1 40
Hitch Optimization TAFE
FEA +
Optimization 1 30
STEERING PUMP SHAFT ANALYSIS RANE STEERING SYSTEMS FEA 2 80
EVALUATION OF DESIGN FOR 300
LITER EXTRACTION VESSEL Thar Technologies FEA 1 20
BOGIE BOLSTER ICF FEA 1 50
THROTTLE BRACKET UCAL FUEL SYSTEMS Vibration FEA 1 15
Vibration Analysis of ETC MOTOR VESTEON Vibration FEA 1 20
Hot Coke Car Frame Analysis FLSMIDTH Structural FEA 2 40
Skid Analysis DURR Structural FEA 1 30
AC Duct Design Borgwarner CFD 2 60

6. CFD PROJECTS

8. PROPERTIES OF FLUID
Density = 998.2 kg/m^3
Kinematic Viscosity = 0.62 m^2/s
Thermal Conductivity (W/m-K) = 0.6x10^-3
Specific Heat (J/kg K) = 4182
Average velocity = 13.8 m/s
Discharge = 0.12 m^3/s

9. CFD VOLUME

10. IMPELLER BLADE

11. MESHED MODEL

12. MID VOLUME

13. VELOCITY DISTRIBUTION

14. PRESSURE DISTRIBUTION
GRAPH

15. VELOCITY DISTRIBUTION AT
OUTLET SECTION

16. ASSEMBLY CUT SECTION
GAP REDUCTION MODEL

17. VELOCITY DISTRIBUTION

18. PRESSURE DISTRIBUTION
GRAPH

19. VELOCITY DISTRIBUTION

20. PRESSURE DISTRIBUTION
GRAPH

21. VELOCITY DISTRIBUTION AT
OUTLET SECTION

22. RESULTS
REVISION 3
AVG OUTLET VELOCITY 1.2M/S
REDUCED GAP
AVG OUTLET VELOCITY 1.4M/S
REDUCED BLADE ANGLE
AVG OUTLET VELOCITY 1.7M/S

23. HEAD - SIX CYLINDER
M/s. ASHOK LEYLAND LTD.
(ENNORE)

35. GLOCON SERVEN
FLOW ANALYSIS OF 20”
Trim Valve CFD Analysis

36. Pump Model

37. Extracted Fluid Domain
Given Conditions
•Fluid – Water
•Sp. Gravity – 1
•Inlet pressure – 4 Bar
•Differential Pressure – 1 Bar
•Temperature – Ambient

38. Sectional View
In Out
Inlet Boundary Condition
Pressure – 4 Bar
Turbulence Intensity – 5%
Outlet Boundary Condition
Pressure – 3 Bar
Wall Boundary Condition
Wall Influence On Flow – No
Slip
Wall Roughness – Smooth Wall
Domain Fluid – Water
Turbulance Model – K-E
Model

39. Repaired Surfaces

40. Meshed Domain Model
•No. of Nodes = 681484
•No. of Elements = 3079508
•Element Shape Used is
Tetrahedral

41. Solution Details
26 iterations
Time Taken for these Iteration is 2 Days
6 Hrs 30 Minutes

42. Streamline Flow (Isometric View)
In
Out

43. Streamline Flow (Front View)
InOut

44. Streamline Flow (Top View)
In
Out

45. Velocity Contour (Mid Plane)
In Out

46. Velocity Contour at Trim (Mid Plane)

47. Velocity Vector
In Out

48. Outlet Dia Vs Velocity
Mean Velocity = 2.506 m/s
Outlet Area = 0.166106 m2
Discharge = 1498.74 m3/hr

49. Calculations
Specific Gravity of Water (SG) = 1
Pressure Gradient (p1-p2) = 1 bar
Discharge (F) = 1498.74
m3/hr
Flow Factor (Kv) =
F*sqrt(SG/(p1-p2))
= 1498.739159
Flow Coefficient (Cv) = 1.16 Kv
= 1738.537

50. Total Pressure Contour
In Out

51. Total Pressure Contour at Trim

52. Result
Average Outlet Velocity After 26 Iteration –
2.5 m/s
Flow Coefficient After 26 Iteration -
1738.537
Note:
 Average Outlet Velocity After 6 Iteration - 2.786 m/s
 Flow Coefficient After 6 Iteration - 1932.662

53. CAR BODY
BORG WARNER

61. AC DUCT DESIGN
BORG WARNER

62. 1
X
Y
Z
0
.222848
.445696
.668544
.891392
1.114
1.337
1.56
1.783
2.006
FEB 16 2005
10:50:08
VECTOR
STEP=7
SUB =1
V
NODE=350
MIN=0
MAX=2.006

63. 1
X
Y
Z
0
.24761
.49522
.74283
.99044
1.238
1.486
1.733
1.981
2.228
FEB 16 2005
11:13:22
VECTOR
STEP=4
SUB =1
V
NODE=527
MIN=0
MAX=2.228

67. FEA
 Radiation
 Non-Linear Materials (Rubber, Composites)
 Explicit Dynamics (Crash, Forming,
Wrinkling)
 Spring Back
 Contact
 Coupled Field (Fluid-Structure interaction
 Thermal-Structural)
 Vibration

68. Transient Radiation
Analysis
AES USA

69. Volume of the Filament = 1.2e-005 m³
Total Heat Generated = 4.4 KW
Heat Generated = Total Heat Generated /
Filament Volume
= 3.67e8 W/m3
Heat Generation Calculation

70. Loading Conditions
 Heat Generated on Carbon Filament - 3.67e8 W/m3
 Emissivity of surfaces
 Stefan Boltzmann Constant - 5.67e-8
 Space Temperature - 22 Deg C
Material Emissivity values
Gold reflector 0.03
Carbon IR emitters 1.0
Aluminum chamber (Side Surface) 0.20
Aluminum chamber (Top & Bottom) 0.10
Steel supports 0.2
Transparent quartz glass 0.8
Transparent glass substrate 0.8

71. End Connector
Quartz Tube
Carbon Filament
Quartz Bulb
Temperature Contour near the End Connector (Sectional View)

72. Temperature Contour Showing Glass Substrate at 100 Secs

73. Temperature Contour Showing Glass Substrate at 100 Secs
Symmetry Side
Symmetry Side

74. Temperature Contour (Half Section) 100 Sec

75. Temperature Contour Showing Glass Substrate at 105 Secs

76. Temperature Contour Showing Glass Substrate at 105 Secs
Symmetry Side
Symmetry Side

77. Temperature Contour (Half Section) 105 Sec

78. Temperature Contour Showing Glass Substrate at 110 Secs

79. Temperature Contour Showing Glass Substrate at 110 Secs
Symmetry Side
Symmetry Side

80. Temperature Contour (Half Section) 110 Sec

81. Temperature Contour Showing Glass Substrate at 200 Secs

82. Temperature Contour 200 Sec

83. Steps Time [s]
[A] Outer
Corner
[°C]
[B]
Corner
on Z
Direction
[°C]
[C]
Center of
Full
Glass
Plate
[°C]
[D]
Corner
on X
Direction
[°C]
1
0. 22. 22. 22. 22.
15.385 22.281 22.322 22.259 22.244
25.385 23.631 23.855 23.493 23.419
35.385 28.27 29.108 27.724 27.437
45.385 35.242 36.936 33.939 33.298
57.549 49.474 52.835 46.553 45.01
69.472 72.531 78.451 66.948 63.582
80.46 101.69 110.68 92.77 86.851
91.447 136.15 148.49 123.24 114.28
124.02 306.02 326.86 271.68 248.7
149.54 488.91 509.52 430.42 396.58
169.23 636.02 651.53 560.56 522.37
188.93 755.43 762.85 669.48 634.79
200. 813.14 815.56 723.08 692.71
Model > Glass Temperature
Temperature Change in Glass Plate
A B
C
D

84. Time
100 S 102.5 S 105 S 107.5 S 110 S
1 160.01 171.17 182.33 193.5 204.66
2 167.53 179.09 190.64 202.19 213.74
3 170.14 182.33 194.25 206.17 218.09
4 174.89 186.84 198.79 210.73 222.68
5 176.35 188.58 200.81 213.04 225.27
6 184.95 197.63 210.3 222.98 235.66
7 185.46 198.2 210.93 223.66 236.39
8 190.49 203.54 216.59 229.64 242.69
9 180.65 192.92 203.18 217.44 229.7
Location Vs Temperature
0
50
100
150
200
250
300
1 2 3 4 5 6 7 8 9
Location
Temperature(DegC)
100 S
102.5 S
105 S
107.5 S
110 S
Temperature Change Middle X-Axis

85. Hyper Elastic Problems

86. SEAL ANALYSIS
CHANGEPOND

87. FLORA ELASTOMER

92. Result for rubber seal
compression Displacement
max(radial)
Stress max
0.2mm 0.2545mm 0.3051 N/mm2
Result for steel rubber seal
compression Displacement
max(radial)
Stress max
0.2mm 0.1143mm 2.682 N/mm2

93. Door Seal Analysis

96. CRASH

101. CO2 PUMP
THAR TECHNOLOGIES

102. MESHED MODEL

103. PUMP-APPLIED PRESSURE
AREA

104. STRESS DISTRIBUTION IN THE
PUMP AT 14000 PSI

106. FILLET GEOMETRY

107. PRESSURE AREA IN THE PUMP
WITH FILLETS

108. STRESS DISTRIBUTION IN RE-
DESIGNED PUMP

109. MANIFOLD MESHED MODEL

110. MANIFOLD-AREAS SUBJECTED
TO PRESSURE

111. STRESS DISTRIBUTION AT
12,000 PSI

112. STRESS DISTRIBUTION AT
14,000 PSI

113. DEFORMATION
(EXAGIRATED)

114. HITCH OPTIMIZATION

116. Testforce (N) 5700 Dynamic
Testforce sideways (N) 4479.25 Static
Testforce vertical (N) 7072.25 Static, downwards
LOADING CONDITIONS

120. SHAPE CONDITION
WEIGH
T
(Kg)
STRES
S
(MPA)
DEFLECTION
(mm)
PIPE SECTION
INITIAL 0.543 25.3 0.025
OPTIMIZED 0.426 51.3 0.038
RECTANGULAR
INITIAL 0.594 36.9 0.018
OPTIMIZED 0.481 49.5 0.028
I SECTION
INITIAL 0.527 20.1 0.021
OPTIMIZED 0.385 51.8 0.034
RESULT REVIEW

121. HOT COKE CAR
FRAME ANALYSIS
FFE MINERALS

122. Deflection- overall

125. RESULTS
 MAXIMUM DEFLECTION IN
THE FRAME IS ON = 5.255 mm
THE BASE CROSS MEMBERS
MAIN MEMBER DEFLECTION = 2.628-3.28 mm
STRESS INDUCED IN = 50-75 N/mm2
THE MAIN BEAM IS
STRESS INDUCED = 110-150 N/mm2
IN THE CROSS BRASS
MAXIMUM STRESS INDUCED = 573.484 N/mm2

126. SKID ANALYSIS
DURR INDIA

132. ETC MOTOR
VESTEON

134. DENTAL PROJECTS

135. FEA FOR BIOMEDICAL
ENGINEERING
 STRESS ANALYSIS OF
 EYE BALLS
 BONES
 TEETH
 LOAD BEARING CAPACITY OF IMPLANT
AND PROSTHETIC SYSTEMS
 MECHANICS OF HEART VALVES.
 IMPACT ANALYSIS OF SKULL
 DYNAMICS OF ANATOMICAL STRUCTURES.

136. MANDIBLE BONE GENERATION

139. Dr.RAMESH
RAGAS DENTAL COLLEGE

143. CAST PARTIAL
DENTURE
Dr.HARI
SAVEETHA DENTAL COLLEGE

148. Dr.RAJKIRAN
SAVEETHA DENTAL COLLEGE

149. CAP SUPPORT ON 2ND
MOLAR AND CANINE AND
CENTRAL INSISOR

151. CAP SUPPORT ON 2ND
MOLAR AND CANINE WITH
50% BONE LOSS

152. CENTRAL INCISOR Dr.RAISON
SAVEETHA DENTAL COLLEGE
Dr.RAISON
SAVEETHA DENTAL COLLEGE

155. DISTRACTION OF
MAXILA BONE
Dr.NAREN
SRI RAMACHANDRA MEDICAL COLLEGE

160. Comparison of Straight
and Inclined Abutment on
a 4 implant Mandible
Dr.Anshu
SRI RAMACHANDRA MEDICAL COLLEGE

164. Analysis of Central Insisor
with and without Ferrule
Dr.Arthi

167. Titanium without Ferrule

168. Comparison Between
Screw and plate
connection on a mandible
Dr.Romita

172. Bridge
Dr.Lin

175. Bridge Implant
Dr.Lambodaran

179. Cantilever Bridge Implant
Dr.Abijitha

182. Two Piece Implant
Dr.Karthikeyen

186. Max torque for Material
removal with Protaper
Files
Dr.Sihivahanan

188. Effective en-masse
retraction design with
orthodontic mini-implant
anchorage
Dr.Ashok

192. Mandible over denture
Dr.Ramakrishna

195. en-masse retraction
design with varying loop
design
Dr.Raghu

198. Maxila with Denture
supported on 4 implants
Dr.Imran

201. THANK YOU