PTC’s Creo Simulate Customer Testimonials

Matthew S. HoytMonday, August 1, 2011

MRC & PTC Corporate Partnership

3

AMST Focuses on Standardizing Product Development with PTC Solutions

© 2011 PTC

AMST is an industry leader in simulation equipment for civil and military flight and pilot education. Approximately 100 employees plan, design, and build AMST’s complex equipment in Ranshofen and Braunau, Austria.

Efficient collaboration across all areas of product development in order to secure market advantage Support from the proposal phase through assembly, including documentation and integration to SAP

for a universal process Auditability and fulfillment of extensive regulations and documentation requirements

The end-to-end product development system from PTC enables the combination of innovation, budget and scheduling goals, and the 30-year product guarantee

Windchill PDMLink serves as the central hub for product development with integrated use of Creo Parametric, Creo Simulate, Arbortext, Creo NC, and numerous companion modules from a PTC reseller.

Complete change management for the product is fully transparent and auditable; this is a prerequisite for support of the 30-year guarantee

Automation of development, production, and documentation processes Intense use in the proposal and design phases prepares for the rapid

creation of representative, digital modules Availability of product data for all departments, both internal and external

Business Initiative

Solution

Result

“The pervasiveness of an integrated solution for all areas helps us not only to operate within ever stricter budget and time constraints, but also raises our competitiveness, most of all through achievement of the highest quality with increased innovation.”

Christian Baischer, CAD/PLM Administrator

1

PTC University Further Educates Alcatel-Lucent in Nonlinear FEM Large Displacement, Contact and Bolt Analysis with Mechanica®

© 2010 PTC

Alcatel-Lucent is the trusted partner of service providers, enterprises and governments worldwide, providing solutions to deliver voice, data and video communication services to end-users. A leader in fixed, mobile and converged broadband networking, IP technologies, applications and services, Alcatel-Lucent leverages the unrivalled technical and scientific expertise of Bell Labs, one of the largest innovation powerhouses in the communications industry.

Alcatel-Lucent wanted to extend its engineers’ and physicists skills in nonlinear Mechanica FEM simulation for examining and optimizing clamped and bolted subassemblies within their typical electrical units

PTC University offered a specially customized Instructor-Led Training course, containing knowledge transfer in Mechanicacontact, bolt and large displacement analysis, and furthermore the opportunity to discuss, analyze and optimize Alcatel-Lucent products

Acquired knowledge in the frictionless and friction involving contact model provided in Mechanica

Acquired bolt analysis theory and its application in Mechanica

Acquired skills in setting up idealized, speed and accuracy-optimized contact and large displacement analysis models, assuring their result quality

Business Initiative

Solution

Result

“The simulation knowledge provided in the PTC University Instructor-Led Training course will allow us to study and compare a lot of design concepts virtually without even paying a penny for different prototypes. In addition, together with the PTC instructor, we have developed and simulated new designs during the training. These will help us to simplify the assembly of the parts and to increase the product reliability in the later serial production.”

Edgar Hochstaetter, HW-Designer, Wireless Network Product Division, Alcatel-Lucent Deutschland AG.

Right: Contact pressure distribution of a gapping, eccentrically loaded bolted connection containing an idealized fastener.

Bottom: A customer application – a quarter model of a bolted clamp to fix electric parts, subjected to a large displacement analysis. Just 10 p-brick-elements (bottom left) allow an extremely fast and very accurate nonlinear analysis and optimization of this highly bending loaded component.

1

PTC University Further Educates Bosch Diesel Systems in Nonlinear Contact Analysis with Pro/ENGINEER Mechanica®

© 2010 PTC

As the world's leading diesel systems manufacturer, the Bosch Diesel Systems Division, headquartered in Stuttgart, Germany, develops, applies and produces diesel injection systems which contribute to making vehicles cleaner and more economical. In the very early development phase, Finite Element analysis and optimization with Mechanica® assuresthat their highly pressurized systems work as reliable in their later service life.

Bosch DS wanted to extend its engineers’ skills in nonlinear Mechanica contact simulation and to familiarize them with the new developed friction contact model of the latest Mechanica release

PTC University offered a specially customized in-center training workshop containing knowledge transfer in Mechanica contact theory and analysis, and furthermore the opportunity to discuss and analyze typical Bosch DS products

Acquired knowledge in the frictionless and friction containing contact model provided in Pro/ENGINEER Mechanica

Acquired skills in setting up idealized, speed and accuracy optimized contact models

Ability to assure the result quality of nonlinear contact analysis by carefully creating and interpreting contact measures and postprocessor plots

Business Initiative

Solution

Result

“PTC University provided a first-rate Mechanica contact workshop that delivered the exact information we were looking for. In the training, our Mechanica Models were discussed and analyzed with reasonable idealizations. Typical difficulties and problems we observe when setting up and running contact analyses were treated and helpful solutions were provided.”

Dipl.-Ing. Matthias Brunner, Engineering Technical Information Processing, Diesel Systems, Robert Bosch GmbH

Top: A typical Bosch common rail Diesel injection system containing several pressurized components and contact analysis tasksBottom: A PTC University contact training example - von Mises stress distribution within a cylindrical roller bearing acc. to the Hertz theory

6

PTC University Educates Bosch Rexroth Engineers in Advanced Nonlinear Contact and Bolt Simulation with Creo Simulate

© 2010 PTC

Bosch Rexroth AG, headquartered in Lohram Main, Germany, is a developer, producer and supplier of drive and control technologies for hydraulic, electric, pneumatic or mechanical applications. In order to increase product quality in spite of reduced development time, the PTC University was charged with the further education in advanced contact and bolt analysis with Creo Simulate.

Bosch Rexroth requested on-site Creo Simulate (formerly Pro/ENGINEERMechanica) contact and bolt simulation workshops for their design and CAE engineers developing hydraulic equipment

PTC offered simulation workshops providing basic principles of bolt analysis, necessary software knowledge, typical application tasks and furthermore solutions for special customer examples

Acquired knowledge about the contact theory used in Creo Simulate and methods to assure numeric solution quality

Acquired solution roadmaps for typical bolt analysis tasks Critical bolted designs can now be analyzed and optimized in

Creo Simulate before prototypes are being built and tested

Business Initiative

Solution

Result

“The Creo Simulate simulation training provided by PTC University exactly met what we needed: Solution methods in Creo Simulate for all types of bolted connections with different precision demands, starting from just obtaining force relations up to evaluating exact load and stress distributions in each single thread turn.”

Dipl.-Ing. Katja Mild, Group Leader R&D, Bosch Rexroth AG

Name

One of the customer’s analysis tasks solved in Creo Simulate during the contact & bolt analysis workshop:

Above: Creo Parametric model of a hydraulic piston prepared for a detailed 2D axial symmetric contact analysis.

Right: Von Mises stress in the piston assembly when preloaded and pressurized.

7

PTC University Educates Carl Zeiss Engineers, Company-Wide, in Finite Element Analysis with Creo Simulate

© 2010 PTC

Carl Zeiss, headquartered in Oberkochen, Germany, is one of the world-wide leading brands for nearly all types of optical instruments. The central Carl Zeiss Mechanical CAx Service Center provides support and further-education to the different subsidiaries like Carl Zeiss SMT (Semiconductor Technologies), Carl Zeiss IMT (Industrial Metrology), Carl Zeiss Optronics, Carl Zeiss Camera Lens Division, Carl Zeiss Medical Solutions, and much more.

The central Carl Zeiss Mechanical CAx Service Center charged PTC University with the further education of Carl Zeiss’ engineers in Creo Simulate (formerly Pro/ENGINEER Mechanica)

PTC University performs different out-of-the-box trainings on site (basic finite element analysis course, workshops for dynamic, thermal contact and bolt analysis). In these trainings, the opportunity to solve participant’s actual analysis tasks is offered.

Acquired skills in many different Creo Simulate analysis types that enable quick product analysis and optimization early in the development process

Solved analysis tasks for Carl Zeiss example models

Business Initiative

Solution

Result

“We have booked different Creo Simulate Finite Element classes provided by PTC University for several years. Through this training, we do not only obtain an excellent education for our design and simulation engineers, we also get valuable, on-the-fly advice and even solutions for analysis problems the participants bring along to the courses.”

Dipl.-Ing. Jürgen Wahl, Manager Mechanical CAx, Carl Zeiss AG

Different Carl Zeiss models analyzed in a MECHANICA basic course:

Left: Geometric nonlinear segment model of a flexible bellow under internal pressure (small image: half symmetric model); top right: Clamped sensor element with fasteners prepared for nonlinear contact analysis; bottom right: Movements of an actuated frame with leaf springs

8

Reinvesting in 3D CAD, CAE and PLM to Respond Quickly to Customers

© 2011 PTC

Spirit of Thule“To be the brand of choice for consumers around the world who want to transport their equipment by vehicles safely, easily and in style”

Thule Towing systems invested in licenses of Creo Parametric for three departments including Engineering, R&D, and Manufacturing Engineering

They invested in Creo Simulate licenses to be used during the design stages To be able to control the data within the company they invested in Windchill PDMLink To be able to use native CATIA models for their primary customers they invested in the

Creo-CATIA interface

Able to put more detail in the technical solution for a better product over the long term Drastic decrease of physical tests by 35% through use of Creo Simulate resulting in decrease of costs, leaving much

more room to invest in better products. Windchill reduces internal discussions and leaves time for better responses internally and externally. Access to the latest knowledge and information.

Solution

Result

“With this software package we are able to fulfill the tough requirements of the worldwide automotive industry even better, and we are well prepared to meet future, challenging goals.”

Arnoud Margadant, Manager Research & Innovation

Business area: Towing Systems Europe Asia develops, produces and markets a complete range of towing systems and wiring kits. The products are mainly marketed under the Brink brand. Customers are leading European aftermarket companies. The business is based in Staphorst, Netherlands, and has seven production and sales facilities in Europe (Netherlands, UK, France, Germany, Denmark, Poland and Sweden).

9

Logitech Improves Design Quality and Efficiency with Consulting and Training from PTC Global Services

© 2010 PTC

Logitech is an industry leader in the personal peripheral market, producing devices for PCs including keyboards, mice, gaming controllers and webcams. Logitech also produces home and PC speakers, headphones, wireless audio devices and audio devices for MP3 players and mobile phones.

Logitech’s design team needed to develop a method to find the relationship between design tolerance, structure and displacement with Pro/Engineer

PTC Global Services provided consulting services in the area of tolerance analysis methodology as well as Creo Mechanism Dynamics and Creo Simulate (formerly Mechanica) training and documentation

Processes improved: Detailed Design; Variant Design and Generation Capabilities implemented: MCAD/CAE/CAM; MCAD Data Management

Improved advanced simulation skills Shortened product design cycle time Reduced development costs and increased product quality

Business Initiative

Solution

Result

“The consulting and training services provided by PTC Global Services have made us more aware of Pro/ENGINEER’s powerful functions, which will help us design more efficiently.”

Aaron Lee, Senior Engineer, Logitech

1

PTC Global Services Examines the Dynamic Structural Behavior of an Opto-Mechanical Subsystem Prototype from Carl Zeiss Optronics with Pro/ENGINEER® Mechanica® Software

© 2010 PTC

Carl Zeiss Optronics GmbH, a member of the Carl Zeiss Group located in Oberkochen, Germany, develops and produces high-precision and robust opto-electronic systems for observation and defense purposes. For such products exposed to intense loading, advanced system analysis with the Finite Element Method is an integral part of the product development.

During the development of new observation systems, Zeiss Optronics performs analyses to study the behaviorof the installed subsystems for assuring that the final product works accurately. For the subsystem shown to the right, PTC Global Services was charged with these examinations

PTC built up the dynamic analysis model in Mechanicawith the help of given Zeiss Pro/ENGINEER Wildfire CAD model assembly data. Reasonable linearizationswere developed for the guiding system and the preloaded drive mechanism. Their validity was strictly controlled during all subsequent analyses. Given sine sweep test data was compared with the dynamic frequency analysis results to assure an accurate mathematical model of the subsystem

Good match of test and analysis result data helped to understand the dynamic characteristics of the subsystem

Points in the design leading to unwanted behavior could be identified and solutions were provided

Business Initiative

Solution

Result

“The dynamic analysis study gave us a very good understanding of exactly what happens in our newly designed subassembly for moving lens elements. PTC’s responsible consultant for the project, Dr. Roland Jakel, also provided excellent ideas for helpful design modifications. With the obtained knowledge, we can now enhance the subsystem in a very early stage of the development, ensuring that it meets the requirements.”

Dr.-Ing. Thomas Meenken, Team Leader Simulation, Carl Zeiss Optronics GmbH

Top Left: The meshed Mechanica FEM model derived by PTC from the ZeissPro/ENGINEER data set, showing the p-elements and idealizations

Top Middle: Pro/ENGINEER assembly model of the optical subsystem showing the dynamic test setup with several attached 3-axis acceleration sensors

Bottom Left: A typical modal shape of the opto-mechanical subsystem attached to a linear roller bearing

Bottom Middle: Frequency response curves in the domain of interest showing good match of measured and analyzed accelerations (sine sweep test vs.Mechanica dynamic frequency analysis)

Bottom Right: Integrated 1-sigma displacement response density functions allowing to judge which frequencies deliver high fractions to the deposition of the optical group of interest (Mechanica random response analysis)

11

PTC Global Services Improves the Image Quality and Shock Strength of a Carl Zeiss Image Conductor for the Periscope of the New German Puma IFV

© 2010 PTC

Carl Zeiss Optronics GmbH, a member of the Carl Zeiss Group located in Oberkochen, Germany, develops and produces high-precision and robust opto-electronic systems for observation and defense purposes. For such products, advanced structural system analysis with the Finite Element Method is an integral part of the product development process.

Carl Zeiss Optronics is the prime contractor of the periscope of the new German Puma tank. PTC Global Services was charged with the design accompanying FEM system analysis and strength proof of this product. As one part of the periscope development, a new imageconductor had to be designed, analyzed and optimized

First, PTC created a simplified beam & shell structure of the initial image conductor design in Creo Simulate (formerly Mechanica) for a quick first system analysis and subsequent optimization steps. When the more detailed design was worked out, PTC built the dynamic system model directly on Carl Zeiss’ given Creo Parametric assembly data for final optimization and verification, including a powerful idealization of all important bolted connections within the image conductor

Improved dynamic behavior of the system led to a superior image quality which was proven in tests and under real service conditions

Increased shock strength was reached due to several design modifications at system, component and bolted connection level

Business Initiative

Solution

Result

“PTC Global Services gave us very important design support with the dynamic system analyses performed in their Mechanica Finite Element code. We received detailed information on which design improvements we had to introduce to fulfill the tough requirements for the optical system. The optimized conductor withstood all loadings in the system tests and delivers now top-notch image quality in real service mounted into the Puma IFV.”

Oliver Römpp, Manager Ground Based Targeting and Fire Control Systems, Carl Zeiss Optronics GmbH

Top: The new German Puma Infantry Fighting Vehicle (IFV)

Left: The new image conductor prepared for dynamic tests on a shaker table

Middle: Snapshot of deformation of the improved image conductor under sinusoidal dynamic loading (MECHANICA dynamic frequency analysis).

Right: The image conductor - realized hardware

Bottom left: Detailed idealization of bolted connections within the assembly allowing to estimate bending loads and to take into account gapping effects

12

CE Masters Uses Creo and Pro/INTRALINK to Develop Best In Class Products

© 2011 PTC

CE Masters is a Dutch engineering company and is active in the field of mechanical product development and consultancy. The company has used PTC solutions since 1993 for their clients to solve a wide variety of mechanical design and engineering challenges.

CE Masters wanted to develop superior mechanical products by using their top-down design strategy as well as their Mechanical Analysis expertise, and also to improve their customers’ development processes

Working with a PTC Reseller, CE Masters adopted Creo Parametric,Creo Simulate (formerly Mechanica), and Pro/INTRALINK

Best-in-class mechanical product development by using the integrated PTC Solutions

Business Initiative

Solution

Result

“Key for using PTC Solutions is the fact that the integrated PTC Solutions are able to support our Top-Down Design strategy for developing best in class products for our customers.”

Sander de Regt, Business Leader, CE Masters

13

Cumitas Decreases the Cost of Prototypes by 35% with Creo Parametric

© 2010 PTC

Founded in 1986, Cumitas is a manufacturer of earth-moving machinery and industrial machinery

Migrate their Product Development System from 2D to 3D Minimize production cost while maintaining high product quality

Displaced AutoCAD and benchmarked CATIA INFOMA Group, an authorized PTC Reseller, deployed Creo Parametric and Creo Simulate

to design, engineer and manufacture products all in one solution on screen Creo Simulate is used to test and analyze products visually to detect problems before

manufacturing the product

Decreased the cost of prototypes by 35% Minimized production errors and caught them early and visually Improved product quality with real-world performance and

analysis

Business Initiative

Solution

Result

14

PTC Global Services Consulting Optimizes Space Station Parts for Astrium

© 2010 PTC

Astrium, a subsidiary of EADS located in Bremen, Germany, is a space company focusing on international space programs. Astrium has developed many systems including the Spacelab for the U.S. Shuttle, Ariane rocket stages and the Columbus Orbital Facility.

Astrium needed a structural analysis and optimization of a leaf spring to be used for the International Space Station (ISS)

PTC Global Services Consulting modeled and analyzed the component in Creo Parametric and Creo Simulate and provided a detailed presentation and solution proposal to Astrium

Precisely located the overloaded areas in the initial design Found and optimized the structure

that will fulfill the requirements Provided an optimized STEP model

directly for the further Astrium design process

Business Initiative

Solution

Result

“The excellent simulation and engineering knowledge provided by PTC Global Services has given us a sound solution for a critical part—and within an incredibly short time frame.”

Dr. Ingo Retat, System Engineer, Astrium

15

PTC Global Services Consults ZF Test Systems in Advanced Dynamic Simulation with Creo Simulate and Mathcad

© 2010 PTC

ZF Test Systems, a business unit of ZF Passau GmbH in Germany, offers its customers the know-how of a major manufacturing group with the flexibility of a small division: Just 70 employees develop and produce tailor-made and ready-to-use test rigs for automotive component and system tests like rolling noise, oscillations, vehicle stiffness or power losses.

Since all test rigs are unique and individually designed for the actual customer demand, ZF Test Systems already uses Creo Simulate and Mathcad at the beginning of the development phase to assure accurate static and modal behavior of each facility. Now, also detailed dynamic analyses shall be performed to further improve the test benches

PTC offered an individual simulation consulting that treated the special dynamic analysis tasks of ZF Test Systems

Simulation knowledge for solving dynamic problems related to unbalanced rotating machinery and pre-loaded systems was acquired

The behavior of the test rigs can now be predicted quantitatively and optimized in more detail long before each individual test bench is being built and put to dynamic tests

Business Initiative

Solution

Result

“PTC Global Services delivered an excellent simulation consultation that provided theoretic knowledge as well as practical software know-how, applied to our special demands. We will definitely use PTC simulation products even more. They enable us to deliver optimal test facilities to our customers.” Jens Eisenbeiß, Manager Mechanical Design Test Systems, ZF Passau

Dynamic analysis results of a rotating, unbalanced shaft. Left: Analytic solution with MathcadRight: Numeric solution with Creo Simulate