FEA

A physics‑based simulation framework was developed to optimize aluminum alloy wheel design and support manufacturing validation, applying structural and fatigue analyses in accordance with international standards. The workflows cover radial rolling, cornering fatigue, and impact scenarios, following protocols such as ISO 3006:2015, ISO 7141, and SAE wheel standards. Accurate material characterization informed both linear and non-linear finite element analyses, ensuring simulation results closely matched physical testing. This approach enables reliable virtual validation, reduces the need for extensive prototyping, and accelerates the overall wheel design cycle.

The hydroforming process of a copper pipe was analyzed to improve forming reliability and reduce material waste. A 3D FEA model simulated deformation under varying pressure levels, enabling optimization of internal pressure and prediction of critical wall thickness reduction. The results demonstrated that simulation-driven tuning can significantly improve process stability and production efficiency.

A transient electro-thermal simulation of a Power Distribution Unit (PDU) was performed to evaluate temperature evolution during alternating current charging and discharging cycles. The analysis was carried out using the Thermal-Electric Coupled Field Transient capabilities in Ansys Mechanical. The simulation includes time-dependent electric current flow, Joule heating, and heat transfer, with switching between charging and discharging paths represented through changes in boundary conditions. Both operating modes are captured within a single transient analysis by sequentially modifying electrical loads, current paths, and material properties.

Simtec conducted a structural analysis of an industrial aluminum roller designed by TEKA Systems S.A. for EL.V.AL. S.A. Using ANSYS Mechanical, the study evaluated the roller's performance under standard and overload forces. The CAD model was simplified and analyzed, revealing that the roller operates within the elastic region, with only minor, non-critical plastic deformations. This ensured the safe and reliable operation of the roller.