Learn More About Simulation & CAE Software
What is Simulation & CAE Software?
Simulation and computer-aided engineering (CAE) software allows engineers, analysts, and designers to perform finite element analysis (FEA), computational fluid dynamics (CFD), multibody dynamics (MDB), and optimization. Simulation software can also be referred to as CAE simulation software due to its association with CAE analysis and its application. Simulation software can create models based on mathematical data and place them in a predefined system. By analyzing these models, engineers study the relationship between model and system and the interactions that happen in a controlled environment. This helps predict performance, defects, and judge the potential product lifespan.
What Does Simulation & CAE Software Stand For?
CAE stands for computer-aided engineering. The term computer-aided engineering is used as a technical term for simulation while the term simulation is what is often heard in the market when users refer to engineering simulation.
What are the Common Features of Simulation & CAE Software?
The following are some core features within simulation software:
Computational fluid dynamics (CFD): One of the main forms of engineering analysis that CAE software performs is CFD. CFD is a way to model the behavior of both fluids and gases. This includes modeling the way they interact with one another as well as surfaces that they come in contact with. This feature can solve problems such as identifying incompressible and compressible fluids, laminar and turbulent flows, as well as multiphase flow problems.
Finite element analysis (FEA): FEA is a numerical method used to solve engineering problems. This process is used to break down one large problem into a handful of smaller ones, called finite elements. Using this method, engineers can break down complex engineering problems into manageable pieces. One of the main ways engineers use FEA is to make model representations in which they can test how objects interact with one another, which provides an understanding of how an actual object would be affected by other physical forces. Examples are bridge modeling, car crash testing, and testing the structural integrity of any given object.
Mechanical event simulation: Mechanical event simulation enables engineers to simulate how objects will react to certain events in real life. A good example of this is a simulation of how a mobile phone will interact with a cement floor in the event that it is accidentally dropped. Within the simulation, the software can indicate if the phone screen will crack or if any other permanent issues will be caused. The software can then suggest changes to be made to the phone to make it more durable and protected in the event of a dropped phone; when considering these changes, users can test the simulation until the product is adjusted to their liking.
Electromagnetic simulation: Electromagnetic simulation allows users to simulate the electromagnetic properties of components or systems. This allows engineers in industries such as electronics and communications to determine how effective their component design is.
Thermal simulation: Thermal simulation allows users to simulate how the physical properties of materials change with changes in temperature. Thermal simulation can be used to simulate areas such as electronics cooling, automotive thermal management, heat exchangers, pressure vessels, and other applications where users need to simulate the effect of thermal loads.
Other Features of Simulation & CAE Software: Structural Simulation
What are the Benefits of Simulation & CAE Software?
Speeds up design time: Simulation software speeds up the time it takes engineers to prototype and test how objects will perform in the real world. This allows product engineers to improve design performance well before a product is manufactured. A major example of this is how airplane engineers manufacture an airplane that can withhold the stress of landing on a runway. Within this process, there are so many variables to take into account, including the material, size, and speed of the airplane. Given the perspective of how many factors go into the safety and performance design of an airplane, one would think it would take countless days of manipulating the design to create a reliable product. However, CAE allows engineers to speed up this process by running simulations of plane landings and detailing exact ways in which the engineer can improve the design.
Saves money: Simulation software is all virtual and done on the computer, hence the name “computer-aided engineering”. Since these simulations are all conducted virtually, it allows companies to save plenty of money by not having to manufacture countless designs before getting the final product correct. For example, car engineers can simulate how a car crash would occur before they even have to conduct the final experiment. This way, before car crash testing occurs, engineering teams already have a good sense of how the test will go. The result is having to spend less money on testing and trashing actual physical prototypes.
Improves testing: When prototypes finally come down to physical testing, simulation software can help analyze what’s occurring during the test and identify any key faults that occurred. For example, if a car was tested for impact and the body of the car wasn’t strong enough to withstand a crash, simulation software can identify exactly what went wrong and suggest what needs to be changed.
Who Uses Simulation & CAE Software?
Simulation and CAE software is used across a variety of industries in the manufacturing and engineering world. Its main functions include simulation, validation, and optimization of products, which can be broadly applied to any business trying to test and improve a manufactured product. With this in mind, here are a couple of industries that use simulation software.
Automotive industry: Historically, automakers spent plenty of time producing physical vehicle models and then testing them for safety by actually crashing them into physical barriers. With advancements in simulation software, however, design and safety testing is all done using computer simulations. Within the virtual simulation, a car can be tested to improve safety, comfort, and vehicle durability. This has saved the automotive industry both time and money by eliminating the need to produce countless physical prototypes.
Manufacturers: Simulation and CAE software can produce simulations of manufacturing assembly lines. This helps manufacturers identify any inefficiencies or issues before they begin construction on expensive production assemblies. By identifying these issues, they can save money and increase the efficiency of their manufacturing systems.
Electronic engineers: Industries that work with developing electronic products can greatly benefit from using simulation software. Some simulation tools offer physics-based electronics design that provides fast and accurate life predictions for electronic hardware at the component, board, and system levels in early-stage design. This can be extremely beneficial to product development.
Education: Simulation and CAE software is also used by educators to teach engineering students. For learning or teaching simulation, several vendors even offer academic or student editions of their software packages, usually at a reduced cost.
Software Related to Simulation & CAE Software
Related solutions that can be used together with simulation and CAE software include:
CAD software: Computer-aided design (CAD) software allows users to design 3D models of physical objects. Before using simulation software, engineers often create a 3D design of whatever they’d like to conduct a simulation on. This can be a building, a mechanical assembly, an engineering plant, etc. Once the design is done, users then upload the product to a simulation software where they can then simulate how the product would react to real-life forces. Some simulation software have robust 3D design capabilities built in, while others are more elementary and are best complemented by a more robust 3D CAD software.
Challenges with Simulation & CAE Software
As a technically involved software, simulation and CAE software can come with a few major challenges. Some of the most common challenges include:
CAD/CAE integration: CAD files are completely different from CAE files. With this in mind, it’s very difficult to produce a model in CAD software, and hope that it will be suited for FEA within CAE software. However, there are software offerings that allow design and analysis to be tested within an integrated CAD/CAE environment, so to avoid this potential issue, it may be best to find a CAD solution that also offers CAE capabilities.
Learning curve: CAE software comes with a steep learning curve. While there are more products and resources that can help beginners, it will still take a significant amount of time to master all the nuances of the software.
Price: Another major concern for small businesses is the high price of CAE software. Some commercial CAE software can range anywhere from $10,000 to $50,000 per person, which is a hefty price tag for a single user in a company.
Which Companies Should Buy Simulation & CAE Software?
Simulation and CAE software has applications that span multiple industries as well as multiple company types.
Structural engineering and automotive engineering companies: Whether a company engineers planes, cars, or buildings, simulation software can solve a lot of use cases for structural engineering teams. With plenty of tools for stress and impact analysis, users can simulate how their structures or products will react to real-world environmental effects.
Manufacturing and industrial equipment companies: It’s critical to test industrial equipment for strength, speed, safety, reliability, and endurance under different operating conditions. Simulation and CAE software can optimize the industrial equipment design early in the design cycle. This ensures the production of high-performance machinery with a shorter time-to-market and lower costs for physical testing. Some of the tools used within typical CAE software include mounting, clamping, adjusting, rotating and other elements.
How to Buy Simulation & CAE Software
Requirements Gathering (RFI/RFP) for Simulation & CAE Software
Requirements gathering for simulation and CAE software is critical to ensure that the business is implementing a product that meets all of their needs. To do so, businesses must evaluate their critical needs.
Compare Simulation & CAE Software Products
Create a long list
Long lists are created by eliminating software options that do not provide critical functionality. To make a long list for simulation software, a buyer should look at the following functionalities and deem which products provide the necessary functionality:
- Finite element analysis
- Computational fluid dynamics
- Thermal simulation
- Continuous event modeling
- Mechanical event simulation
- Manufacturing process simulation
- 3D design and modeling
- Drawing tools
Create a short list
Once a buyer has narrowed down their list from the following functionality above, it’s then important to get even more specific requirements. A buyer may be looking for simulation software that allows for a wide range of CAD integrations, or some buyers may be looking for solutions that specialize specifically in multibody dynamics or electronics simulation. Additionally, CAE is not easy to learn so it may be important to narrow it down to vendors that have great implementation support or additional resources to help learn how to use the simulation software.
Conduct demos
Demos are one of the most important stages in the buying journey. This allows a buyer to sit through an actual product demo and see if the product matches all of the requirements. To make sure the demo runs smoothly, users must ensure that the vendor has all of the requirements beforehand so they can showcase their features properly. Some of the use cases that a business should ask the vendor to showcase are:
Specific simulation features: Before getting into the demo, a potential buyer needs to hone in on what simulation features are the most important to them. If a buyer is looking for thermal, fluids, or structural simulation then the buyers should make sure that the vendor showcases those specific features.
Workflows: Another important feature to showcase is workflow functionality. How does the solution offer better workflow management for CAE projects? Can users share projects easily, are there simple functions for content management?
Selection of Simulation & CAE Software
Choose a selection team
Simulation and CAE software is going to most often be used by engineers as well as managers who oversee these teams of engineers. As such, a few senior engineers and relevant managers need to be involved in the decision-making process. At a minimum, the selection team should be at least three senior engineers and two members from management. Since simulation software is costly, this will ensure that enough eyes are on the project to make sure the best decision is made.
Negotiation
When negotiating during the purchasing stage, it is advisable to always start small in terms of licenses and functionality. Licenses will always be the biggest cost within any purchase, and oftentimes, companies purchase additional licenses or features in a product that they don’t necessarily need. During this negotiation, vendors will try to convince buyers that they can offer discounts on more functionality or licenses if they buy in bulk, but most businesses don’t need this. If businesses end up needing a few more licenses down the road, they can always add as need be.
In addition to this, the selection team should always strive to have implementation and ongoing support fees included in the cost. As stated previously, simulation software is not easy to learn. Before purchasing, buyers must ensure that the vendor offers regular training or even online training options to help new users onboard quickly. This way, if any ongoing support is needed, businesses can always contact their customer success or support representative.
Final decision
After the negotiation stage is conducted, the final decision requires buy-in from everyone on the selection team. It’s important to ensure that all requirements are met and the final decision is supported by everyone involved.
What Does Simulation & CAE Software Cost?
There are a variety of factors that will play into both the upfront and ongoing cost of simulation software. For upfront costs, a business will pay for setup, any custom integrations, and training. The ongoing cost is the subscription cost to actually use the software. Many simulation software options are usually run on a subscription model which means users will pay a monthly or yearly rate to use the software. The subscription model is generally set up as a per-user model and will ultimately be the biggest cost. As stated previously, to limit the upfront cost, it’s important to pay for a limited number of licenses right away as buyers still need to figure out if the software will ultimately be the best choice for their company. In terms of hard numbers, there is simulation software for as little as $30 per user on a monthly basis, whereas some go up to $100 per user per month.
Return on Investment (ROI)
Below is the breakdown of the estimated time to ROI according to the review data on G2 as of May 4, 2021:
35% of buyers see an ROI in 6 months or less
26% of buyers see an ROI in 7-12 months
19 % of buyers see an ROI in 13-24 months
7% of buyers see an ROI from 24-36 months
7% of buyers see an ROI in 48+ months
7% of buyers haven’t realized a full payback yet
Simulation & CAE Software Trends
Machine learning
Machine learning can help speed up engineering simulations by enabling highly accurate predictions. With tools like statistical learning, computers are able to learn and develop better data on their own. This can help speed up the optimal design of a product. An example would be data that is extracted from a car crash simulation repeated thousands of times. Within simulations, machine learning tools can understand which changes need to be made to make the car safer without sacrificing the integrity of the design.
