What is CAE?

CAE Technology and Market Needs

Cybernet Systems is a company

that supports manufacturing with
Computer Aided Engineering

Energy for your innovation 1

 1. What on earth is CAE?
Dad, you work at a car company don’t you? When I visited you at work
before, you were sitting in front of a computer…what were you doing?

I was running various simulations with the computer. For

example, what would happen if two cars crashed into
one another. Actually crashing real cars into one another
costs money and is difficult work, but with a computer
we can do it over and over again!

Eh! You crash cars together inside the computer? I didn’t know computers
could do things like that!
That’s right. Because we can do experiments on the computer before
actually making things it also reduces the need for prototypes and
waste/garbage produced, so it’s kind to the environment, too! It also helps
reduce the amount of time from starting the design to when the car is
actually completed. We call these computer-based experiments “CAE.”

CAE? What’s that?

CAE stands for “Computer Aided Engineering.” I suppose it’s a kind of

computer-based engineering support system. It’s used in the design and
development of all kinds of things apart from cars, too, from familiar
appliances and devices like refrigerators and smartphones to things like
rockets and robots!

Dad, that’s amazing! Maybe I’ll write a report about CAE for my free-study
project this year. Dad, please teach me all about it!

Ok, you got it! Now, first of all, let’s take a look at the history of CAE, shall
we? Let’s take a look at how and in what kind of situations it’s used, too!

[Contents]
1. What on earth is CAE?
2. The history of CAE: The birth of computer simulation
3. The process up to completion of a car: In what ways is CAE used?
4. Review: Manufacturing & CAE
5. Benefits of introducing CAE
6. Industries in which CAE is used
7. CAE has many specialist fields!
8. More accurate simulations that consider various specialist fields together, at the same time:
Multi-domain solutions
9. Summary: Things that can be done with CAE & things that we can do because we are Cybernet

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2. The history of CAE:
The birth of computer simulation
The history of CAE is surprisingly long, and the range of fields in which it is
used is becoming increasingly wider, too. Originally, CAE began with the
idea of first thinking of the design and then simulating whether or not that
shape would work properly. Now, we’ve come to a stage where CAE is
being used even before the design is actually drawn.

Expansion of the use of CAE during the initial

stages of design and development (the
2000s ~ appearance of 1D CAE)
The number of scenes and situations in which CAE is used is
present day becoming increasingly wider, and is now not only limited to the use of
3D CAE based on 3D design data, but also 1D CAE, which
mathematically simulates the feasibility of performance and
functionality during the initial design and development stages.

Period of growth and expansion for 3D CAE

(application in a widening range of fields)
With improvements in computer performance, the use of CAE became
1970s ~ 2000s more typical and widespread. It became possible to model and
analyze fluids such as air and water, and other things such as heat,
light, electromagnetic fields and sound. It also became possible to
model and analyze collisions and falls of objects.

The birth of general-purpose structural

analysis (3D CAE) software using the Finite
Element Method (FEM)
1960s During the 1960s, structural analysis software utilizing the Finite
Element Method (FEM) came to be developed. The ANSYS®
software sold by Cybernet was also created during this time, thanks to ANSYS Developer,
the research efforts of Dr. John A. Swanson, who then worked at Dr. John A. Swanson
Westinghouse Electric Corporation.

Development of the Finite Element Method

1950s (FEM)*
During the 1950s, a transition was underway for passenger aircraft,
shifting from propeller aircraft (which had been the mainstream until
that time) to jet aircraft. There was therefore a demand for high-
precision oscillation analysis for jet planes which fly at high speeds.

*Finite Element Method (FEM) is a numerical technique that subdivides a large problem (i.e. the object being modelled) into smaller,
simpler parts that are called finite elements. The characteristics of these finite elements are expressed using simple formulae and
equations, which are then combined to analyze the entire problem. This technique forms the basis for present-day CAE.

Bell Labs, USA, develops Ballistic Computer

for calculations of ballistic trajectories
1940s Spurred on by the breakout of World War II in 1939, the USA
succeeded in developing the world’s first computer capable of near-
instantaneous calculations of the trajectory of shells and other ballistic
projectiles. The computer was named ENIAC.

ENIAC Computer
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 3. The process up to completion of
a car: In what ways is CAE used?
Let’s ask Mr. Tanaka from ABC Automotive about the process leading up to
the completion of a car, and in what kind of ways CAE is used during that
process!
Hello! OK, first of all, let me explain about what kind of jobs are involved in
making a car. There are actually a lot of different jobs involved between the
beginning of the process—when we are deciding what kind of car we are going
to make—and when the cars are actually lined up on sale at the dealership.

1. Thinking of a New Car [planning ~ concept finalization]

Planning for a new car begins from between three and four years earlier. We think about changes
in trends and lifestyles, etc., and decide on a general direction for what kind of car we are going to
make.
2. Determining Specifications
For example, let’s consider specifications for a car that is geared towards mothers with babies or
small children, which places more emphasis on safety and fuel economy than on speed.
- If we place importance on engine power, the fuel economy will be bad. For
housewives, fuel economy might be more important than engine power,
mightn’t it? What kind of fuel economy and power will we give our engine?

- We want to reduce oscillations (shaking and vibrations) so as not to wake

the baby, too, don’t we? What level of performance should the suspension
have? We also have to consider cost properly, too!

How do you run simulations when you don’t even

know the shape of the car yet?
Because we don’t know the shape, we think about specifications using mathematical models
of the way things move.
It’s a bit difficult. For example, let’s think about the specifications for our engine. For this, we
decided that we should place more importance on fuel economy than power, didn’t we?
We do various simulations by expressing the way the engine will work in terms of
mathematical formulae; for example, how much power we get and how much gasoline is
consumed when we inject this amount of gasoline into the engine with this much force.

These simulations used for designing specifications are called “System Level
Simulations” or “1D CAE.” It’s a bit of a specialist term, but in the Control
Simulation field we sometimes also call it MBD (Model Based Development).
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3. Detailed Design
Once the specifications are decided, we use software called CAD (Computer Aided Design) to
decide the shape of the vehicle body and various parts. We then run simulations from various
viewpoints to check whether the car will work properly in that shape, and to check the strength of
parts and the impact of heat, etc.

Wah! There’s strings coming off the car!

Hahaha. Those aren’t strings. We’re simulating
the flow of the air around the car when it’s
moving. The wind whirls around in a whirlwind
behind the car after it passes.

This is a simulation of a touch panel for

a car navigation system. We’re testing
to see how the force of a person
Data provided by: Advantage CFD
pressing the screen will affect the panel.

Repeating these kinds of virtual experiments (i.e. simulations) allows us to rectify (fix) the
problems that we identify before the prototyping stage. In this way, we can shorten the time
between discovering the problem and finding a solution, and reduce the number of prototypes
we need to actually build.

4. Prototyping & Testing

After conducting many simulations and fixing various faults
and problems, we build a prototype (a test version of the
car) and test it under actual driving conditions. Finally, we
actually drive the prototype around a test course.
What happens if you find a problem at this stage?
That’s a good question! If that happens, we have to go
back to the drawing board to check what was wrong with
the design and then make another prototype. This takes
more time, effort and money. Simulations also play an
important part in avoiding that.
Once we make a prototype and test it, we can collect various kinds of data. We use the
data to check if our simulations were correct, or if there is a disparity (difference)
between the simulations and the actual test results. If there is, we think about why, and
come up with ways of ensuring that we can run more accurate simulations for the next
product that we design.

5. Assembly & Production ⇒ Sale

We prepare for production by thinking
about the order in which we will assemble
the various parts, and about the slight
differences in sizes and positions of parts
that will inevitably occur.
We even have software that calculates and
tells us just how wide a margin of error is
acceptable! 5
 4. Review: Manufacturing & CAE
What is CAE?
CAE is a technology that enables us to reduce the number of prototypes and tests
required to predict and resolve various problems (from various different directions) in
manufacturing a product by running simulated (i.e. virtual) experiments and tests on a
computer and analyzing the results.

By using CAE we can…

1. Check how a product will move/work before we build a prototype
2. Eliminate problems at an early stage in the design process and improve quality
CAE is also
CAE: environmentally friendly!
Enables new products to be launched
onto the market at an early-stage
Reduces prototyping and testing costs
Lets us handle simulations for products
for which it is difficult to build a prototype
Performs where high-precision product
design is demanded
Is essential where particular attention is
being focused on safety

CAE is a “trump card” that has revolutionized processes

like R&D, design, manufacture and maintenance; and
caters to the diversifying and increasingly sophisticated
needs of customers.

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5. Benefits of introducing CAE
Mazda succeeds in development of high economical engine
making full use of CAE for SKYACTIV Technology
development
Source: Nikkan Kogyo Shimbun, p26, 2014/10/17

Mitsubishi Heavy Industries shortens time taken for analysis

in development of gas turbines, etc., (which took around 30
days 5 years ago) to half a day
Source: Nikkan Kogyo Shimbun, p6, 2015/4/7

Asics shortens development times by utilizing CAE in

development of soles for running shoes
Source: Nikkan Kogyo Shimbun, p5, 2015/4/27

Konica Minolta shortens time taken for inspection / validation

in the development of commercial printers (that originally took
3 months) down to 1~2 days
Source: Nikkan Kogyo Shimbun, p5, 2015/6/29

Nissan and Osaka Prefecture University shorten time taken

between analysis of welding conditions for steel sheets of
vehicle body and actual production line application to around
1/6 of the original time taken
Source: Nikkan Kogyo Shimbun, p8, 2016/1/22

JAXA and partners reduce noise on airplanes by analyzing

airflow and the shape of main wing and fuselage /
undercarriage parts of aircraft
Source: Nikkan Kogyo Shimbun, p5, 2016/4/12
So CAE isn’t only used in making things like robots and cars…It’s even used in
making shoes!

It can even be used to do things like analyzing the movement of air when a soccer
ball is flying through the air, and simulating how the ball will move when it is kicked.
It’s also used in the development of things like the printers you use at school, in
thinking of the shape of plastic PET bottles to make them easy to crush. Actually,
CAE technology is used in making lots of familiar things around us.

Pressure Flow
distribution lines

Image provided by: Dyson Ltd.

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 6. Industries in which CAE is used
Let’s take a more detailed look at what kind of industries CAE is used in. I
wonder what industries you’d like to know more about, Taro… If there are any
that interest you, why don’t you check them out on the Internet!
http://www.cybernet.co.jp/english/products/cae/field/

Automotive Aerospace Electronics

Energy & environment

Industrial machinery Chemical & materials

Construction & civil Healthcare & foods

Shipping & maritime engineering

Sports CAE education & Production technology

promotion

CAE really is used in all kinds of different places, isn’t it?!

I want to know even more about it now!
It makes me really happy to hear that.
OK, let’s take a look at a few more real-life examples.

■ Robots ■ Pharmaceuticals
This is an example from Waseda University. This
robot is controlled using a simulation of the
movements made by a human tongue when
playing a flute, created using a piece of 1D CAE
software called Maple.
This research laboratory also develops other
robots, including a “jaw robot” that doctors can This is a simulation of how drops of eye
use for practicing surgery on a human jaw. medicine fall from the bottle when it is
“Flute-playing Robot” squeezed…because there would be problems
Photo provided by: Takanishi Laboratory, Waseda University if it all came running out at once!

■ Luxury Cruise Ships ■ Smartphones

This example is for the design
of a luxury cruise ship. Based
on the shape of the ship (CAD
design), CAE is used to check
how the ship will deform
(change shape) when the force
of the ocean waves are applied
to it, and what problems seem This example is a simulation for the built-in
likely to occur. antenna inside a smartphone. It’s good if
we can check that there is no negative
effect on human users using a simulation,
Example: German cruise ship builder Jos. L. Meyer GmbH & Co.
isn’t it!
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7. CAE has many specialist fields!
It gets a bit difficult from here. In many cases, the CAE software used differs
between different specialist fields. Let’s take a look at what kind of specialist
areas there are.

Software: mainly ANSYS (an ANSYS Inc. product)

MCAE
MCAE is short for Mechanical CAE. Mechanical means “relating to machines or
physical (dynamic) forces.”
This group of software applications is used mainly after the shape of the product
has been decided to a certain degree, and the CAD design has been completed.
The eye-dropper, luxury cruise ship and internal smartphone antenna examples
shown on the previous page are example applications of ANSYS Inc. software.

In reality, MCAE is subdivided further into fields such as heat analysis, fluid analysis and acoustic analysis. If you
would like to know more about these, look them up on the internet.
http://www.cybernet.co.jp/ansys/case/

Optical Design Software: Mainly CODE V, LightTools and other Synopsys products

These pieces of software are used to simulate the way in which light
progresses (i.e. moves through different objects and media), and are used to
design things such as lenses (for products such as cameras and machines for
manufacturing semiconductors), LED lights and other lighting fixtures, and
backlights such as those used in LCD displays (lights shone behind displays to
make the screen appear brighter).
They are also used in designing things like radars, and lights used in cars.

EDA Software: Mainly HyperLynx and other Mentor Graphics products

Taro, I wonder if you’ve already studied about how electricity works?

EDA stands for Electronic Design Automation. These software
applications are used in automating the design of electronic devices
and things like semiconductors.
They allow us to design electronic circuits and printed circuit boards
so that they will work as designed, and to run simulations to check
that they will actually work properly as intended. It might be a bit
difficult for you to understand yet Taro…

1D CAE (MBD) Software: Maplesoft products (Cybernet group development)

1D CAE software allows us to perform mathematical calculations to

check whether or not products will perform as expected, during the first
stages of the design, before the shape of the product has even been
decided. I wonder if you remember… If we say it in terms of the software
used at the company where I work, it corresponds to software such as
Maple and the MapleSim software that we use together with it.
Maple is a piece of STEM (Science, Technology, Engineering, and
Mathematics) software. MapleSim is used for the MBD (Model Based
Design) processes used in the automotive industry, so it is also
sometimes called MBD software.
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 More accurate simulations that consider various specialist fields
together, at the same time

8. Multi-domain* Solutions
*”Multi-domain” means an analysis domain that bridges multiple domains, such as heat/thermal analysis and light/optical analysis.
CAE software is very specialized, so software types are divided between different fields (domains),
such as those used in light/optical, heat/thermal and sound/acoustic analysis. But in reality, multiple
phenomena like these occur and interact with one another, so in order to carry out more realistic
simulations that are closer to actual real-world conditions we need to combine multiple pieces of
specialist software. On the other hand, combining different pieces of specialist software that are
used to analyze different physical phenomena—for which the various software developers who
produce and sell them are different, and for which the units of measurement also differ—is said to
be very difficult.
Using its strengths as a company that has been dealing in CAE software for various different
domains for over 30 years, Cybernet has developed a method for achieving overall simulations by
weaving together different pieces of specialist software. We call these “multi-domain solutions.”

Case study 1: Lens design (heat and light)

Problem Lens design and structural design are developed through simulations, using optical tools and MCAE
tools, respectively. Even though the design seems to perform as intended during simulations, the
prototype didn’t work as it should…
Cause The cause of the problem was that the plastic lens warped due to the heat of the light source, distorting
the shape of the lens.

Proposal

Typically, optical, MCAE (structural) and MCAE

(thermal) elements are analyzed separately,
using separate tools. We proposed linking these
separate tools together using the Cybernet-
developed software Optimus and running an
integrated, overall simulation.

Case study 2: Oscillations and sound in cars

Problem We wanted to reduce the rattling noise produced while a car is moving, but first of all we wanted to
begin by investigating which part of the car we need to fix to reduce the noise…

Proposal
We ran various simulations from various aspects to investigate the properties of sound sources
(oscillations from the tires and suspension) and different materials used in the car body and tires, etc.,
and combined acoustic and oscillation analysis tools to achieve an oscillation-to-sound simulation.

Techniques for
Techniques for analyzing Techniques for
analyzing sound
materials with different material analyzing the
and oscillations
properties simultaneously whole system
simultaneously

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 9. Summary: Things that can be done
with CAE & things that we can do
because we are Cybernet
Issue/Problem
1. Cost reduction:
Measures for improving
competitiveness of prices and
increasing profits
2. Shortening time taken:
Manufacturers that launch their
products onto the market at an
earlier stage enjoy greater
profits/revenues
3. Making environments that are
difficult to test in real life
testable/verifiable by virtual
simulation
Issue/Problem
4. Performance, quality and cost
improvement:
Measures for seeking to differentiate
from competitors by adding additional
value to products
Solutions using CAE
(1) Reduce number of prototypes
In the case of cars, prototyping costs for one vehicle model are
over 1 billion yen.
(2) Reduce the number of tests/experiments
In the case of cars, one collision test costs over 100 million yen.
(1) Shorten testing times
• One example is rusting experiments (where actual real-life
testing) would take too long. CAE simulations cut 10 years down
to one day
• Tests for fatigue due to long-term use can also be carried out in
the space of a few hours
(2) Shorten development times (see page 7)
(1) Simulations under extreme environmental conditions, such as
in space, ultra-fine/nanoscale environments, ultra-low and
ultra-high temperature, in high vacuums, etc.
(2) Analysis of dangerous phenomena, such as collisions and falls
Cybernet’s unique solutions using multi-
domain solutions
Simulation by multi-domain simulations that analyze according
to the actual phenomena are indispensable.
(1) Solving noise problems inside cars and other vehicles
• 1D CAE analysis, acoustic analysis, ANSYS
(2) Batteries for hybrid vehicles
• Optimization analysis of engine and battery
performance by 1D CAE
• Chemical cell property analysis (numerical formula
processing), thermal analysis and vehicle fuel
economy (1D CAE) analysis for maximal optimization
of batteries
(3) Advanced driving support systems
• Optical analysis and control design technology for
designing headlights that shine in the direction of
motion, even around curves
• Optical analysis for creating digital meters
(speedometers, etc.), navigational displays and HUDs
(heads up displays) that are easy to see and
unaffected by ambient brightness
• Thermal, oscillation, electrical noise and materials
analysis for designing ECUs and light harnesses that
can perform even in cars undergoing heavy vibrations
and high temperature conditions
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 CYBERNET SYSTEMS CO.,LTD.
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Address: Fuji Soft Bldg., 3, Kanda Neribei-cho, Chiyoda-ku, Tokyo 101-0022, Japan
TEL: +81-3-5297-3066
FAX: +81-3-5297-3609
E-mail: irquery@cybernet.co.jp
URL: http://www.cybernet.co.jp/english

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