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Simulation and visualization in the product life cycle
Application and benefit examples from mechanical and plant engineering

VDMA 2018
60 pages, web service
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Mechanical and plant engineering companies are increasingly using simulation tools. In addition to speeding up product development processes, particular attention is being paid to improving quality and reducing costs in order to further increase customer satisfaction.
Digital simulation in its various forms is becoming an integral part of the product development process (PDP). It is also used in almost all phases of the product life cycle. With the respective technology such as
- the finite element method in design,
- the collision check in work preparation,
- the sequence simulation in production,
- the visualization in virtual commissioning or
- the AR and VR applications in service
, simulation contributes significantly to efficient production.
To accompany this development, the VDMA has founded the working group "Simulation and visualization in the product life cycle". The working group has set itself the goal of motivating small and medium-sized companies in particular to use these technologies. Even in the early stages of product creation - still in digital format - findings from simulation can be incorporated directly into development in order to increase product and manufacturing quality and shorten development times. An additional argument in favor of the introduction of simulation systems is that the effort involved is far less than is often assumed and is also much lower than it used to be.
In its first action, the working group conducted a trend analysis to find out the current status of the use of simulation tools in the product life cycle of mechanical engineering companies. The results of this survey encouraged the creation of this publication with 15 user examples that illustrate the benefits of digital simulation tools in different development phases. In the examples, companies from various sectors describe their experiences with simulation systems and describe the benefits they have gained from using these systems and the savings or improvements they have led to.
The compilation of the articles makes it clear that everyone needs to get to grips with these technologies in order to meet customer requirements, be on time in the market and keep costs and quality under control.


Contents

1 Foreword
2 Introduction
2.1 Simulation and visualization in the product life cycle
2.2 Effects of simulation systems
2.3 Assignment of user examples to PLM phase including brief description of the benefit effects and objectives
3 User reports: Simulation applications in different phases of the product development process and from different industries
3.1 Forestry: Prototype of the company Binderberger in productive use
3.2 Woodworking machines: Digital twins for the Homag Group
3.3 Virtual commissioning: several application examples (anonymized)
3.4 Automotive engineering: rolling bearing modeling in FE simulation at Daimler
3.5 Agricultural engineering: weight, production and complexity reduction at Amazone
3.6 Engine manufacturing: virtual predictive manufacturing at MAN Diesel & Turbo SE Simulation of the machining process
3.7 Engine manufacturing: Error-free production and minimization of set-up times at L'Orange
3.8 Machine tools: Virtual commissioning at Maier Werkzeugmaschinen
3.9 Pharmaceutical industry: Virtual reality in product presentation at Seidenader
3.10 Precision tools: Analysis of the deformation of finely adjustable reamers at Mapal
3.11 Laser beam melting in additive manufacturing at Hirschvogel Automotive
3.12 Elevators: Electromagnetic and structural mechanical design
3.13 Plant engineering/filling technology: simulation of the stack load at Krones
3.14 Automation and system integration: manufacturing simulation at MBFZ toolcraft High-end precision parts with high-speed simulation (interview contribution)
3.15 Synchronization of development and simulation pays off
4 Summary ...
4.1 ... of the survey results
4.2 ... of the user examples Use of simulation tools
Appendix 1: List of employees of the working group