By SysCAD Techno Solutions | Trusted Global Partner in Automotive Simulation
As automotive technology accelerates toward electrification, lightweighting, and ADAS integration, CAE (Computer-Aided Engineering) and CFD (Computational Fluid Dynamics) have become mission-critical. These simulations minimize the need for physical prototypes, optimize performance, and cut down development cycles—saving millions for OEMs and suppliers worldwide.
At SysCAD Techno Solutions, we deliver high-accuracy CAE & CFD services with deep domain expertise, helping our clients reduce cost, improve safety, and achieve regulatory compliance globally.
What Is CAE in the Automotive Industry?
CAE enables virtual testing and optimization of vehicle components before production. From structural integrity to thermal performance, it supports confident, data-driven engineering.
🔧 Key CAE Capabilities:
- Crashworthiness & Impact Analysis
- 56 km/h frontal impact simulations (as per NCAP)
- Passenger compartment intrusion: ≤ 90 mm
- Peak deceleration: < 30 g
- Chassis Durability & Fatigue Life
- Load cycles: 10⁶ – 10⁸
- Stress limit: ≤ 250 MPa for mild steel
- NVH (Noise, Vibration, Harshness)
- Engine-induced frequency range: 20 – 300 Hz
- Cabin noise during idle: ≤ 65 dB
- Thermal Stress Analysis
- Brake disc heat load: Up to 600°C
- Cylinder head max operating temp: ≤ 250°C
- Topology & Design Optimization
- Material savings: Up to 22% without compromising strength
- Lightweight chassis design for improved fuel efficiency
What Is CFD in Automotive Engineering?
CFD simulates the behavior of fluids and gases, allowing you to refine aerodynamics, cooling systems, and combustion processes without costly testing.
Key CFD Applications:
- Aerodynamics (Drag & Lift Optimization)
- Cd (drag coefficient): Target 0.25 – 0.32
- Cl (lift coefficient): -0.05 to 0.02
- Simulated wind speeds: Up to 140 km/h
- Battery Thermal Management (EVs)
- Safe cell operating range: 20°C – 40°C
- Max temperature gradient: ≤ 5°C
- Liquid cooling velocity: 0.5 – 2 m/s
- Underhood Thermal Simulation
- Radiator inlet air: 90°C – 120°C
- ECU case temp limit: ≤ 85°C
- Fan capacity: 1500–3000 CFM
- Brake Cooling CFD
- Heat flux during braking: 600–800 kW/m²
- Cooling time (400°C to 150°C): < 40 seconds
Advanced Simulation Techniques We Use
- Coupled FEA-CFD multi-physics simulations
- Transient and steady-state flow modeling
- Nonlinear material and contact behavior
- Design optimization via DOE & RSM
- Mesh independence studies with <5% result deviation
- HPC-based solvers for large, complex simulations
We work with industry-leading platforms.
Industry Applications & Results
Passenger Cars
- Crash simulation reduced B-pillar intrusion by 24 mm
- NVH tuning lowered idle cabin noise to 58 dB
Electric Vehicles (EVs)
- Battery cooling simulation eliminated thermal hotspots (↓31%)
- Thermal runaway protection increased reaction time from 6s to 12s
Commercial Vehicles
- Chassis fatigue life improved by 40%
- Brake disc temperature recovery improved by 37%
Motorsport Vehicles
- Aerodynamic optimization reduced drag by 12%
- Engine bay thermal resistance improved using advanced CFD
