1. Train to Vein – CAE is the Way of Life
My Success Stories in Building Robust Products
Consultancy Services, Bengaluru
Prof. L Ramanan
Researcher & Subject Matter Expert – CAE , DFSS & Medical Devices
By
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2. Acknowledgements
• Sincere Thanks to Leadership of ANSYS, Mr. Kiran,
Mr. Anands, Dr. Bahshyam, many of my friends Mr.
Hans, Mr. Harsha, Mr.Amit, Dr.Ravi,…. both at
ANSYS Inc, & at ANSYS India for the decades of
professional association & Cherished relationship
• Our Customers, Partners, vendors, all of my past
employers - GE, Lucas TVS, Indian Railways, IITM,
Teachers, Mentors, all my professional associations -
ASQ, ASME, QCI, IEI, ASM, IUSSTF, IUCEE, BMSI &
PDMA, Our Partners in Research - Minitab, ANSYS,
my family, relatives & friends across global poles for
the contributions, in my growth as a SME in CAE &
DFSS for Predictive and Robust Design
Note:
• Opinion expressed here are purely that of the author &
only for academic purpose of enhancing knowledge.
No other interpretations are implied or intended or
shall be made. Practical examples picked-up are from
the published / presented work of the author and
others in public domain. They are referenced and
greatly acknowledged, if I missed any in reference I
sincerely apologize and is not intentional –
Ramanan, RAISE

3. 3 /
LRamanan, June 28, 2013Safety - Risk Prediction in Early Stages of Design
Rail Car – Product Touches Life Everyday
• Locomotive Cum Passenger Car
• Challenges – Complicated Structure with
Continuous & Spot Welds, Many thin & thick
Sections, Complex Loading Pattern
• Elements – Combination of Shells, Rigid, Beam,
MPC & Weld
• Upfront Usage in CAE Design
Ref:
1. L Ramanan et. al., (1999) Computer Aided Rail Car Design, Proceedings of the
International Seminar on Manufacturing Technology Beyond 2000,India.
2. L Ramanan et al., (1998) Application of CAD in Rail Roads, Proceedings of 14th
International Conference on CAD – CAM & Factories of the future (1998)
3. L Ramanan et. al., (1999) Designing of a Bogie Bolster of a Rail Coach – A Finite
Element Approach” Proceedings of the 15th ISPE/IEE International Conference on
CAD/CAM, Robotics and Factories of the Future”, Brazil

4. 4 /
LRamanan, June 28, 2013Prediction - In Safety Critical Assembly
Safety Critical Joint Design & Mfg Process
Ref:
1. L Ramanan et. Al (1998) Thermo-Mechanical Analysis of Rail Wheel, Interference Fitting
of Axle into Rail Wheel, Proceedings of IV International Conference on Stress and
Vibration, Organised by NAFEMS, Ireland, Dublin
2. L Ramanan (2006), Simulation of Non-Linear Analysis in ANSYS, ANSYS India Users
Conference
3. L Ramanan et.al, (2008) “Mechanical Joint With Interference Fit For Use in Hand Rail of
Patient Table ” IP Publication IPCOM000169885D
4. L Ramanan (2010) “System and Method of Making Safety Critical X – Ray Tube Anode
Assembly” IPCOM000193550D
5. L Ramanan et. Al (2000) Simulating a Plastic Deformation in ANSYS, ANSYS Solutions
6. L Ramanan et. Al (2001) Non Linear Simulation of Alternator Shaft into Stator Core and
Impacting the Productivity
Interference Assembly of Axle into Rail Wheel
Non Linear Material Model
Safe JointInterference Assembly in X-Ray Tube

5. 5 /
LRamanan, June 28, 2013Prediction in Multiphysics Environment
Coupled-Thermo Mechanical Field Impact & Structural Integrity Flow & Thermal Management
Ref:
1. L Ramanan et. Al., (1998) “Thermo-Mechanical Finite Element Analysis
of A Rail Wheel” in International Journal of Mechanical Sciences.,
Vol41/4-5,pp487-505
2. L. Ramanan. et.Al. Al (1998) “Contact Stress Analysis of A Rail Wheel –
Global-Local Approach – Using ABAQUS Proceedings of the Eleventh
Worldwide ABAQUS Users Conference, pp 585-595
3. L Ramanan et.al, (2008) “Patient Table with Impact Resistant
Mechanism” US Patent 20080060127
4. L Ramanan (2007) “Computer Aided Engineering – An Inevitable
Technology for Bio-Medical Engineering”, National Bio-Medical Medical
Conference., Manipal, India
5. L Ramanan et.al, (2008) “Simulation in Real World”” National
FEA Workshop, VIT University, India
6. L Ramanan, CAE Simulation – An Inspiring Technology in
Medical Device Design , (2008), ANSYS lndia Users Conference
Restrictions to airflow
path in real-life
scenario while
designing a heat sink
Other Physics – Predictive Approach

6. 6 /
LRamanan, June 28, 2013Prediction in Multiple Environments & Products
Simulation of Physics of Behaviour
Predictive Approach – Micro Mechanics & Multibody Dynamics
Rigid & Flexi Body Dynamics
Bearing Bolt Pre-Tension
Interaction of Ball with Return Tube of Ball Screw
Ref:
1. L Ramanan (2010) Design for Six Sigma – An Ingredient to Innovative Product Design, Indo-US
Workshop
2. L Ramanan, (2007) Simulation of O Ring Behaviour Inside the Oil Groove, ANSYS India Users
Conference
3. L Ramanan, (2012) Design of Experiments in Solving Real Life Problems, Indian Machine Tool
Manufacturers Association
4. L Ramanan (2007) Role of Simulation in Predictive Design of Medical Equipment & Devices,
S.Asia CAE Users Conference
5. L Ramanan (2009) Role of Six Sigma in Building Robust Products – Examples from Medical
Devices,, IV International Conference in New Product Development at IITM
6. L Ramanan, (2008) CAE Simulation – An Inspiring Technology in Medical Device Design,
ANSYS lndia Users Conference

7. 7 /
LRamanan, June 28, 2013Prediction in Early Stages of Design
System Level Simulation – Pride in Prediction
Ref:
1. L Ramanan.,(2011) US Patent 2011/0309944, Patient Table System for Medical
System for Medical Applications and Associated Medical Imaging Device
2. L Ramanan (2009)., “One-Dimensional Linear Motion System for Three Dimensional
Translatory Motions” IPCOM000182841D
3. L Ramanan, (2010) “Method of Testing Patient Handling Table Top” IP publication
IPCOM000193362D
4. L Ramanan, (2008) CAE Simulation – An Inspiring
Technology in Medical Device Design, ANSYS lndia Users
Conference
5. L Ramanan, (2008) Design for Six Sigma – Ingredient to
Innovative Product Design, Indo-US Workshop
6. L Ramanan, (2009) Creativity and Innovation in New
Product Development, National Conf., Anna University

8. Prediction for Product Living in the Heart
Challenges Are Huge!!!

9. Summary – Simulation is Way To Live
• Simulation Success is Based on
• How Close we are Modelling Physics
• Assumptions Closer to Reality
• Embracing of Variations
• Adopting Domain Knowledge
• Living Closer to Product & Customer
• Marriage of product functional
knowledge, Domain Expertise,
Statistical & Simulation Expertise.
Value to Product… Value to the Business
Dream to Simulate - Ideas to Virtual Product
Simulate to Produce – Virtual to REALITY

10. 10 /
LRamanan, June 28, 2013
About The Presenter…