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When visionary companies need to know how their world-changing ideas will perform, they close the gap between design and reality with Ansys simulation. For more than 50 years, Ansys software has enabled innovators across industries to push boundaries by using the predictive power of simulation. From sustainable transportation to advanced semiconductors, from satellite systems to life-saving medical devices, the next great leaps in human advancement will be powered by Ansys. 

Take a leap of certainty … with Ansys. 

Dr. Christophe Bianchi

Dr. Christophe Bianchi

Chief Technologist



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16 July 2021


See FISITA Library items from Ansys


Mrs. Bhakti Kalghatgi, Deputy General Manager, TATA MOTORS LTD


Automotive Propulsion systems have seen a great disruption in past few years. The rapid adoption of EV and constant efforts in Fuel cell as the main driver of today’s automobiles has brought a lot of change in the vehicle architecture. Today’s vehicles consist of more complex systems that comparatively would require more rigorous testing. Moreover the constant evolution in the domain asks for accelerated Validation cycles with minimum cost and efforts. Traditional Validation techniques like Physical validation are time consuming and have a large cost associated with them. Though virtual simulation based techniques are prevalent most of them are limited to component level and do not consider interaction within different vehicle subsystems, the controller software and the hardware. An approach to develop an integrated closed loop virtual test environment incorporating system interactions controller behavior and inputs/outputs is explored. The architecture of i-CVT take its inspiration from the actual EV architecture, real component placing and the real system interdependencies on one another. In this approach plant models of physical systems with an appreciable level of fidelity are developed and integrated with respective controller software to mimic the real vehicle interactions and manifest a virtual vehicle environment which can be harnessed for various development and validation activities like i. Capturing the issues in Control Software at much earlier stage of the Software Development V-Cycle ii. Identify the potential design flaws and vehicle limitations before physical prototypes are built. Rigorous research on available testing methods and software for virtualization of automotive components and subsystems was done. Based on which a vehicle virtualization approach was chosen where plant modelling was done using ANSYS and simulations of integrated virtual system was done in MATLAB software. The Virtual Test Environment shall capture the control strategies flaws, hardware limitation. Thus reducing the costly design changes and rework late in development process. A holistic virtual vehicle closed loop environment was developed which is used to validated and identify potential safety issues, controller response w.r.t. issues observed. This reduced the validation lead time associated with physical testing and minimized the number of physical prototypes. Which also reduced the environmental impact of validation activities in the product life cycle. The current project deals with the functionality of EV subsystems and validation of EPT components. Chassis level CAE and CFD simulations can be integrated in the virtual environment to improve existing vehicle dynamics models and validate the same. This paper is focusing on building a flexible virtual testing environment that can be easily modified to validate different vehicle configurations to reduce validation efforts in product development life cycle.

FISITA World Congress 2023




Development of an Integrated Closed Loop Virtual Test Environment (i-CVT) for Electric Vehicle, FWC2023-DGT-009, FISITA World Congress 2023


Paper + Video

Mr. SWAPNIL KUMAR, Additive Manufacturing Institute of Science and Technology, University of Louisville, UNITED STATES
Dr. Sundar V Atre, University of Louisville, UNITED STATES


Analysis of brake disc is carried out to depict the nature of Braking behavior with respect to bump, Analysis of brake disc is carried out to depict the behavior of the braking system with respect to bump, droop in endurance, maneuverability, hill Climb & acceleration. Design calculation and analysis have been carried out for the brake disc and subsequently, design calculations have also been carried out for the brake caliper. Structural, thermal, vibrational, computational fluid dynamics and fatigue analysis has been carried out to optimize and validate the performance of disc brakes. The design of experiments has been carried out for the brake disc in order to optimize the performance of the braking system. Ventilated disc brake with an outer diameter of 175 mm has been used and 83 % performance efficiency is achieved after all the proper validations and analysis. Very fine Meshing has been considered for analyzing the disc brake to obtain maximum efficient results. Stainless Steel (SS-410) Material configuration has been considered for disc brake and performance enhancement of ventilated disc brake is carried out using Matlab, Ansys, and Solidworks. The brake disc is going to be deployed as a common brake disc in the rear part of the ATV responsible for providing effective rear wheel locking. Piaggio double piston fixed calipers have satisfied the piston diameter for wheel locking conditions at rear wheels with DOT-4 Brake fluid in the master cylinder to provide effective braking. The rear disc brake was fixed on the gearbox output shaft and a caliper mount is welded on a rear member of the roll cage. A mathematical model has been generated for carrying out Multi-objective genetic algorithm optimization. The newly designed brake disc is optimum in terms of weight, a factor of safety, thermal dissipation, equivalent stress, vibration with enhanced airflow behavior. Converged residual plots have been obtained in computational fluid dynamics simulation by using 2nd-degree order. In order to meet the frequency of rear disc brake to firing frequency of engine, brake disc has been optimized in terms of vibration considering all the parameters.

FISITA World Congress 2021

ADM - Advanced Vehicle Driveline and Energy Management



Design and optimization of brake disc using Multi-Objective genetic algorithm, F2020-ADM-071, FISITA World Congress 2021




Mr. Swapnil Kumar, University of Louisville, UNITED STATES

Dr. Thundil Karuppa Raj Rajagopal, Vellore Institute of Technology, Vellore, INDIA

A braking system is an important system for a vehicle To stop a vehicle, brake torque needs to be delivered

from the brake caliper to the disc brake which eventually stops the rotating wheels The torque produced by

the brake caliper needs to be greater than the torque produced at the wheels and therefore, to develop

efficient design parameters for a brake caliper, vehicle design parameters need to optimize so that optimum

torque can be generated at the wheels from vehicle design calculations Design and analysis of metallic based

brake caliper has been carried for an All-Terrain vehicle using Additive Manufacturing For design modeling,

Solidworks has been used and from the simulation manufacturing aspect, Ansys and Simufact have been

used to analyze the stress, displacement, and surface deviation In addition to that design and performance

optimization has been carried out in Solidworks Ansys, and Simufact respectively Force and Torque

the calculation has been carried out for the brake caliper using Matlab Fine Meshing has been carried out while

analyzing the brake caliper in Ansys and Simuafact for optimum efficiency in results The designed brake

caliper is optimum in terms of weight, cost, and efficiency.

EuroBrake 2021




Design and Development of Brake Caliper using Additive Manufacturing, EB2021-MDS-005, EuroBrake 2021

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