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Engineering blog
How we model composites, crashes, flows and heat, and where machine learning earns its place in the loop. Written by the engineers who run the projects.
When machine-learning surrogate models are worth building for CFD and FEA, how to train and validate them, and how physics-informed methods and uncertainty estimates keep them honest.
How cemented carbide simulation links WC-Co grain size and binder fraction to toughness and crack initiation, pressing and sintering to shrinkage and distortion, and cooling, brazing and coating to residual stress, with surrogates.
How rubber finite element analysis links compound tests to part behaviour: hyperelastic calibration, Mullins softening, volumetric locking, cord layers and belts, tyre contact, heat build-up, crack growth and surrogates.
How composite impact simulation links a drop-tower hit to ply damage, delamination and compression after impact: explicit models, cohesive-zone mesh rules, erosion and mass-scaling pitfalls, rate and heat effects, crush structures and surrogates.
How fibre orientation simulation links injection-moulding flow, skin, shell and core layers and weld lines to structural FEA of short-fibre plastics: tensor mapping, anisotropic stiffness, warpage, creep, crash, fatigue and surrogates over gate and wall thickness.
How discontinuous fiber composite simulation links prepreg chip flow and orientation to cure stress, inter-chip cracking, weld lines and scatter: flow models, orientation mapping, random-chip models, thermoset and thermoplastic matrices, surrogates.
How braided composite simulation links braid angle on a tapered mandrel to unit-cell stiffness, torsion and progressive tube crush: process models, mesoscale cells, crush damage choices, calibration and surrogates.
How woven composite simulation links yarn-level unit cells, crimp and nesting, 3D weave interlaminar behaviour, draping shear and locking, and the mapping of fibre angles into the structural model, with validation, scatter and surrogates.
How composite delamination simulation works for unidirectional laminates: ply-level damage against cohesive zones and XFEM, mixed-mode delamination, mesh and cohesive-length rules, size and ply-thickness effects, coupon calibration, design allowables and surrogates.
How plasma nanoparticle synthesis simulation links the temperature history of the vapour to the size distribution: nucleation, condensation and coagulation in thermal plasma, particle charging and afterglow aggregation in low-pressure plasma, population balance choices, scale-up and surrogates.
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