Travel Trailer Analysis in ANSYS Discovery

ANSYS Discovery is a wonderful tool for fast and first look structural, fluid flow, and thermal simulations. Discovery gives us the ability to modify geometry very quickly within the interface and to add or remove features to view realtime simulation reactions. This allows us to quickly iterate, explore design changes, and better understand interaction between our design and the environment. Today we are going to be investigating the pressure profile on the exterior of a travel trailer being pulled behind a truck down the highway.

Truck and Trailer with velocity streamlines

In this analysis we are using a 2018 Chevy Silverado 2500 model pulled from GrabCAD with a generic 25 foot travel trailer. Based on described experience we’ve noticed that the roof and sidewalls of a moderately sized travel trailer seem to bow outwards at highway speeds near the front of the trailer.

The first thing to do is to put this model in an enclosure and prescribe a flow condition at the inlet and a pressure boundary at the outlet. Modeling the truck/trailer combo at a speed of ~55 mph (25 m/s) confirms that there is suction (negative pressure) present in these key areas:

Negative Pressure: Truck and Trailer in 25 m/s airflow, -500 Pa isosurface

While the actual roof and sidewall separating could be attributed to poor manufacturing processes we wonder if there could be a design change to minimize negative pressure/suction. One idea would be to incorporate some sort of turbulator to break up the laminar flow. I’ve seen turbulator tape in a zig-zag pattern used in aviation for this specific purpose so we’ll try recreating the travel trailer equivalent and see how it goes.

I started with a zig-zag pattern about 4″ tall on top of the trailer to see if I could “pop the bubble”

This did have the intended consequence and it was curious to see how much impact the turbulator on top of the trailer had on the negative pressure at the sidewall of the trailer:

The next thing I wanted to try was moving the turbulator forward or backward to see the effects. Moving the turbulator towards the aft of the vehicle has limited effects but moving it to different locations within the suction “bubble” seems to effect our -500 Pascal isosurface:

This would seem to indicate the presence of a “sweet spot” for turbulator location that merits further research in either the “Analyze” mode within Ansys Discovery or within Ansys Fluent.

Before I hang up my coat I’d like to investigate one alternate design that I’ve seen more often in automotive applications. I’m going to try adding vertical pillars and see how that goes:

We can easily change the height and position of the pillars to see the resultant effects on the pressure isosurface. The pillars also have a significant effect on the suction bubble but I notice that it has less effect on the suction on the sides of the trailer.

Using Discovery we can quickly and easily iterate on designs, get a first-view of the physics, and determine which change or design merits further investigation. In this analysis we can see that there is most definitely a suction profile at the front of a generic travel trailer. If the suction proves damaging we can see that there are several design changes which will help to mitigate this effect.

For more information on ANSYS Discovery please reach out to info@padtinc.com.

If you would like to play with the models themselves, you can download a zip file with all three models here.

Press Release: Ansys Elite Channel Partner and Stratasys Diamond Channel Partner, PADT Announces Jim Sanford as Vice President of Sales & Support

The Sales and Support team at PADT is the group that most of PADT’s customers interface with. They sell world-leading products from Ansys, Stratasys, and Flownex and then provide award-winning support long after the initial purpose. The team has grown over the years and has plans for even more growth. To help make that happen, we are honored to have Jim Sanford join the PADT family as the Vice President of our Sales & Support team.

Many of our customers and partners know Jim from his time with industry leaders Siemens, MSC, Dassault Systems, and NextLabs, Inc. He brings that experience and his background as a mechanical engineer before he entered sales, to focus PADT on our next phase of growth. He also fit well in PADT’s culture of customer focused, technical driven sales and support.

Our customers have a choice of who they purchase their Ansys multiphysics simulation, Stratasys 3D Printers, and Flownex system simulation software from, and who delivers their frontline support. We know with Jim leading the team, even more companies will make the choice to be part of the PADT family.

The official press release has more details, and can be found at these links or in the test below.

Press Release: PDF | HTML

Want to have a conversation about your Simulation or 3D Printing situation? Contact PADT now and one of our profesionals will be happy to help.


Ansys Elite Channel Partner and Stratasys Diamond Channel Partner, PADT Announces Jim Sanford as Vice President of Sales & Support

Sanford Brings a Wide Range of High-Profile Leadership Experience Across Technology and Aerospace and Defense Sectors to his New Position

TEMPE, Ariz., February 11, 2021 PADT, a globally recognized provider of numerical simulation, product development, and 3D printing products and services, today announced the addition of Jim Sanford as vice president of the company’s Sales & Support department. In his new position, Sanford is responsible for leading the increase of sales and customer support for a range of best-in-class simulation and additive manufacturing solutions. Sanford reports to Ward Rand, co-founder and principal, PADT.

“In the last few years, PADT has expanded across the Southwest, adding new expertise and technologies to our product and service offerings,” said Rand. “Jim is a valuable addition to the team and will be instrumental in sustaining PADT’s growth across the region. His leadership, experience, and knowledge of the industry will allow us to increase the pace of expansion and bring our solutions to serve new and existing customers in deeper and more impactful ways to their businesses.”

After a comprehensive search, Sanford proved to be the most experienced and capable leader to take on the vice president role. He will focus on providing visionary guidance, strategy, and tactical direction to the department. His responsibilities include refining the company’s sales team structure, recruiting, hiring, training, managing for profitable growth, and leading the support team to ensure an optimal customer experience for their use of Ansys, Stratasys, and Flownex products.

Prior to joining PADT, Sanford held business development and engineering positions in a diverse range of aerospace and defense, modeling and simulation, and software companies. His 30-year career span includes executive leadership roles at Siemens, MSC, and Dassault. Most recently he served as the VP for NextLabs Inc., a leading provider of policy-driven information risk management software for large enterprises, and the VP of Business Development for Long Range Services, where he was engaged in the development and testing of various classified items for the U.S. Department of Defense. He holds a bachelor’s degree in Mechanical Engineering from the University of Arizona, with emphasis in materials science and physics.

“PADT is a well-respected brand well-known for its product knowledge, customer-centric approach, and expertise,” said Sanford. “My career has been defined by my ability to take technology-focused companies to the next level of success, and I’m thrilled to join PADT and help continue its expansion by supporting highly innovative customers.”

PADT currently sells and supports the entire Ansys product line in Arizona, California, Colorado, Nevada, New Mexico, Texas, and Utah as an Ansys Elite Channel Partner. They also represent all Stratasys products in Arizona, Colorado, New Mexico, Texas, and Utah as a Diamond Channel Partner and are the North American distributor for Flownex.

To learn more about Sanford and PADT’s products and services, please visit https://www.padtinc.com/products/

About PADT

PADT is an engineering product and services company that focuses on helping customers who develop physical products by providing Numerical Simulation, Product Development, and 3D Printing solutions. PADT’s worldwide reputation for technical excellence and experienced staff is based on its proven record of building long-term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because “We Make Innovation Work.” With over 90 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, Austin, Texas, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at www.PADTINC.com.

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Optimizing Electronics Reliability with Ansys Sherlock – Webinar

Ansys Sherlock automated design analysis software is the only Reliability Physics/Physics of Failure (PoF)-based electronics design analysis software that provides fast and accurate life predictions for electronic hardware at the component, board and system levels in early design stages. A unique, powerful capability of Sherlock is its revolutionary ability to rapidly convert electronic CAD (ECAD) files into CFD and FEA models with accurate geometries and material properties.

Through its powerful parsing engine and embedded libraries containing over 500,000 parts, Sherlock reduces pre-processing time from days to minutes and automates workflows through its integration with Ansys Icepak, Ansys Mechanical and Ansys Workbench.

With its extensive parts/materials libraries, Sherlock automatically identifies your files and imports your parts list, then builds an FEA model of your circuit board in minutes. It also produces a holistic analysis that is critical to developing reliable electronics products. It enables designers to simulate each environment, failure mechanism and assembly that a product might encounter over its lifespan.

Join PADT’s Systems Application & Support Engineer Josh Stout for an introduction to this powerful tool along with a look at what new features and updates have been added in the Ansys 2020 R2 version.

Register Here

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5 questions we ask before preparing a CFD consulting quote

This post was created based on the expert advice of PADT CFD engineer and Project Lead, Nathan Huber.

Simulating the behavior of liquids and gases has become a standard part of product development in products where fluid behavior plays an important role.  Here at PADT, we have been using Computational Fluid Dynamics, or CFD, for years to model everything from combustion in turbine engines to cooling of electronics, to golf balls. With that experience, our estimates for a given project have become reasonably accurate.

However, we can only estimate accurately if we have complete and accurate information on what you need simulated and what you hope to gain from the simulation. To help everyone arrive at more accurate cost and schedule estimates, even if you are planning a project internally, we offer the following list of five questions we always ask:

1: Have we signed a Non-Disclosure Agreement (NDA)?

Before we can do anything, we need to have an agreement in place that clearly defines how both sides handle proprietary information.  When we have tried holding meetings to gather information for a quote before an NDA is in place, we almost always waste time. There is just too much that is proprietary in most products.

2. What does your CAD Geometry look like?

We also need to know the physical geometry of your system.  That is why we ask for an accurate and complete CAD model.  We take some time to poke through the files in our software to make sure we can use the geometry, it is accurate, and it has the level of detail required for CFD. Basically, we check to see if we can pull a fluid domain from your CAD models. Remember, we are not simulating the solid part of your product; we are modeling the inverse and therefore need to pull a negative volume from your geometry.

3. What are the Boundary Conditions and Material Properties?

Now that the geometric domain is understood, we need to know what is inside that domain, and what is acting upon it.  We will ask you for boundary conditions, and for the material properties of the fluid or fluids you are asking us to model.  The complexity, time variation, and severity of the loads drive the difficulty of setting up and running the simulation. And the material properties can also impact the sophistication of the model as well as its robustness.  Both, therefore, have a significant impact on cost.

4. What results do you want to see?

When a simulation finishes, it can be post-processed to get a vast array of plots, figures, animations, pretty pictures, etc.  Those take time to create, so we need to know what you want to see. Also, we set up some post-processing parameters before we start the simulation.

5. What do you want to learn from your CFD Simulation?

The whole point of doing a CFD simulation is to study the behavior of your system. We need to know what behavior you need to understand so we can make sure that the simulation we propose answers your questions and guides you in your design process. 


We hope you find this review useful when you are planning your internal CFD project as well as those you outsource. And speaking of outsourcing, please consider PADT as your resources for any future simulation projects of any type, not just CFD.  Now, you already know what questions we will ask.

Designing Better Rocket Engines with Ansys – Webinar

In 2017 Colorado based company Ursa Major Technologies put together an expert team of designers and engineers to realize its vision of providing the microsatellite industry with the best rocket engines in the business. Utilizing Ansys simulation software, additive manufacturing, and modernizing staged combustion, the company successfully designed and built two liquid oxygen and kerosene engines and has a third engine in development.

With Ansys, Ursa Major Technologies is accomplishing design goals faster and more efficiently than ever before. Using Finite Element Analysis (FEA), the company can run models with 30-40 unique parts to analyze entire turbo pumps in one simulation. Thrust analysis, which the company had previously done with 2D models, can now be done all in the Ansys CFX tool more cost-effectively.

Join PADT and Ursa Major Technologies for a brief overview of applications for Ansys in the aerospace industry, followed by an exploration of how they are using these simulation tools to better design and optimize the next generation of rocket engines.

Register Here

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You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!

Fluent Updates in ANSYS 2020 R1 – Webinar

Computational fluid dynamics (CFD) can be challenging for a multitude of reasons, but not with ANSYS Fluent. Anyone can get great CFD simulation results with ANSYS solutions. Fluent software contains the broad, physical modeling capabilities needed to model flow, turbulence, heat transfer and reactions for industrial applications. These range from air flow over an aircraft wing to combustion in a furnace, from bubble columns to oil platforms, from blood flow to semiconductor manufacturing and from clean room design to wastewater treatment plants.

Fluent spans an expansive range, including special models, with capabilities to model in-cylinder combustion, aero-acoustics, turbomachinery and multiphase systems. The latest innovations and updates simplify and speed setup and meshing while adding even more accurate physical models. The outcome: great results, without compromise.

Join PADT’s Senior CFD & FEA Application Engineer, Sina Ghods, for a look at what’s new and improved in this latest version of ANSYS Fluent, including:

  • User Interface/Graphics
  • Meshing Workflows
  • Multi-phase Robustness
  • Solver Enhancements
  • And much more

Register Here

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All Thing ANSYS 054: Talking CFD – Discussion on the Current State of Computational Fluid Dynamics with Robin Knowles

 

Published on: January 13th, 2020
With: Eric Miller & Robin Knowles
Description:  

In this episode we are excited to share an interview done with host and Co-Founder of PADT, Eric Miller and host of the Talking CFD podcast Robin Knowles, regarding the history of PADT’s use of simulation technology as a whole, and the current state of all things CFD.

If you would like to hear more of Robin’s interviews with various other CFD based companies both small and large, you can listen at https://www.cfdengine.com/podcast/.

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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All Things ANSYS 049: Predicting & Controlling Environmental Pollution with ANSYS Simulation

 

Published on: October 21st, 2019
With: Eric Miller & Clinton Smith
Description:  

In this episode, your host and Co-Founder of PADT, Eric Miller is joined by PADT’s CFD Team Lead Engineer Clinton Smith for a discussion on how ANSYS fluids tools are being used to help predict and control environmental pollution. This information is helping engineers in a variety of ways, such as understanding the formation and dispersion of pollutants such as NOx, SOx, CO and soot.

If you would like to learn more about what this application is capable of, check out our webinar on the topic here: https://www.brighttalk.com/webcast/15747/374571

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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Predicting & Controlling Environmental Pollution with ANSYS Simulation – Webinar

Environmental pollution has been a fact of life for many centuries, though it became a real issue after the start of the industrial revolution. An estimated 6.5 million premature deaths have been linked to air pollution every year.

In order to properly combat this growing issue, the world’s leading minds have turned to a more effective tool for environmental analysis; numerical simulation. Computational fluid dynamics has proven to be a powerful tool when it comes to predicting and controlling air, water, and noise pollution. Saab Bio Power can guide you more to measure and control pollution.

Join PADT’s CFD Team Lead Engineer Clinton Smith to learn how ANSYS fluid mechanics solutions provide insight and detailed understanding of the formation and dispersion of pollutants such as NOx, SOx, CO & Soot as well as effective ways for modelling pollution control equipment such as ESP’s, bag filters, and wastewater treatment plants.

Register Here

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You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!

All Things ANSYS 046: The Founding of CFX

 

Published on: September 9th, 2019
With: Eric Miller, Paul Galpin, & Brad Hutchinson
Description:  

In this episode, your host and Co-Founder of PADT, Eric Miller is joined by Paul Galpin and Brad Hutchinson, two founders of the Computational Fluid Dynamics (CFD) simulation tool now owned by ANSYS, called CFX. They discuss how they initially got into the world of simulation, the current state of CFD, and what is important to be aware of as it continues to grow and develop.

If you would like to learn more about what’s new in the latest version of CFX, check out PADT’s webinar on fluids updates in ANSYS 2019 R3 here: https://www.brighttalk.com/webcast/15747/369903

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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Press Release: PADT Awarded U.S. Army Phase I SBIR Grant for Combustor Geometry Research Using 3D Printing, Simulation, and Product Development

We are pleased to announce that the US Army has awarded PADT a Phase I SBIR Grant to explore novel geometries for combustor cooling holes. This is our 15th SBIR/STTR win.

We are excited about this win because it is a project that combines Additive Manufacturing, CFD and Thermal Simulation, and Design in one project. And to make it even better, the work is being done in conjunction with our largest customer, Honeywell Aerospace.

We look forward to getting started on this first phase where we will explore options and then applying for a larger Phase II grant to conduct more thorough simulation then build and test the options we uncover in this phase.

Read more below. The official press release is here for HTML and here for PDF.

If you have any needs to explore new solutions or new geometries using Additive Manufacturing or applying advanced simulation to drive new and unique designs, please contact us at 480.813.4884 or info@padtinc.com.


PADT Awarded U.S. Army Phase I SBIR Grant for Combustor Geometry Research Using 3D Printing, Simulation, and Product Development

The Project Involves the Development of Sand-Plugging Resistant Metallic Combustor Liners

TEMPE, Ariz., August 15, 2019 ─ In recognition of its continued excellence and expertise in 3D printing, simulation, and product development, PADT announced today it has been awarded a $107,750 U.S. Army Phase I Small Business Innovation Research (SBIR) grant. With the support of Honeywell Aerospace, PADT’s research will focus on the development of gas turbine engine combustor liners that are resistant to being clogged with sand.  The purpose of this research is to reduce downtime and improve the readiness of the U.S. Army’s critical helicopters operating in remote locations where dirt and sand can enter their engines.  

“PADT has supported advanced research in a wide variety of fields which have centered around various applications of our services,” said Eric Miller, co-founder and principal, PADT. “We’re especially proud of this award because it requires the use of our three main areas of expertise, 3D printing, simulation and product development. Our team is uniquely capable of combining these three disciplines to develop a novel solution to a problem that impacts the readiness of our armed forces.”

The challenge PADT will be solving is when helicopters are exposed to environments with high concentrations of dust, they can accumulate micro-particles in the engine that clog the metal liner of the engine’s combustor. Combustors are where fuel is burned to produce heat that powers the gas turbine engine. To cool the combustor, thousands of small holes are drilled in the wall, or liner, and cooling air is forced through them. If these holes become blocked, the combustor overheats and can be damaged.  Blockage can only be remedied by taking the engine apart to replace the combustor. These repairs cause long-term downtime and significantly reduce readiness of the Army’s fleets.

PADT will design various cooling hole geometries and simulate how susceptible they are to clogging using advanced computational fluid dynamics (CFD) simulation tools. Once the most-promising designs have been identified through simulation, sample coupons will be metal 3D printed and sent to a test facility to verify their effectiveness.  Additionally, PADT will experiment with ceramic coating processes on the test coupons to determine the best way to thermally protect the 3D printed geometries.

“When we developed new shapes for holes in the past, we had no way to make them using traditional manufacturing,” said Sina Ghods, principal investigator, PADT. “The application of metal additive manufacturing gives PADT an opportunity to create shapes we could never consider to solve a complex challenge for the U.S. Army. It also gives us a chance to demonstrate the innovation and growth of the 3D printing industry and its applications for harsh, real-world environments.”

Honeywell joined PADT to support this research because it is well aligned with the company’s Gas Turbine Engine products. The outcome of this research has the potential to significantly improve the performance of the company’s engines operating in regions with high dust concentrations.

This will be PADT’s 15th SBIR/Small Business Technology Transfer (STTR) award since the company was founded in 1994. In August 2018, the company, in partnership with Arizona State University, was awarded a $127,000 STTR Phase I Grant from NASA to accelerate biomimicry research, the study of 3D printing objects that resemble strong and light structures found in nature such as honeycombs or bamboo.

To learn more about PADT and its advanced capabilities, please visit www.padtinc.com.

About Phoenix Analysis and Design Technologies

Phoenix Analysis and Design Technologies, Inc. (PADT) is an engineering product and services company that focuses on helping customers who develop physical products by providing Numerical Simulation, Product Development, and 3D Printing solutions. PADT’s worldwide reputation for technical excellence and experienced staff is based on its proven record of building long-term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because “We Make Innovation Work.” With over 80 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, Austin, Texas, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at www.PADTINC.com.

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All Things ANSYS 040: Live From the 2019 ASME Turbo Expo – CFD Applications for Turbomachinery

 

Published on: July 1st, 2019
With: Eric Miller, Robin Steed of ANSYS, & Chris Robinson of PCA Engineers Limited
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by ANSYS CFX & Turbo Tools Lead Technical Product Manager Robin Steed, and Managing Director at PCA Engineers Limited, Chris Robinson, live at the 2019 ASME Turbo Expo in Phoenix Arizona, for a discussion on the past, present, and future of ANSYS CFD and its use in the realm of turbomachinery. Both Robin and Chris have multiple years of experience working in this industry, and their expertise provided some fascinating insight into what this tool is all about.

If you would like to learn more about what’s available in the latest CFD update check out PADT’s webinar on Fluids Updates in ANSYS 2019 R2 here: https://bit.ly/2J6l5We

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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All Things ANSYS 039: Updates for Design Engineers in ANSYS 2019 R2

 

Published on: June 17th, 2019
With: Eric Miller, Ted Harris, & Tom Chadwick
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by PADT’s Simulation Support Manager Ted Harris, and Senior CFD Engineer Tom Chadwick for a discussion on what new capabilities (beta or otherwise) are available for design engineers in the latest updates made to Discovery Live in ANSYS 2019 R2.

If you would like to learn more about this update and see the tool in action, along with others in the 3D Design family of products (Discovery AIM, SpaceClaim & Live) check out PADT’s webinar on the topic here: https://bit.ly/2KfO0tK

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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Fluids Updates in ANSYS 2019 R2 – Webinar

ANSYS CFD goes beyond qualitative results to deliver accurate quantitative predictions of fluid interactions and trade-offs. These insights reveal unexpected opportunities for your product — opportunities that even experienced engineering analysts can miss.

Products such as ANSYS Fluent, Polyflow, and CFX work together in a constantly improving tool kit that is developed to provide ease of use improvements for engineers simulating fluid flows and it’s impacts on physical models.

Join PADT’s Simulation Support and Application Engineer, Sina Ghods, for a look at what is new and improved for fluids-related tools in ANSYS 2019 R2. This presentation includes updates regarding:

A new fluent experience

Parallel Mosaic-enabled meshing

Discrete Phase Modeling

Creating high-quality meshes for complex models

Transient elasticity for fluid structure interaction

And much more

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Optimize Product Performance with ANSYS Digital Twins – Webinar

Engineering simulation has traditionally been used for new product design and virtual testing, eliminating the need to build multiple prototypes prior to product launch.

Now, with the emergence of the Industrial Internet of Things (IIoT), simulation is expanding into operations. The IIoT enables engineers to communicate with sensors and actuators on an operating product to capture data and monitor operating parameters. The result is a digital twin of the physical product or process that can be used to monitor real-time prescriptive analytics and test predictive maintenance to optimize asset performance.

Join PADT’s Senior Analyst & Lead Software Developer Matt Sutton for an in depth look at how digital twins created using ANSYS simulation tools optimize the operation of devices or systems, save money by reducing unplanned downtime and enable engineers to test solutions virtually before doing physical repairs.

This webinar will include an overview of technical capabilities, packaging for licensing, and updates made with the release of ANSYS 2019 R1.

Register Here

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