V 3 Structural Analysis Zeus Numerix Structural and

V 3 Structural Analysis @ Zeus Numerix Structural and FEM Capabilities at Zeus Numerix for the strategic and industrial sector along with coupled problems Abhishek Jain Build-to-Specifications | Product Approval | Engineering Services | Software Development

Presentation Overview § Zeus Numerix – an Introduction Journey started from engineering services in FEM No 1 Know-Why company for design optimization, failure analysis & build-to-spec products Structural analysis for strategic sector Structural analysis for industrial sector Design and coupled problems § Team and Closure § The presentation is non-confidential and some data may be masked Legends in the presentation are not shown purposefully 16 June 2019 Structural Capabilities @ Zeus Numerix 2 2 © Zeus Numerix Pvt Ltd: Confidential Document § Non-confidential Case studies

1 st Project Completed Large Defense Project 2005 2004 Incubated at IIT Bombay Journey Begins with India’s 1 st Commercial CFD software! Control Software In-house development 2011 CEMILAC Certification 1 st Store Separation project complete 2012 2006 1 st Built-to-Spec project Supersonic ground vehicle developed 2010 2009 Fire Safety & Comfort Building fire and HVAC Parallel GPU code Devp Visualize big data – 4 billion points 2013 2015 2007 2008 CEM Software UAV RCS Reduced 1 st foreign missile project Integration & Certification Floating Panel Design Solar Panels in Lake 16 June 2019 Lockheed Innovation Medal & India Govt R&D Certificate CEM Software 2017 400 th project completed www. zeusnumerix. com/portfolio 2018 1 st MSME TDF Winner D&D of Composite Sea Water Pump Structural Capabilities @ Zeus Numerix 2019 3 3 © Zeus Numerix Pvt Ltd: Confidential Document The Journey 1 st Software Export System design software: Korea

20 -July-2019 Capabilities on Aerospace Systems @ Zeus Numerix 4 4 © Zeus Numerix Pvt Ltd: Confidential Document Accolades

Product Development Product Approval Engineering Services Software Development Initial sizing from first principles Performance estimate by analysis Design calculation reports Pre-processing Automation Detailed analysis based design Detailed Report Generation Analysis – CFD, FEM, CEM Solver development from Literature survey Prototype development Review with approval agency Failure analysis and design suggestions Visualization, parallel code CPU/GPU & GUI Testing and validation Final submission and product approval Multi-disciplinary design optimization System simulation tools 16 June 2019 Structural Capabilities @ Zeus Numerix 5 5 © Zeus Numerix Pvt Ltd: Confidential Document Core Offerings

FEM Capabilities Industrial Sector Design & Coupled 16 June 2019 • Static and dynamic loads • Random vibration, shock load, reliability • MIL 810, JS 5555 load certification • Static and cyclic loads, fatigue • Vibration loads and Campbell curve • Hoops stresses, thermo-structural loads • Coupled CFD+FEM simulations • CFD+FEM+Dynamics of flexible structures • Engineering software development in FEM Structural Capabilities @ Zeus Numerix © Zeus Numerix Pvt Ltd: Confidential Document Strategic Sector Thermal and structural analysis Hypersonic wind tunnel Product verification: Pressure Vessel Von-Mises Stress Plot 6 6

© Zeus Numerix Pvt Ltd: Confidential Document Case Studies: Strategic Sector Non-confidential examples of completed projects in strategic sector 16 June 2019 Structural Capabilities @ Zeus Numerix 7 7

Design of Wire Rope slung system § Certification of wire rope slung system used to lift light weight gun by helicopter Dynamic & fatigue analysis of wire rope for helicopter load factor and wind effect Analysis of positive locking system, hooks etc. found inadequate factor of safety 16 June 2019 Structural Capabilities @ Zeus Numerix 8 8 © Zeus Numerix Pvt Ltd: Confidential Document § Redesign of critical components as per MIL standards

Structural Design & Certification § Shock & Vibration loading on sub-surface vessel Enclosure breakage due to loading § Redesigned – PDR/CDR conducted by DMDE Reliability, multi-body dynamics and fatigue studied 16 June 2019 Structural Capabilities @ Zeus Numerix 9 9 © Zeus Numerix Pvt Ltd: Confidential Document Typical sub-system Multi-body with Fatigue

FEM of Aircraft Armrest to Reduce Weight Complex geometry required cleaning like flushing of rivets and removing holes Material properties assumed linear for various types of lightweight materials Local stresses high at very few places; product approved as safe Bush Pivot Printed Semi Armrest Left Spring CAD 16 June 2019 Fine mesh Structural Capabilities @ Zeus Numerix Stresses 10 10 © Zeus Numerix Pvt Ltd: Confidential Document § Estimate the Limit load for an aircraft armrest assembly

Fatigue Analysis of Jet Engine Test Cell § Augmenter Tube and Blast Bucket Setup Fatigue analysis to estimate the life of test set-up Random vibration to find the natural frequencies Rough Schematic 16 June 2019 Structural Capabilities @ Zeus Numerix 11 11 © Zeus Numerix Pvt Ltd: Confidential Document Acceleration vs. Frequency

Composite Landing Gear § Objective – Concept design of UAV composite landing gear § Only structural perspective taken into account § Main & nose landing gear design follow FAR 23 regulations § Design consideration included one wheel landing Main Landing Gear One Wheel Landing 16 June 2019 Nose Landing Gear Structural Capabilities @ Zeus Numerix 12 12 © Zeus Numerix Pvt Ltd: Confidential Document Stress and deformation

Non-Metal Mechanical Timer: Design Review § Plastic use to prevent detection; design for shock, vibration & drop loading Math model developed to simulate escapement mechanism Calculated torque balance between gear elements to estimate time of operation Pallet-Escape Wheel mechanism 16 June 2019 Stress Distribution on gear teeth Structural Capabilities @ Zeus Numerix 13 13 © Zeus Numerix Pvt Ltd: Confidential Document § FEM failure prediction matches physical observation

Product Approval for Missile Container Secure storage of the missile on the inside using metallic mechanisms External box made of FRP; to sustain drop and vibration load (MIL 210 D & MIL 810 F) Stacking, 12 m drop, air pressure test, lifting hooks & fasteners calculations etc. Design approval after extensive studies and end user review 16 June 2019 Structural Capabilities @ Zeus Numerix 14 14 © Zeus Numerix Pvt Ltd: Confidential Document § Approval of missile storage container for static and vibrational loading

Non-confidential examples of completed projects in Industrial sector 16 June 2019 Structural Capabilities @ Zeus Numerix 15 15 © Zeus Numerix Pvt Ltd: Confidential Document Case Studies: Industrial Sector

Structural Approval of Control Valve § Structural analysis of valve designs ranging from 2” to 12” diameter § FEM based on ASME Section VIII, div 2: Pressure ~ 250 Bar and temperature ~ 300 C Product approval delivered to the customer 16 June 2019 Structural Capabilities @ Zeus Numerix 16 16 © Zeus Numerix Pvt Ltd: Confidential Document

Surge & Stress Analysis for Pump Piping Layout § Surge load in pipes due to pumps stopped, started, switched-over or tripped FEM for the supports and pipes Worst case scenario out of multiple stoppage scenarios found 16 June 2019 Structural Capabilities @ Zeus Numerix 17 17 © Zeus Numerix Pvt Ltd: Confidential Document § ASME Boiler and Pressure Vessel Code, Section III to calculate stresses and reactions

FEM Analysis of Fan Impellers Entire impeller modelled along with the shaft FEM analysis used for design approval of the assembly CAD Model 16 June 2019 Structural Capabilities @ Zeus Numerix Deformation plot 18 18 © Zeus Numerix Pvt Ltd: Confidential Document § Structural analysis of fan impellers at maximum load

Artificial Palm Tree leaves ‘Tree leaves’ found to be breaking under wind load conditions FEM analysis to estimate the fatigue life of the leaves Mesh 16 June 2019 Stress on the leaves Structural Capabilities @ Zeus Numerix 19 19 © Zeus Numerix Pvt Ltd: Confidential Document § Artificial trees installed on communication towers for aesthetic look

FEM of Composite Material Engine Cover § Modal analysis of the engine cover carried out for first 10 mode shapes Analysis showed that stiffness of few panels need to be enhanced Deflection (Y-axis) 16 June 2019 Structural Capabilities @ Zeus Numerix 20 20 © Zeus Numerix Pvt Ltd: Confidential Document § FEM forced due to ‘g’ load; spring force added to gravity

Random Vibration for Automotive Component Modal analysis to find natural frequencies and mode shapes Calculate stresses and deformations under PSD (Power Spectral Density) acceleration input. Fatigue life estimation 16 June 2019 Structural Capabilities @ Zeus Numerix 21 21 © Zeus Numerix Pvt Ltd: Confidential Document § Automotive electronic component faces vibration loads in travel

© Zeus Numerix Pvt Ltd: Confidential Document Case Studies: Special Problems Non-confidential examples of completed projects for coupled problems or software development 16 June 2019 Structural Capabilities @ Zeus Numerix 22 22

Design of Winglet § MDO framework built based on genetic algorithm (GA) Coupled CFD and FEA on computing grid of 256 nodes (2048 cores) 16 June 2019 Structural Capabilities @ Zeus Numerix 23 23 © Zeus Numerix Pvt Ltd: Confidential Document § 14% drag reduction achieved w. r. t. base configuration

Customized Aero Elasticity Analysis Software for Slender Spinning Rockets § Estimation of aero-elastic phenomena of spinning rocket Good comparison with Zeta factor and Q divergence Limited literature on the topic causes validation issues DRDL 16 June 2019 Structural Capabilities @ Zeus Numerix 24 24 © Zeus Numerix Pvt Ltd: Confidential Document § Inter-code comparison with DRDL data

Dynamics of Parachute opening Coupled CFD & FEM for membranes (parachute cloth) Validation with wind tunnel experiment Inflation in Para. Z 16 June 2019 Structural Capabilities @ Zeus Numerix 25 25 © Zeus Numerix Pvt Ltd: Confidential Document § Multidisciplinary software for parachute design ADRDE wind tunnel test Multi-disciplinary Simulation for Parachute

Bullet Resistant Jacket: Custom Software § Effect of multiple bullet impact on jacket § Study of various materials/insertions Custom software delivered to lab for extensive numerical testing of various configurations Software GUI 16 June 2019 Structural Capabilities @ Zeus Numerix 26 26 © Zeus Numerix Pvt Ltd: Confidential Document Bullet penetration animation

Modal & Rigid Body Analysis for Chain Drive § Modal analysis of the chain drive mechanism for structural integrity 16 June 2019 Structural Capabilities @ Zeus Numerix 27 27 © Zeus Numerix Pvt Ltd: Confidential Document § Rigid body analysis of the chain at different RPM and chain tension

Design Modifications of Artillery Recoil System Estimate the forces due to internal ballistics and movement of piston due to recoil Unsteady simulation for pressure & thermal stresses due to fluid and nitrogen compression 20 May 2019 Capabilities on Land Systems @ Zeus Numerix 28 28 © Zeus Numerix Pvt Ltd: Confidential Document § To ascertain the failure of rings and small parts after firing

© Zeus Numerix Pvt Ltd: Confidential Document Team and Closure Details of the team and consultants and summary of presentation 16 June 2019 Structural Capabilities @ Zeus Numerix 29 29

Core Team § Prof Gopal Shevare (Chairman) – Ph. D IIT Bombay with 40+ years research exp Expert in MDO, fluid dynamics, numerical methods and simulation product development § Basant Kumar Gupta (CEO) – Masters IIT Bombay with 16 years experience Expert in preliminary design, project management, and optimization Expert in mesh generation, drawings, product development and vendor management § Sumit Jana (Head – Solver Devp) – Masters IIT Kharagpur with 12 years exp Expert in parallel solver development for CFD, Electromagnetics and free surface flows § Suman Mohandas (Head – Software Devp & Visualization) – Bachelors Computer Expert in new software development, visualization, parallelization and GUI § Ten engineers certified by CEMILAC including above 16 June 2019 Structural Capabilities @ Zeus Numerix 30 30 © Zeus Numerix Pvt Ltd: Confidential Document § Irshad Khan (COO) – Bachelor Mechanical with 22 years experience

Consultants and Collaborations § MOUs and Collaborations Centre for development of advanced computing – HPC usage in Teraflops NIT Nagpur – Joint R&D projects in coupled problems (CFD+FEM) IIITDM – Joint projects of analysis adding to product development Mr. SG Joshi – 40+ years experience in pump design and manufacturing Prof S C Lakkad – 45+ years experience in composite design and manufacturing process Prof K Sinhamahapatra – 20+ years experience in acoustic prediction Mr S Panse and H Ketkar – 35+ year exp in tool room, jigs/fixture design, special projects Mr V Kamat – 40+ years experience in hydraulic machine design, fabrication & maintenance Mr A Patki – 40+ years experience in space systems for reliability and weight reduction 16 June 2019 Structural Capabilities @ Zeus Numerix 31 31 © Zeus Numerix Pvt Ltd: Confidential Document § Expert Panel (partial)

Closure § Experience of 400+ high tech projects in both strategic and industrial sectors Engineers trained in Aerospace grade quality and confidentiality Modular code development with high reusability Experience of parallelization and cloud computing § Domain expertise in aforementioned sectors Contribution by the engineering team enhanced to design suggestions § Flexible engagement model Fixed cost, Time and Material, Cost plus or models as per problem statement § Unafraid to take R&D projects – Test Us 16 June 2019 Structural Capabilities @ Zeus Numerix 32 32 © Zeus Numerix Pvt Ltd: Confidential Document § Robust engineering software development experience

Thank You ! Abhishek Jain +91 98190 09836 abhishek@zeusnumerix. com www. zeusnumerix. com 33