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Tata Motors, a large automotive company in India, has selected PAM-Stamp 2G, ESI’s sheet metal forming simulation suite, to investigate and completely redefine and optimise its oil sump concept.

The main objective was to reduce noise by implementing ‘Silent Steel’ in the new engine oil sumps for upcoming vehicle platforms.

‘Silent Steel’ is a three-ply sandwich material in which two sheets of steel are held together by a layer of polymer.

The resulting material displays inherent advantages in noise-vibration harshness (NVH) characteristics, which are particularly significant in the immediate vicinity of the vehicle engine.

Changing the material to the layered silent steep also meant completely redesigning the part; changing the shape of the oil sump and adopting new stamping tools.

The initial sump design, as conceived by the product designer, needed to be prototyped for validation.

Although the techniques used for prototyping, including heating and hammering blank sheets, provided fairly accurate product geometry, they were not nearly representative of the stamping process that would be implemented later on.

Feasibility could not be assessed and tooling limitations could not be anticipated with the three-ply silent material.

Due to the progress of vehicle development, additional constraints from interfaces and assembly accumulated.

As constraints from the vehicle environment, from tooling and from the material itself were building up, more than 25 different geometry modifications were needed before reaching a satisfactory final design that was good enough to be tried out physically with silent material.

PAM-Stamp 2G’s, complete, integrated, scalable and streamlined stamping solution covering the entire tooling process including quotation and die design with formability and try-out validation, springback prediction and correction, was thus used to validate each design evolution until a defect-free feasible solution was reached.

The first physical prototypes in the stamping tool workshop matched very closely the modelled result.

PAM-Stamp 2G allowed Tata Motors to realise an early resolution of various manufacturing and vehicle-level constraints, leading to a marked reduction in prototyping time and significant gains in time to market.

ESI is a world-leading supplier and pioneer of digital simulation software
for prototyping and manufacturing processes that take into account the
physics of materials.

ESI has developed an extensive suite of coherent, industry-oriented
applications to realistically simulate a product’s behavior during testing,
to fine-tune manufacturing processes in accordance with desired product
performance, and to evaluate the environment’s impact on product

ESI’s products represent a unique collaborative and open environment for
Simulation-Based Design, enabling virtual prototypes to be improved in a
continuous and collaborative manner while eliminating the need for physical
prototypes during product development.

A scalable Simulation-Based Design solution to accelerate innovation

ESI’s End-to-End Virtual Prototyping solutions, including software and
services, allow to manage with remarkable efficiency the virtual prototyping
of industrial products from creation through to end development, to limit
its complexity and risks, resulting in the successful validation of real
prototypes “to get it right at the right time”.

The company employs over 750 high-level specialists worldwide covering more
than 30 countries.

ESI Group is listed in compartment C of NYSE Euronext Paris.

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