TOOLTECH SOFTWARE

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TOOLTECH SOFTWARE (India) Pvt. Ltd. Corporate
Presentation
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Introduction
TOOLTECH GROUP

• Concurrent design solutions in a wide
  spectrum of domain areas
• Automotive, General Engineering, Aerospace,
  Marine Tooling, Oil and Gas
• Clear competencies in Knowledge Management
• European Focus in depth understanding of
  cultural business practices
• Flexible business model
• functionality of a local company offshore
  cost advantage

Among 1st few Asian companies to be selected
as a Tier 1, Offshore Strategic Design
partner by BMW AG
Similar long term Partnerships with
Atlas Copco, Mann
Hummel
Chosen by Aker Yards Finland,
to set up a dedicated facility
for 100 people in India
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TOOLTECH GROUP CORPORATE PROFILE
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Group Structure
Employee Strength Last Year 150 Current Year
270
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Locations
Sweden

Germany
Finland

U.S.A.

Romania

France

India
Tooltech Deutschland GmbH (Germany) Munich
Tooltech Software Bangalore
Tooltech Romania
Tooltech Inc. (USA) Michigan
B2i-Tooltech S.A.S. (France) Paris
Tooltechsoft (Sweden) Göteborg
Tooltech Europe Oy (Finland) Helsinki Turku
Tooltech Software (India) Pune / HQ
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Economics of Outsourcing
Source McKinsey analysis 2002
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Corporate Rationale - India The ITES
Outsourcing Capital of the World
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Head Office Location
Pune Indias foremost Engineering Hub
World Class Telecommunication Infrastructure
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Clients
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Management
Board of Directors

• J.K Khanna, Chairman
• Well established and highly reputed Chartered
  Accountant and Financial Consultant based in
  Bombay, India.
• Atul Khanna, Director and Chief Promoter
• Successful entrepreneur having promoted various
  businesses involving international collaboration
  with Germany, the USA and Sweden. New project in
  Bioinformatics.
• Mr. Vivek Annaswamy, President and Chief Mentor
• Mr. Annaswamy was previously the Head of the
  Passenger Car business of Tata Motors and
  spearheaded its famed turnaround. He has also
  consulted on the Board of Hyundai Motors India.
• Dr. Klaus Faust, Director and Managing Director,
  Tooltech Deutschland GmbH
• Former Senior Executive in the German auto
  industry. Now heads a family concern, Lodenfrey
  GmbH, based in Munich.
• G Dentler, Director
• Recently retired as a Director with a German
  engineering company. Expertise in technology
  transfer.

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Key Personnel

• S. Manivasagam - Head, Engineering
• Graduate in Mechanical Engineering, Post
  Graduate in Engineering Design and Doctorate in
  Mechanical Engineering with 17 years of
  experience in CAE and New Product Development
• of auto components and air conditioner
  compressors.
• V. Ravindra - Manager Operations
• Graduate in Mechanical Engineering with 15 years
  experience in automobile industry
• and project management.
• Pradeep George Manager CAD
• Graduate in Mechanical Engineering with 8 years
  experience in automotive and hydraulic
• components.

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Key Personnel

• Harald Reukauf - Head CAE, Tooltech Deutschland
  GmbH
• Master in Mechanical Engineering from Karlsruhe
  University, Germany with 10 years of experience
  in CAE
• N.B. Srinivas Head, Oil Gas
• Murali Veeravalli Senior Project Manager CAE,
  BMW/Automotive, Tooltech Software (India) Private
  Limited
• BE and M.Tech in Mechanical Engineering with
  more than 13 years of focused CAE experience
• S. Gunaseelan Manager CAE, Tooltech Software
  (India) Private Limited
• ME in Engineering Design and BE in Mechanical
  Engineering with 9 years of experience in
  Research and Development mainly in Pumps industry

B.E. in Civil Engineering over 23 years of rich
experience in Oil and Gas industry of which 22
years was in Oil and Natural Gas Corporation
Limited (ONGC) in India
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Key Personnel

• Anil Talwani - Country Manager Finland
• Graduate in Mechanical Engineering with 12
  years of Marketing experience in sectors
• including industrial, heavy engineering,
  OE, hydraulic components and material handling
• both in India and Germany.
• Abhay Jahirabadkar - Country Manager Sweden
  Graduate in Production Engineering with 9 years
  experience in design and development
• of assembly fixtures, off high way equipments,
  industrial gear boxes and machine
• tool components.
• Kurt Isaksson Senior Advisor, Sweden
• Former president of SAAB Rosemount AB, well
  known for his views on globalization in the
  Swedish industry
• B. V. Patil - Country Manager USA
• Diploma in Tool and Die Making with 10 years
  experience in mold, Tool Design and
  Manufacturing.

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Activities
CAD
CAE
CAM
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CAD Skill Sets
Software Capabilities
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Capabilities CAE
Software Capabilities
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Concurrent Engineering Project Methodology
Assignment of a dedicated team
Assimilation of Clients industry product
expertise
Replication of Client engineering methods and
Quality Standards
Onsite Project Coordinator for seamless
outsourcing project integration
Secure FTP sites for file transfer and online
collaboration.

• Effective Client Communication through
• Teleconferencing
• Collaborative net meetings brain -
• storming sessions
• Email and PowerPoint graphics
• Regular onsite visits / onsite collaboration

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Interaction Example
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Concurrent Engineering Project Methodology
A seamless extension of the Clients design
office without the additional manpower
and infrastructure investment.
The Outcome
Client retains control
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Project Management

• Common Project Management Information System
  (PMIS) for all CAD CAE Projects
• - Common portfolio templates and
  checklists used for new project
• - When required, Client templates and
  checklists used

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Tooltech Competitive Advantages

• Engineering our core competence not an annex
  to software development
• Small, nimble and quick reacting organisational
  structure
• Capital Adequacy
• Regular investment in people, hardware,
  software systems to support necessary ramp ups
• Proven concurrent engineering approach buddy
  system, effective simple
• collaboration methods
• Experience in setting up ramping up dedicated
  teams for diversified Clients
• - Team sizes 2-5 members / 5-10 members /
  10 members
• Project facilitation through local offices in
  the market that we operate in.
• European focus
• - In depth understanding of work, cultural
  business practices

• Atlas Copco

• MannHummel

• BMW AG

• Autoliv B.V. Co. KG

• Aker Yards Finland

Due to non disclosure agreements we are not
permitted to disclose all client names and details
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CASE STUDIES
In accordance with Non disclosure and
Confidentiality agreements, certain Client names
confidential project information are omitted.
All names, information diagrams that follow,
are mentioned with prior permission of the
concerned Client.
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Dedicated India Engineering Facility Client Aker
Yards, Finland

• Tooltech has been chosen by Aker Yards Finland,
  one of the
• worlds largest shipyards, to set up a Dedicated
  Facility
• Ramp up 100 people in 1 year .
• Hulls
• Superstructures
• Engine Rooms
• Machine Drawings
• Current team size 20 people
• Facility Manpower Ramp Up Ahead of Schedule

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CAD

• Current Projects include
• Detail Design Production Drawings of Hull in a
  Ro Ro Vessel
• Software Tribon AutoCAD
• Input
• Classification Drawings of Hull in DWG formats
• Available drawings in Kronodoc
• Project Specifications
• Scope
• Generation of 3D Model of Hull in Tribon
• Approval/Checking of basic hull structure, mainly
  position scantlings
• Detail Design/Modeling of Hull in Tribon
• Approval/checking of production drawings
• Nesting and part list generation
• Output
• Production drawings
• Nesting and part list generation

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Design Manufacture of a VIP Military Helicopter
Interior Client Indian Government Defense
Aeronautical Agency

• Awarded first of its kind full programme
  contract for the design manufacture of a
  World Class VIP Helicopter Interior.
• To be certified to FAR Part 25
• Concept Design, Development, Cabin Noise
  Reduction, Weight Optimisation
• Original design to be led by Tooltech German
  Aircraft Interior Specialist.
• Manufacture (panels, sound insulation, carpets,
  etc) outsourced to a Bangalore based Aero
  Structures Company
• Project management full programme
  responsibility with Tooltech
• Software used Catia V5

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CAD
We partner with MannHummel GmbH, Germany to
design Air Intake Plastic Manifold Assemblies

• Software used ProEngineer
• Creation of a 3D solid Model
• Definition of runner length profile
• Definition of runner cross section considering
  section area
• Definition of Plenum considering volume
• Resolve issues of Tooling Plastic Welding
• Supply of 2D manufacturing drawings

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CAD
We partner with BMW AG for the Design of Various
Interior Exterior Components
Software Used CATIA V4 V5
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CAD
Design of Fabricated Structures Client Atlas
Copco, Sweden
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CAD
Master Model creation of Plywood Manufacturing
Machine Components Client Machine Manufacturer,
Finland
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CAD
Design of Reduction Gear Box Client Marine
Equipment Manufacturer, Norway

• Software used Inventor 10, MathCAD
• Input
• Technical Specifications such as Torque, RPM and
  Space Availability
• Scope
• Designing of 2 stage reduction gear box of 160
  ratio using helical gears.
• MathCAD calculations for AGMA certification.
• Creation of 3D models 2D manufacturing drawings
  with required
• technical details.
• Output
• 3D model of all parts used in Gear Box
• 2D manufacturing drawing with technical
  specifications
• Calculations in MathCAD for certification

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CAE

• Fatigue Analysis of Engine Assembly
• Client Diesel Engine Manufacturer, Finland

• Software Hypermesh, Abaqus, FEMFAT
• FE Modeling
• Crankcase, Bed Plate, Cylinder Head Bolts, Valve
  Seats
• Hexa elements with critical requirements such as
  
• No. of elements over Cylinder Bores
• Mesh pattern around Crankcase Bearing and
  Cylinder Head Bolt Holes
• Diameters of Bolts for precise pre-tension loads
• Mapped meshing (second-order Tetra elements) on
  contact regions of seat and bolts.
• Model size approx. 1 million DOF

• Analysis
• Multi-step and Non-Linear Analysis (consisting of
  assembly loads, firing pressure
• and thermal loads) using Abaqus Standard
• 2-3 load cycles analysed. At the end, FE model
  unloaded in a specific order
• Results imported in FEMFAT for evaluation of low
  cycle and high cycle fatigue
• using Haighs theory for uni-axial and multi-
  axial loads.
• Analysis cycle repeated to achieve desired
  results.

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CAE
Static Buckling Analysis of a Turbine
Casing Client Aero Engine Manufacturer, Germany

• Software used ABAQUS, ABAQUS/CAE, Hypermesh
• FE Modeling of symmetric sector using 2nd order
  brick elements
• Static Analysis
• TIE Contact between casing and bolts
• Gas pressure, vane loads
• Extraction of severe temperature fields from
  Transient Analysis
• Multiple thermal loads
• Modal Analysis
• Hot and cold conditions hot state temperature
  field as preload
• Temperature-dependent properties
• Campbell diagram plots

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CAE

• Elastic Buckling Analysis
• Bending and twisting loads, hot state temperature
  field as preload
• Results in the form of Interaction diagrams
• Plastic Buckling Analysis
• Riks Method of Analysis
• Load Vs. Displacement plots for pre and post
  buckling range

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CAE
Crash Simulation Client BMW AG, Germany

• FE Modeling of following vehicle sub systems
• Body in White
• Drive line assembly (except front and rear axis
  assembly)
• Front and rear bumper assembly.
• Door assembly (excluding interiors)
• Bonnet and front panel assembly.
• Quality criteria for FE Modelling
• Element length 6 - 12 mm, Average 10 mm.
• Warpage lt 15 degrees.
• Quad angle between 40 - 140 degrees.
• Tria Angle between 20 to 120 degrees.
• Percentage of tria. elements lt 5.

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CAE

• Integration of systems
• Creation of spotweld file, with and without
  rupture model for Body in White,Door
• assembly and bumper systems, etc.
• Integration of all systems using NULL shell
  elements and tied contact.
• Removing penetration between all systems upto 0.7
  mm, used for contact initialization.
• Preparation of complete input deck for various
  calculations and load BC file, apart
• from various vehicle sub-system FE models.
• Calculations
• Full frontal impact as per US-NACP         
• Overall dynamic deformation gt 650 mm.
• Steering column displacement lt 80 mm.
• 40 overlap offset frontal crash as per EURO-NCAP
• Firewall intrusion lt 150 mm.
• A pillar displacement lt 50 mm.
• Steering column displacement lt 80 mm.
• Minimal deformation between B pillars and doors.

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CAE

• Side impact as per EURO-NCAP, US-NACP, IIHS and
  SINCAP.
• Max. intrusion velocity of B pillar lt 7 m/sec.
• Rear impact as per FMVSS
• Minimal deformation of fuel tank.
• Rear seat relative movement lt 50 mm.
• Slow speed frontal impact as per FMVSS
• Contain damage within bumper system, no permanent
  deformation in any other system.
• Pre development activities for child and adult
  head impact calculations
• HIC value below 1000 in the bonnet middle region,
  less than 2000 near outer edges.
• Post- Processing
• Preparation of storyboards and reports for
  performed calculations .
• Compare the results for base model and modified
  model for set target of project.
• Discussion with design and development engineers
  for design and manufacturing
• Tools
• i. Pre-Processor (mesh generation) -
  ANSA, HYPERMESH
• ii. Pre-Processor (Spot weld generation) -
  FEMOD
• III. Solver - PAMCRASH

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CAE
Strength and Fatigue Analysis of BIW Client BMW
AG, Germany

• FE Modeling
• Components Body in White, Drive Line Assembly
  and Spot Welds using
• multi beam
• Sub modeling and mesh refinement at critical
  areas
• Quality criteria for FE Modelling
• Element length 6 - 12 mm, average 10 mm.
• Warpage lt 15 degrees.
• Quad angle between 40 - 140 degrees.
• Tria angle between 20 to 120 degrees.
• Percentage of tria. elements lt 5.
• Circle around circle near holes with minimum 8
  quad elements
• Neglect holes less than 6 mm.

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CAE

• Analysis
• Dynamic Analysis using Abaqus Explicit for
  vehicle passing over obstacles
• Luggage retention using Abaqus Explicit
• Fatigue Analysis using Falancs for
• Entire BIW.
• Failure of Spot Welds
• Post- Processing
• Preparation of storyboards and power-point
  presentation reports for performed calculations
• Results compared between base model and modified
  model for set target
• Discussion with design and development engineers
  for design and manufacturing
• Tools
• i. Pre-Processor (mesh generation)
  - ANSA, Hypermesh
• ii. Pre-Processor (Multi beam Spot weld
  generation) - ANSA, Medina
• iii. Solver - Abaqus, Nastran,
  Falancs
• iv. Post Processor - ANIMATOR,
  Abaqus Viewer,
• Hyperview

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CAE
FE Analyses of Intake Manifold Systems Client
MannHummel GmbH, Germany

• Software Hypermesh, Abaqus
• FE Modeling
• Combination of Shell and Hexahedral/ Tetrahedral
  elements
• Special meshing methods used for simulation of
  weld rim areas of plastic Intake
• Manifold Systems
• Meshing of plastic parts for Mould Flow
  Simulation
• Structural Analysis
• Burst pressure calculation in view of non-linear
  properties
• Thermo-mechanical stress simulation in view of
  Exhaust Gas Recirculation (EGR)
• Frequency response simulation with Engine
  excitations, as dynamic load varies
• according to engine running speed (obtained from
  test data).
• Study of response of systems at critical
  locations such as connectors
• Optimization of parts as per FE Analyses
• Vibro-Acoustic Analyses
• Transient loads (in the form of internal
  pressure) applied
• Weak structural areas determined and stiffened in
  next phase of design

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CAE

• CFD Analyses of Engine Assembly
• Client Luxury Car Manufacturer , Germany

• Software Ansa, StarCD, Ensight
• CFD Meshing
• CFD grid generation for Flow Analysis
• CFD grid generation for Conjugate Heat Transfer
  (CHT) Analysis
• Flow Simulation
• Components Cooling Circuit of an Engine which
  includes Cylinder Head, Crankcase,
• Water Jackets and Water Pumps
• Analysis
• Pressure Drop Evaluation
• Effect of variation of pressure drop with
  different flow rates
• Optimization of pressure drop
• Optimization of geometries for uniform flow
  distribution (involving design of gasket profile)
• Model size 3 million tetrahedral cells with
  critical grid connectivity at Gasket Connections

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CAE

• Conjugate Heat Transfer (CHT)
• Components Engine Assembly which includes
  Cylinder Head, Crankcase, Valves,
• Guides, Seating Rings, Spark Plug, Injector and
  Gasket
• Analysis
• Engine assembly analysed for simultaneous effect
  of flow and heat transfer
• Inputs from 1D simulation (GT-Power) applied on
  CFD model in view of temperature and heat fluxes
  in critical areas
• Fortran sub routines used for application of
  material properties and nucleate boiling effect
• Model size 6 million fully connected cells, with
  15-18 different solid materials defined in the
  model
• Results
• Study of temperature distribution and matching of
  results with GT-Power / test results
• Optimization of design for uniform temperature
  distribution
• Mapping of temperature results on FE Mesh for
  structural simulation.

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CAE
CFD Analysis of Vacuum Amplificator of
Automobile Client Automobile Supplier, Germany

• Software used Fluent 6.1 / Gambit 2.1
• Design of vacuum amplificator with a blow-by
  inlet, based on
• venturi principle
• Verification of hand calculations with 2D and 3D
  simulations of 3 models
• 3D incompressible turbulent flow Analysis to
  study flow behaviour in
• terms of velocity, pressure and mass flow
• Optimization of blow-by inlet position and
  amplificator geometry for
• given area ratios, pipe length, velocity and
  other parameters
• Further 3D CFD simulations were carried out to
  achieve optimised
• geometry having better flow characteristics
  meeting design constrains
• and objectives

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Domain Expertise
Automobiles Auto Components Aerospace Press
Tools Molds Dies Machine Tools Cutting
Tools Marine Oil and Gas
Please ask us for more information on industry
specific capability
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OUR GOAL
To be your business partner and provide you
with a seamless, design outsourcing
service
so that you can more
profitably manage your
business.
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Contact Us
TOOLTECH Software (I) Pvt. Ltd. Maa
House, No. 6, Service Road, 1st Stage, Domlur
Layout, Bangalore 560071, India Tel
91-80-41256556
TOOLTECH Deutschland GmbH Schleißheimer Straße
375, 80935 München, Germany Tel
49-89-35719100 Fax [phone]
Head Office TOOLTECH Software (I) Pvt. Ltd. 401
Beta 1, Gigaspace, Viman Nagar, Pune 411 014,
India Tel [phone] / Fax
91-20-30511201 Email info_at_tooltechsoft.com
www.tooltechsoft.com
B2i TOOLTECH S.A.S. Parc d'Affaires SILIC, 1,
rue Traversière, BP 20327, 94598 Rungis Cedex,
France Tel [phone]
TOOLTECHSOFT Sweden Box 184, Drakegatan 10,
S-401 23  Göteborg, SwedenTel . 46 (0)31 773
7163
TOOLTECH ROMANIA Sos. Borsului nr. 20 410605
Oradea Rumänien Tel [phone]
TOOLTECH Europe Oy
Bulevardi 2-4 A, 00120 Helsinki, Finland Tel
358-9 6150 7560
TOOLTECH INC.5351, Rusche Drive NWComstock
Park, MI, 49321Tel [phone]