Virtual validation refers to the use of CAD and CAE technologies to validate a product design by implementing its 3D virtual copy and test and approve it using the softwares. It includes product simulation and testing in a variety of environments and conditions to make sure that they function properly. 

As manufacturing processes become more complex, virtual validation can assist businesses in planning, designing, and implementing systems before investing significant capital.

Virtual Validation services enables companies to reduce time for launching the product in market, reduce production cost, examine the defects or the design prior to turning it into an actual product and therefore better the product/machine performance.

Automakers are increasingly testing self-driving vehicles and electric vehicles using virtual validation. In addition to simulating batteries and electronic design systems, virtual validation can be used to test billions of miles of driving and millions of lines of code without ever building a prototype. 

Steps and Methodology involved in Virtual Validation

Virtual validation is focused on the ability to accurately represent the physical product as a math model in the digital world. As math models, FE/CFD models capture complex geometries, handle diverse material behaviors, and account for diverse manufacturing processes, which is crucial to accurately predicting product performance. In addition to Multiphysics, advances in solver technology have made it possible to handle geometry nonlinearity, material nonlinearity, and contact nonlinearity for virtual validation. 

The advancement that HPCs and GPUs have made in virtual validation is also very commendable. The need for high-quality FE / Virtual Validation models is the common denominator that drives these techniques. The required design space and design variable creation process, as well as system and subsystem virtual validation and builds, are critical for success. DEP MeshWorks CAE software is used, which is capable of handling high-quality models at all stages of product development and provides an integrated CAE platform that allows users to use virtual validation while optimizing workflows.

Maturity and trust in the virtual validation process have also paved the way for less reliance on multiple physical prototypes. In the context of Industry 4.0, virtual validation has become more integrated into the fast-to-market and data-driven product development processes. To shorten product development time, virtual validation has been pushed forward to drive design right from the concept phase, allowing for greater design space exploration and optimization of product performance upfront. Acceptance of virtual validation results by various regulatory agencies worldwide across industry verticals is a significant step forward.

The device will be tested extensively during the design validation process. Depending on the circumstances, you can do this in a variety of ways. Among the possible activities are:

• Comparing similar equipment used for similar purposes.
• Mathematical modeling is used to simulate functionality.
• Testing the final design to ensure that it works as intended by the user.

As part of the design records, the test plan, test cases, test execution records, and test results should be documented and kept. Validation as a whole is not the result of a single activity, but rather the sum of all validation activities.

Benefits of Virtual Validation 

Virtual validation services allow you to accelerate parts of a project’s integration testing by simulating it and working in a parallel process in which the real and virtual development phases interact in real time. 

There are several benefits of virtual validation of a product design: 

• Reduction in product launch times

When design testing is done virtually, it helps to shorten the market launch time. As the tests are done virtually, there is no need to destroy a completely ready product just to testify its reliability and usability. It is very beneficial to perform the tests virtually than physically as it aids in faster production cycle and thus reducing the  launch time. 

• Reduction in Production and Material Costs 

Virtual Validation is an excellent method for testing product designs and determining whether they are ready to be turned into reality. The design is put through various real-life scenarios with the help of Virtual Validation to ensure that it is ready  to be converted into an actual product. Virtual Validation uses CAD and CAE technologies therefore it does not require an actual completed product to test it by destroying it in various ways, therefore it reduces material costs. 

• Enhanced product performance

Virtual validation services enables engineers to test a variety of real life scenarios on the design to examine the minute aspects of the product design, highlighting the defects and then eliminating those defects thus improving the performance of the product. 

Rheomold is the best Virtual Validation Service Provider 

With virtual environments we aim to verify and validate all phases of vehicle development while maintaining a holistic view of the vehicle. Based on our connections with software engineering, we developed a co-simulation platform that connects and combines different validation methods and allows multi-directional communication between tools. This allows us to model the interactions between software and physical characteristics of a vehicle, resulting in realistic virtual validation. 

We at Rheomold have established ourselves as an Engineering consulting firm with FEA and CFD experts available to assist you in resolving your most challenging engineering problems. As an extension of our customers, our engineering teams are responsible for delivering effective results on time. We complement the capabilities of your engineering teams with unmatched global delivery excellence.