In today’s mechanical and manufacturing industries, increasing demands for durability, safety, and cost optimization are driving the adoption of advanced CAE simulation. Recently, VBTech successfully deployed the Simcenter 3D Structural (Linear & Nonlinear) solution for a customer specializing in industrial forklift design and manufacturing, delivering significant improvements in design efficiency and product reliability.

Challenge: Complex Structural Behavior of Forklifts

Forklifts are heavy-duty mechanical systems operating under demanding conditions. Key components such as the mast, forks, and load-bearing frame must ensure:

• High static and dynamic load capacity
• Fatigue resistance under repeated operations
• Minimal deformation affecting stability
• Compliance with strict safety standards

However, traditional calculation methods and physical testing present several limitations:

• High testing costs
• Long development cycles
• Difficulty in capturing nonlinear behaviors such as:

• • Contact interactions
  • Large deformations
  • Nonlinear material ( Plastic, Supperelastic…)

Solution: Simcenter 3D Structural Simulation

VBTech implemented the Simcenter 3D solution with advanced structural analysis capabilities:

1. Linear Analysis

• • Rapid evaluation of overall structural strength
  • Identification of stress concentration areas
  • Assessment of stiffness and deformation

2. Nonlinear Analysis

• • Simulation of contact between components (mast – carriage – fork)
  • Analysis of large deformation under maximum load conditions
  • Evaluation of material behavior in plastic regions
  • Simulation of real-world scenarios (lifting, braking, uneven loads)

Key Implementation Highlights

Beyond simulation execution, VBTech supported the customer in building a standardized CAE workflow:

• Technical training for internal engineering teams
• Support to setup and simulation on customer’s product
• Realistic boundary condition setup
• Optimized computation time using advanced solvers

The integration of both linear and nonlinear analyses enabled the customer to:

• Shorten design iteration cycles
• Reduce reliance on physical testing
• Improve prediction accuracy of structural failures

Achieved Results

Following implementation, the customer achieved measurable benefits:

• Lower prototype testing costs
• Reduce design cycle time
• Enhanced safety and product reliability

Value Delivered by VBTech

With strong expertise in CAE solutions, VBTech delivers more than just software:

• Strategic consulting for simulation adoption
• Tailored implementation for specific engineering challenges
• Advanced technical support
• Training and knowledge transfer

The application of Simcenter 3D in forklift structural analysis highlights the critical role of simulation in modern product development. This successful project demonstrates VBTech’s implementation capabilities and opens new opportunities for manufacturing enterprises pursuing digital transformation.

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