Title: "Overview of Virtual Product Development at Caterpillar"

Abstract
Researchers at Caterpillar have been using Finite Element Analysis (FEA), Discrete Element Models (DEM), computational fluid dynamics (CFD), multi-body dynamics (MBD), extensively to model full machine systems during earthmoving operations. Multi-body dynamics models using both flexible and rigid body have been used to model the machine dynamics. The proper soil and machine models along with the operator model are linked via co-simulations to numerically model any earthmoving operation of interest. The soil – machine interaction phenomenon has been a challenging subject for many researchers. In practice this macro level mechanical behavior is not achieved by modeling the exact physics of the microfabric structure but rather by approximating the microphysics; similarly, all physics are approximated using fundamental physics and mathematical formulations, which are acknowledged by designated researchers and scientists in the field. Saying that, there is always a low possibility that the model can be highly predictive, due to the different assumptions and approximations necessary for such applications. Model parameters can be obtained either by running extensive DOEs and/or by linking model parameters to physical quantities, which most of the time can be obtained from simple tests. Validation and model fidelity can vary depending on the needs, surrounding conditions and availability of test data. Different numerical approaches developed by Caterpillar Inc. researchers will be presented and discussed; model validation will be also briefly visited throughout this presentation.

Bio
Mustafa Alsaleh has a PhD degree in Geomechanics from LSU in 2004. He started working at LSU as a visiting research assistant professor for a short period of time before he joined Caterpillar Machine Research division as a Senior R&D engineer. Mustafa was recruited and hired by Caterpillar to develop their numerical modeling capabilities to simulate the mechanical behavior of geomaterial, which is part of the full virtual product development processes. Over the last 18 years, Alsaleh was able to help Caterpillar succeed in optimizing the design of their products by leveraging state-of-the art in-house developed and validated virtual tools. These tools helped in saving millions of dollars and increased the sales of variety of products globally. Alsaleh stayed active and connected with many national and international schools and researchers, which has been of a big help to recruit best in class talent and excel the development of Caterpillar virtual tools, he also coached and mentored 100’s of engineers and helped them grow their career at Caterpillar. Finally, Alsaleh is the owner and chairman of the Caterpillar annual engineering conference, which is attended by 1000+ engineers every year.