EMUG Tech delivers six virtual testing service areas: structural FEA using ANSYS Mechanical, Abaqus, Simcenter Nastran, MSC Nastran, and LS-DYNA; computational fluid dynamics (CFD) for aerodynamics, thermal management, HVAC, and underhood cooling using ANSYS Fluent, Star-CCM+, and CFX; multi-body dynamics (MBS) for vehicle handling, suspension, and mechanism analysis using MSC Adams and Simcenter Motion; hardware-in-the-loop (HIL) and software-in-the-loop (SIL) for ISO 26262 embedded software verification; fatigue and durability simulation using nCode DesignLife and FEMFAT; and simulation model correlation and validation against physical test measurements. All programmes follow the EMUG MODEL Framework.

EMUG MODEL is the five-phase virtual testing delivery methodology: Map — virtual test requirements mapping and simulation method allocation; Outline — model strategy, load case definition, and correlation test planning; Develop — simulation model build, material model calibration, and baseline validation; Execute — HPC simulation campaign execution and results extraction; Link — physical correlation assessment, model validation, and RTM linkage with V&V evidence. MODEL ensures every simulation programme is designed with a correlation strategy before modelling begins — preventing the common failure of running comprehensive simulations without the physical correlation data that regulatory authorities require before accepting simulation as verification evidence.

Simulation can replace or reduce physical testing for verification when four conditions are met: the simulation method has demonstrated accuracy for the physics and geometry type being analysed (established by correlation with physical measurements); the simulation model for the specific product has been validated against physical measurements (model correlation); the regulatory authority applicable to the product accepts simulation as verification evidence for the requirement type (regulatory precedent); and the simulation acceptance criteria are clearly defined and accepted by the authority or customer. Physical testing cannot typically be fully replaced for crash (FMVSS, UNECE ECE R94/R95), road load durability (OEM specification), and EMC compliance (most EMC regulations). EMUG MODEL helps engineering organisations identify which requirements can be verified by simulation and which require physical test evidence.

Simulation model correlation is the process of comparing simulation predictions against physical measurements on the same hardware to assess and demonstrate the accuracy of the simulation model. Regulatory authorities accept simulation as verification evidence when the simulation model has been shown to predict physical test results to an acceptable accuracy level — typically within 10 to 15 percent on key response quantities for structural FEA, or within defined MAC value thresholds for modal analysis. Without correlation evidence, simulation results demonstrate computational capability rather than physical accuracy. EMUG MODEL programmes plan correlation tests at programme start: specifying the physical measurements required (strain gauges, accelerometers, thermocouples), the test conditions, the correlation quality metrics, and the acceptable correlation threshold before the simulation model is used as verification evidence.

EMUG Tech delivers HIL and SIL testing for ISO 26262 ASIL A through ASIL D verification: SIL (Software-in-the-Loop) testing running production software code against a plant model for functional regression and back-to-back testing between model and software; MIL (Model-in-the-Loop) testing verifying control logic at the model level; HIL (Hardware-in-the-Loop) testing running production ECU hardware connected to a real-time plant simulation for functional test, fault injection, and safety mechanism verification. ISO 26262 software verification deliverables include: requirements-based test cases with coverage tracking, structural coverage measurement (statement, branch, MC/DC), fault injection test results demonstrating diagnostic coverage, and back-to-back test comparison reports for software qualification.

EMUG MODEL manages large simulation campaigns through automated batch submission and monitoring: simulation models are packaged with solver input files, material databases, and result request definitions; jobs are submitted to HPC schedulers (LSF, PBS Pro, SLURM) with appropriate resource requests (cores, memory, wall time) per simulation type; job status is monitored with email notification on completion or failure; failed jobs are classified by failure type (convergence, resource limit, licensing) with retry logic; and completed jobs trigger automated post-processing pipelines extracting standard results to the results database. Cloud HPC burst capacity on AWS, Azure, or Google Cloud handles peak demand periods without permanent on-premise investment.

EMUG MODEL stores simulation results in PLM using the platform’s simulation management objects: in Teamcenter, simulation models and results are stored as Simulation objects (Teamcenter Simulation Manager) linked to the Item Revision being verified, with the requirements traceability matrix cross-referenced with simulation result references and pass/fail status; in Windchill, simulation results are stored as Windchill documents linked to the relevant Part configuration; in 3DEXPERIENCE, simulation objects in the SIMULIA environment link to the ENOVIA product structure. PLM storage ensures simulation results are: traceable to the specific design revision they verify; accessible to quality auditors through standard PLM access control; and version-controlled so design changes that invalidate previous simulation results are flagged.

Virtual testing programmes are delivered across automotive OEMs and Tier 1 suppliers (FEA, CFD, MBS, HIL, fatigue), aerospace and defense manufacturers (FEA, CFD, HIL, DO-178C SIL), industrial machinery producers (FEA, CFD, fatigue), energy companies (FEA for pressure equipment, CFD for flow systems), and electronics firms (thermal FEA, ANSYS Icepak, structural reliability) in 20 countries: Germany, France, UK, Netherlands, Sweden, Italy, Spain, Poland, Czech Republic in Europe; India, Japan, South Korea, China, Malaysia, Thailand in Asia-Pacific; UAE and Saudi Arabia in the Middle East; USA, Canada, Mexico, Brazil in the Americas.