I worked at Ford when they started using FEA and computer modelling to help with their designs. One of the things we found is that knowing the tools (CAD, FEA, etc.) didn't guarantee better design. If the tools weren't used in conjunction with sound engineering principles, they would often mislead you. "Garbage in, garbage out." This was really evident in some of the early FEA work. Ford still spend huge amounts of money testing prototypes and Design Verification and Proveout. We all continue to get better but there were some real setbacks when "computer based tools experts" produced some designs that failed miserably. Some of Ford's management was ready to throw out the tools. Thankfully, the engineers recognized the value of the tools when combined with real engineering expertise. The best tools speed up the process. The best designs are based on good physics and engineering knowledge.


Les Gallagher