From Hand Calculations to Advanced CAE: How Hewland Uses the Full Spectrum of Engineering Tools

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Early in my career as a junior CAE analyst, I was often reminded by senior colleagues how fortunate I was. They had started out in the era of punch cards and room-sized computers—where running a finite element (FE) analysis meant physically submitting code on cards and waiting days for results. Today, modern CAE tools offer incredible capabilities at our fingertips: powerful non-linear solvers, particle-based CFD, GPU-accelerated simulations… the list goes on.

With each technological leap, it’s hard not to envy the next generation of engineers. Soon enough, I’ll be the one reminding them how lucky they are never to have spent days meshing or deciphering why an analysis failed—by flicking through paper manuals!

But despite all this progress, it’s important to remember: advanced CAE is just one part of the toolbox.

The Value of Simplicity

At Hewland, we believe that no single tool suits every problem. Hand calculations, first-principle estimates, and lower-fidelity models still play a vital role throughout the product lifecycle—especially in the early design stages. Whether it’s a quick back-of-the-envelope stress calculation or a spreadsheet-based concept tool, these simpler methods help us move fast and make informed design decisions early.

A Layered Approach to Simulation

From concept to validation, we apply a layered CAE strategy across the development of our gearboxes:

• Early Stage – Custom tools help shape the initial layout, including condensing customer load data and optimising planetary gear tooth counts. (We’ll explore that planetary gear optimisation in a future Tech Article—stay tuned!)
• Development Phase – We bring in high-fidelity CAE models where needed, but only after ensuring that the model matches the question we’re asking—whether it’s bearing life, oil flow, or stress distribution.
• Final Validation – Our most detailed simulations are built on everything we’ve learned from earlier steps. Post-processing focuses on key targets: durability, strength, vibration characteristics, and more.

This modular approach ensures we use the right tool at the right time, improving speed, reducing bottlenecks, and increasing accuracy.

Democratising CAE

A key enabler of this approach is our skilled team. Multiple engineers across Hewland’s design group are trained to carry out analysis work, helping us move quickly and collaboratively.

Alongside our simulation tools, we also use custom-built calculation tools—many developed internally or brought in by team members—to handle critical component sizing (fixings, splines, etc.).

Bringing It All Together: Simulation Meets Testing

With the opening of our new Technical Centre, we’ve expanded our testing capabilities, including a state-of-the-art rig for endurance testing. Simulation supports this too—before a test begins, we can model the rig’s torsional vibration to predict and avoid issues during operation.

Why It Matters

Combining broad engineering experience with a full range of CAE and calculation tools allows Hewland to deliver robust, high-performance transmissions—from clean-sheet designs to track-ready, validated gearboxes.

Our team continues to push the envelope, developing new tools and workflows to make our design process smarter, faster, and more effective.