How much FEA and CFD play a role?
I have been working in the automotive related industry for a couple of years, and I have always been flabbergasted by the lack of basic understanding of strength, stiffness and CFD of the average designer.
We have designers that have auto sport backgrounds, but usually they just "make a thing" in CAD and then throw it to FEA and CFD guys. Usually the thing has no thought given about load introduction, supports, optimal geometry or manufacturing (the last bit always puzzles me, that I, a FEA guy, have to ask if the designer thought about how the hell it is manufactured). Not to mention thought given to corrosion.
CFD and cooling is also something that goes over the head of most. Designers are one thing, but Chief Engineers and Senior Engineer Managers are another. Because they want light, simple, cheap and fast things. Every project is done in a rush, with a tight budget. Then comes the reclamation that something isn't working, or has broken. Because it wasn't tested and it was the first idea that came to CE's or SEM's or designer's mind and they just put that into the production. The first FEA and CFD is usually done after the reclamation. And because it is already in production, it cannot be altered much. Only "a quick cheap fix" is allowed. Which usually ends up not working, because it was not designed properly in the first place, and trying to fix something fundamentally wrong with 5c fix does not make it work.
Is this like this everywhere, or am I unlucky?