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INTERNATIONAL

Worldwide Simulation

J O U RNA L

In the Heat of the FireSimulating the Burning

Process in Coal-Fired Boilers

Brakes without Squeal

Paint Simulations for the Acura TL

A New Road to Improve Your Products, Making Them More Reliable.

Combine the ease of use of ANSYS Workbench with design optimization and reliability evaluations with optiSLang.

optiSLang inside ANSYS Workbench

www.cadfem-us.com/optislangwww.optislang.com

To learn more about optiSLang inside ANSYS Workbench visit:

About this IssueIf you are thinking about starting a new magazine, I can assure you, some things will go wrong. Well, actually I can’t be sure, butsaying it, makes me feel better about our start of the CADFEM International Journal. While the international part of the magazine

makes it interesting it also makes it challenging. Justthink about the time difference from Russia to

the United States. Depending on wheresomeone is in Russia and the United

States, it can be quite complex tofigure out if the other person is cur-

rently working or sleeping. But wefinished the magazine and I’mproud of the result you arereading now. I like the work ofall the authors, editors, proofreaders and of course the sim-ulation engineers. We have anaward winning article fromCADFEM CIS in Russiaabout simulations of burning

processes within a coal-firedboiler. A wonderful work by our

colleague Alexey Fomichev, andvery much worth reading. We have

an article about car paint simulationsof luxury cars and also about simula-

tions of the precise mechanisms in luxurywatches. While one article describes the use of

simulation for heavy mining machinery working un-derground, another article describes the need of lightweight

composite materials. We show new technologies to simulate theconditions which most of us will experience again within the on-coming winter months, driving through snow. And we present ayoung company working on improving our climate by catching thecarbon dioxide which slowly turns our earth into a greenhouse.

I want to say thank you for all the work to all the authors andto our customers allowing us to present their work. And to allreaders, enjoy the magazine. If you are interested in any of the workyou read about, please feel free to contact the authors or yourlocal CADFEM contact. Enjoy the CADFEM InternationalJournal.

Teresa Alberts

CADFEM INTERNATIONAL Journal

here is a long history behind this journal, a history startingwith a small magazine, mostly written, printed and shippedby my family and close friends. As early as 1989 CADFEM GmbH, the ANSYS Channel

Partner in Germany, launched a first copy of its magazine Info-planer (which, today, is named CADFEM Journal). Since then itis published semiannually and is well received by its German readership. Copies are sent out to more than 35.000addresses. The CADFEM Journal covers newsabout CADFEM GmbH services andproducts, ANSYS and complementaryCAE-software, and case studies fromour customers. Please feel free andbrowse through our digital editionof the journal at www.cadfem.de.

Motivated by the success of the CADFEM Journal andby the idea to reach an in-ternational audience, we de-cided to launch CADFEM International Journal. Thismagazine will feature articlesfrom our partner companiesand their customers located invarious countries in Europe, Asiaand the United States.

I am very pleased that Teresa Alberts from CADFEM US, Inc. volunteered as editor for this journal. I know Teresa for many years while she was working for CADFEM in Switzerland andI am excited about her talents and her will-power. I am sure that the magazine will have a great future.

If you have an interesting CAE story you want to publish, please do not hesitate to contact her ([email protected]).

Guenter MuellerPresident of CADFEM International

� www.cadfem-international.com

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Welcome to the First Issue of our“CADFEM International Journal”

E D I T O R I A L

02 CADFEM INTERNATIONAL Journal

C A D F E M I N T E R N AT I O N A L

04 CADFEM International

CADEFM’s CAE Know-How around the Globe

C A S E S T U D I E S

06 Simulation with ANSYS and optiSLang in the development of electronic connectors

Reliable Connection

08 Simulations of burning processes in boilers with nontraditional ring furnaces

In the Heat of the Fire

12 Cost-effective design of a carbon-fiber-based bicycle frame

Ply-Cycle

15 Design and optimization of watch mechanisms with ANSYS,LS-DYNA and optiSLang

Time for ANSYS

18 Optimization of a Power Roof Support with ANSYS

Working Under Extreme Conditions

20 CADFEM supports IAG in the development of new press types

Machine Tool Development

22 Brake squeal simulations with ANSYS and optiSLang

Brakes without Squeal

24 Innovative dental implants, designed and improved with ANSYS

A Firm Bite

Brakes withoutSquealA German daily newspaper recently published the following court decision:“Brake squeal is a significant lack of comfort of a luxury car. If the squealingnoise cannot be eliminated by repair thebuyer may be eligible to withdraw fromthe purchase of the car.” The automotiveindustry is well aware of the unpleasanteffect of brake squeal and relies also onsimulation to avoid squealing brakes. This article describes brake squeal simu-lations with ANSYS and optiSLang.Page 22 – 23

C O N T E N T S

In the Heat of the FireCADFEM CIS presents a remarkable simulation of burning processes withincoal-fired boilers. The simulation resultswere used to identify the potential of newfurnaces. This paper was awarded the third prize at the Third All-Russian Contestfor Young Specialists in Electrical Power Engineering in 2009.Page 08 – 11

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CADFEM INTERNATIONAL Journal 03

A P P L I C AT I O N S & T E C H N O L O G Y

26 Adding particles to classic simulations with Diffpack

Simulating Particles

28 Paint simulations for the Acura TL

Durable Paint with Virtual Paint Shop

I N N O V AT I O N

30 Technology for our environment

The CO2 Catcher

C A E E D U C AT I O N

32 Industry related CAE education

Learning and Working

34 A long-term basis for simulation

Training at BSH Opens Doors for the Future

J O I N T R E S P O N S I B I L I T I E S

36 Orphans villages in Tibet

The Tadra Project

PublisherCADFEM International GmbHMarktplatz 285567 Grafing near MunichGermanyE-Mail: [email protected]

Executive EditorTeresa Alberts, [email protected]

Editorial AdvisorMatthias Alberts, [email protected]

AdvertisementAlexander Kunz, [email protected]

LayoutG & K Design, Rechtmehring, Germany

CoverAnton Balazh/shutterstock.com G & K Design, Rechtmehring, Germany

ProductionBechtle Druck & Service, Esslingen, GermanyIssue 1.500 Copies

Board of DirectorsChristoph Mueller, Guenter Mueller, Margaretha Mueller, Annik Bohnert

RegistrationHRB Munich Number 182398

VAT Registration NumberDE 131171831

Tax Number114/123/00175

Comprehensive General LiabilityZurich Gruppe Deutschland

PublicationWorldwide

Copyright© 2012 CADFEM. All rights reserved.

Neither CADFEM International GmbH, nor G & KDesign, guarantees or warrants accuracy or completeness of the material contained in thispublication.

ANSYS, Aqwa, Asas, Autodyn, BladeModeler, CFD,CFD-Flo, CFX, Composite PrepPost, DesignModeler,DesignSpace, DesignXplorer, EKM, EngineeringKnowledge Manager, Explicit STR, Fatigue, Fluent,Full-Wave SPICE, HFSS, ICEM CFD, Icepak, Icepro,Maxwell, Mechanical, Mesh Morpher, Meshing,Multiphysics, Nexxim, Optimetrics, ParICs, PExprt,Polyflow, Professional, Q3D Extractor, RigidDynamics, RMxprt, SIwave, Simplorer, SpaceClaimDirect Modeler, Structural, Super-Compact, SVDFast Solve, TGrid, TPA, TurboGrid, Vista TF, WinIQSIM,Workbench, AnsoftLinks, Ansoft Designer,QuickEye, FLUENT for CATIA V5, Realize YourProduct Promise, Simulation-Driven Product Deve-lopment, Simulation Driven, Solver on Demand,VerifEye, RedHawk, Totem, PathFinder, Sentinel,PowerArtist, CPM, RPM, PACE, and any and allANSYS, Inc., brand, product, service, and featurenames, logos and slogans are registeredtrademarks or trademarks of ANSYS, Inc., or its subsidiaries located in the United States or othercountries. ICEM CFD is a trademark licensed byANSYS, Inc. LS-DYNA is a registered trademark of Livermore Software Technology Corporation.nCode DesignLife is a trademark of HBM nCode. All other brand, product, service, and featurenames or trademarks are the property of their respective owners.

A D V E R T I S E M E N T

Avoiding damage to the car due to corrosionis understandably a highpriority in the automo-tive industry. Honda relies on simulation toachieve a high quality of protective paint forthe new Acura TL.Page 28 – 29

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U2 optiSLang21 ANSYS Conference & 30. CADFEM Users‘ Meeting 2012 in Kassel27 Nafems


C A D F E M I N T E R N AT I O N A L

The Companies under theCADFEM InternationalUmbrellaMost readers will know CADFEM or oneof the companies under the CADFEM International umbrella from their work with us. Starting with its foundation,CADFEM’s core business always focusedon ANSYS and we are strengthening ourgood partnership and friendship withANSYS from year to year. CADFEM inGermany, Switzerland, Austria and Russiaare all ANSYS Channel Partner in theircountries, covering simulation from soft-ware sales, to training, technical support,and consulting. A long friendship existsbetween CADFEM and MESco, ANSYSChannel Partner in Poland, and with SVS FEM, ANSYS Channel Partner in Pic

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CADFEM’s CAE Know-Howaround the GlobeWhat started as a small company in a living room of a talented engineer, is today a successful company with business locations around the globe. For nearly 30 years now, CADFEM is well known in the area of Computer Aided Engineering (CAE). CADFEM started in Germany and CADFEM GmbH, headquartered in Grafingnear Munich, is still the largest part of CADFEM’s globalbusiness. But CADFEM grew, new companies in newcountries started and are now an important part of CADFEM’s global success. Our investment in innovativeideas and technology is done by CADFEM International.While some of the companies under the CADFEM International umbrella add new simulation technology to CADFEM’s portfolio, some are investments in newareas and innovative ideas.

knowledge in geomechanics brought simu-lation into the world of hydraulic frac-turing. And with software technologybeyond the capabilities of standard simu-lation tools we step into new fields, explo-ring new possibilities. These technologiesare a wonderful example why CADFEMInternational exists. We are growing ourknowledge, and maintain the standing wehave within the simulation world.

A Benefit for our CustomersCADFEM wants to continue to step intonew markets, technologies and countries.We see that our customers benefit fromCADFEM’s international activities. Allcompanies of CADFEM Internationalhave impressive knowledge in simulationwork, and this knowledge should be shared.

the Czech Republic and Slovakia. Startingin 2013, CADFEM will grow into NorthAfrica and start in exciting and new ter-ritory.

The technical expertise of CADFEMranges from structural to electro-mechani-cal, fluid flow, and system simulations. With locations in China, Japan, India andthe United States, CADFEM transfersANSYS simulation and technical know-ledge to these countries.

CADFEM grew up with ANSYS andANSYS is today the most important partof our business. But, we also look for newideas and learn from new technology.Design optimization and reliability evalu-ations with optiSLang are part of the portfolio of all CADFEM locations aroundthe globe. With new technologies we havenew possibilities in new areas. Impressive

CADFEM locations worldwide

CADFEM North Africa

05

InfoAuthor & InfoContact| CADFEM

Matthias Alberts, CADFEM US, Inc.Phone: +1 864 214 2160E-Mail: [email protected]

Or your local CADFEM contact

Investment in InnovationCADFEM International invests in inno-vative technology and ideas the same wayour founder invested in the innovative ideaof simulation nearly 30 years ago. We be-lieve in young companies with new ideasand the will-power to be successful. Overthe last years we have invested in com-panies working on a greener environmentor virtual cities.

CADFEM International will continuethe way into new markets, new and exci-ting countries and innovative ideas.

“Any intelligent foolcan make things bigger, more complex,and more violent. It takes a touch of genius – and a lot ofcourage to move inthe opposite direction.” E.F. Schumacher

E.F. Schumacher published his book Small is Beautiful in 1973. The idea becameCADFEM’s guideline over the years.

It is useful and important to companies within other regions of the globe or with other target markets. We want to bring this knowledge to all our customers, worldwide. CADFEM International allows our cus-tomers, some of them early birds in the global economy, to transfer simulation knowledge from one location to another. Trainings given to employees in Europe can be given to employees in the United States or Asia, or the other way around. Consulting knowledge can be used and trained at locations in different countries. CADFEM International will always follow an idea close to Small is Beautiful, but growing into different markets and areas will allow us to share simulation technology and knowledge. And more important, we can share it with our customers around the globe.



C A S E S T U D Y

his article shows how ANSYSWorkbench is used in combinationwith optiSLang to reduce a con-nector’s initial failure probability

of 89 % to a six-sigma conforming design,and a failure probability of less than0.00034 percent. Further application areasof both simulation tools are in mechanical,thermal, and electric analyses, as well assimulations of the connectors’ manufac-turing process.

The Robust DesignOptimization ProcessANSYS Workbench provides several toolsfor different simulation physics, all inte-

quire a closer look and a way into simula-tions. Robust Design Optimization (RDO)achieves this goal of a reliable, yet cost ef-fective product. Integrated into ANSYSWorkbench, optiSLang provides the capabilities for successful Robust DesignOptimization. optiSlang inside ANSYSWorkbench uses the parametric capabil-ities of ANSYS Workbench and combinesease of use with technology.

A sensitivity study provides engineerswith information about important param-eters. Knowing where modifications will ac-tually change a products performance helpsengineers to understand and improve theirdesign. But, not only parameters with a highinfluence are important, parameters without

T grated in a single environment. The inter-connection between different analyses is asolution for an essential challenge in the de-velopment and manufacturing of electronicconnectors. The connector’s reliability.

Traditional product development basedon simulation starts with a design and isfollowed by a simulation. Based on resultsof this simulation, the design is modified,analyzed, evaluated, and improved.However, reliability and safety of a productis not necessarily guaranteed once theproduct is used in its working environment,where uncertainties and conditions changea products behavior. Variations in materialproperties, assumptions in loads and inputsignals, and manufacturing tolerances re- Pic

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While developing new connectors, engineers face severalrequirements from design to manufacturing. Connectorsshould guarantee perfect electric and thermal conductivity,robust mechanical properties, and a perfect signal trans-mission. All this should be combined with high reliabilityand low-cost manufacturing. TE Connectivity relies on ANSYS and optiSLang within their development to simulateand optimize connector designs and manufacturing.

ReliableConnection

Simulation with ANSYS and optiSLang in the Development of Electronic Connectors

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influence are also given by optiSLang, iden-tifying cost saving potential and parametermodifications not worth investing any moretime. With these informations of a sensi-tivity study and smart algorithms optiSLangruns design improvements on the fly,without new simulation runs.

By including uncertainties and variationsof design parameters in a robustness eval-uation, optiSLang analyzes and improvesfailure probabilities, safety, and reliability ofa design. Naturally, whenever failure prob-abilities are given, it is important to knowhow reliable they are. optiSLang providesinformation about how accurate the givenfailure probabilities are and how to improvethem. By combining this with the ease of useof ANSYS Workbench, Robust Design Op-timization is now as simple and reliable asit has never been before.

Case Study TE ConnectivityTE Connectivity uses ANSYS and opti-SLang in their development of highquality connectors. Specifications givenby the manufacturer itself require a

would lead to unnecessary solver runs. Thenumber of design dimensions for theRobust Design Optimization was reducedfrom 36 dimensions to 15.

The following Robust Design Opti-mization increased the contact forces bymore than 30 percent. However, its mostimportant part was reducing the failureprobability. TE Connectivity reduced thefailure probability from 89 percent to therequired six-sigma design and a failureprobability of less than 0.00034 percent. Aremarkable improvement of the design andits reliability.

Simulations by ANSYS and optiSLanggave TE Connectivity direct benefits.

● Identification of important parameters● Significant cost savings and deeper un-

derstanding of their design● Higher reliability● A six-sigma design

OutlookAnalyzing the electrical field of connectingelements provides important informationabout losses within the electronic con-

TE Connectivity is a technology leader in the world’s fastest growingmarkets, helping connect power, dataand signal in everything from auto-motive and aerospace to broadbandcommunications, consumer, energyand industrial applications. By hel-ping our customers meet the need for greater energy efficiency, ever-in-creasing productivity and faster, morereliable data, TE’s market-definingtechnologies and engineering exper-tise is setting the pace for the futureof connectivity.

Infos: TE Connectivity

Figure 2: Analyzing the ampacity of an electrical contact.

Figure 1: CAD Design and dimensions.

minimum contact force for all pins of the analyzed connector of 1N. This ensures a safe connection. However, the overall contact force for all elements of the con-nector should not exceed 50N. With these design requirements, and 36 design di-mensions, the engineers at TE Connec-tivity had to find a six-sigma design witha failure probability of less than 0.00034 percent.

TE Connectivity used a sensitivity study to analyze the influence of all design dimensions on the contact forces of the connector. The most important design di-mensions were identified, as well as di-mensions without influence on either me-chanical strength or contact behavior. While these dimensions would not in-fluence the reliability of the design, they


nector. Coupled thermal and electricalanalyses in ANSYS Workbench includetemperature dependent material propertiesand increase simulation accuracy. Byadding information about the contact sit-uation from mechanical simulations the in-fluence of contact pressure on electricaland thermal conductivity is analyzed.Robust Design Optimization can add adirect benefit to these analyses involvingmany uncertainties and variations. The re-liability of electronic connectors would beimproved and failure probabilities reducedeven more.

InfoAuthor | CADFEM

Christof Gebhardt, CADFEM GmbH

InfoContact | CADFEM

GermanyChristof Gebhardt, CADFEM GmbHPhone: +49 8092 7005 65E-Mail: [email protected]

USAMatthias Alberts, CADFEM US, Inc.Phone +1 864 214 2160E-Mail: [email protected]


InfoSoftware applied

ANSYS Mechanical, optiSLang


C A S E S T U D Y

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In this article, we present a remarkable analysis of a coal-fired boiler with nontraditionalring furnaces for a 600-MW unit. ANSYS Fluent was used in this work. We present data on the

temperature distributions in the boiler, the nitrogen oxide concentrations, and numerous other simulation results and calculations, all of which are important to bring further improvements

to the technology of boilers with ring furnaces.

ith the second largest re-serves of coal in the worldafter the United States, coal-based energy production

has great potential in Russia. The reservesof coal in Russia are roughly five times thecombined reserves of oil and gas. The con-tributions of coal to fuel energy and elec-trical energy are currently about 12 % and26 %, respectively, whereas coal has beenand continues to be the foundation ofenergy production in the world. Coal pro-duction is increasing rapidly in almost allcountries. Over the last 10 to 15 years, coalproduction in Australia has increased by3.7 %; similarly, those in South Africa,China, India, and the USA have increasedby 3.2 %, 3 %, 2.6 %, and 1.7 %. The con-tribution of coal to worldwide energy production is about 50 %, and as high as 86 - 96 % in some countries.

Given the “freeze” on building newpower plants, the large amount of wear inexisting equipment, and inadequate fi-nancing, an increase in the amount of workneeded on repair and replacement of out-

of-date equipment is expected. There is yetanother reason forcing the funding of re-construction, the increasing competitionin selling energy. Strict ecological specifi-cations for both, new and existing powerplants, must also be taken into consider-ation.

When a plant is rebuilt because of needsto replace its worn out boiler unit, the useof boilers with a ring (circular, annular)furnace chamber is appropriate. This tech-nology has a number of indisputable meritsand advantages over other technologies.

In this paper, we present several variationsof boilers developed at ZiO-COTES inconjunction with the factories of Podol’skMachine Construction Factory. Along withtraditional boilers, a ring boiler design wasdeveloped for a 600-MW unit with a capacity of 1905 ton/h by using Ékibastuzcoals. In the design calculations, the spe-cialists at CADFEM CIS used ANSYSFluent to gain a complete understanding of the physical processes in the furnacechamber.

Key Features of the RingFurnace TechnologyRing furnaces should be regarded as anadvancement of traditional tangential fur-naces. A ring furnace has the structure ofan octahedral prism within which an octa-hedral shielded insert is installed over itsentire height. The distinctive feature of thisfurnace is the vortex flow of the furnacegases in the annular space between theouter and inner shields. [1]

Efficient low-temperature combustionof fuel in a ring furnace is achieved as aresult of installing the additional surfaceof the shielded interior insert, together withintensification of mixing and the use of in-furnace gas recirculation.

The boiler with a ring furnace is not astall as a traditional furnace; it is 30–40 %lower in height and its mass is 15–20 %less. This type of boiler has a number of advantages, such as higher operational reliability owing to the aerodynamics ofthe furnace, and the ability to reduce ni-trogen oxide emissions. Most importantly,when an existing plant is rebuilt, a boiler ofthis type with a higher steam capacity canbe installed in the space occupied by theexisting unit. In 2001, the Scientific andEngineering Council of the OAO RAO

In the Heat of the FireSimulations of Burning Processes in Boilers with Nontraditional Ring Furnaces

Figure1: Boiler with a ring furnace.

W

This paper was awarded the thirdprize at the Third All-Russian

Contest for Young Specialists inElectrical Power Engineering in

2009. (Organizer: All-RussianThermal Engineering Institute)

Figure 2: Comparison of boilers for the600-MW unit. The left image shows a tra-ditional boiler with a rectangular-shapedconfiguration, the right image a configu-ration with a ring furnace.


“UES of Russia” recommended the com-mercial introduction of boilers with ringfurnaces (Figure 1).

Within work on a boiler for a 600-MWunit, and in addition to traditional T-shapedand rectangular-shaped boiler layouts, weanalyzed advanced technology for a boilerwith a ring furnace. The warranty calcula-tions and choice of auxiliary equipmentwere done for Ékibastuz coal (Qd = 3917kcal/kg, Ad = 39.6 %, Wd = 6.3 %, Vv =31.4 %, Sd = 0.6 %). Within this projectwork, the first design of a ring furnace fora rectangular-shaped boiler configurationwas developed (Figure 2).

Simulations by ANSYS Fluent with cal-culations of the particle trajectories in thefurnace chamber and the velocity and tem-perature distributions at the level of thefirst and second burner rows allowed cap-turing a picture of the physical processesin the furnace chamber. The simulationmodel and results are described below.

Simulation ModelAll of the furnace processes (aerody-namics, ignition, burnup, heat and masstransfer, and chemical reactions) were an-alyzed with their mutual couplings as onesystem. The gaseous medium in thefurnace is assumed to consist of chemi-cally inert carbon dioxide CO2 molecularnitrogen N2, water vapor H2O, and reactiveoxygen O2 as well as volatile substances.The trajectories of the moving solid coalparticles were calculated with a Lagrangianformulation. Heat and mass transfer in thedispersed phase were determined, as werethe trajectories of the particles. The RNGk-epsilon turbulence model was used. [4]

The particles are assumed to bespherical and consist of a mixture of ashresidue and coke. In addition, they containmoisture and fuel components (volatiles).The Rozin–Rammler formula was used totake the polydispersity of the particles intoaccount. [5] The following stages of particlecombustion were included in the calcula-tions: evaporation of moisture, heating, ig-

nition and combustion of volatiles, andburnup of the coke residue. In the furnace,a particle is subjected to thermal processingthrough radiative-convective heat transfer(Figure 3). As the particlesare heated up,moisture is vaporized. With further heating,volatile substances are released, ignited, andburnt up. After the release of the volatiles,the coke residue burns up, and ultimately, anash residue is left. The reaction C+O2-CO2

was introduced for the burnup of the coke.

C A S E S T U D Y

Figure 3: Schematic burnup illustration of a fuel particle.

Figure 4: Cross-sectional averages of temperature, concentrations of oxygen andnitrogen oxides, and burnup as functions of height.

“We believe that these results are very important for the development of scientific andengineering recommendations for choosingthe design parameters of ring furnaces for boilers at thermal power plants.”Alexey S. Fomichev, CADFEM CIS

11

Radiative heat transfer in the furnace was modeled in the P1-approximation. All known mechanisms for the formation of ni-trogen oxides were used in modeling their amounts in the boiler furnace: thermal,“fast”, fuel, involving N2O, and reduction of NO on the surface of coke particles. The following model was used to calculate the fuel-nitrogen oxides: all of the nitrogen comes from the fuel, along with volatiles, in the form of a mixture of NH3 and HCN. [3]


Simulation Results

The main results for 100 % loading areshown in Figure 4. The average temper-ature of the flare at the outlet from theactive combustion zone is 1580 °C. Here,because of intensified mixing, a high levelof fuel burnup (98.5 – 99 %) is maintai-ned in the furnace. The calculations (cross-sectional averages) show that this schemefor burning fuel can maintain a low level of

nitrogen oxides at the outlet from thefurnace chamber (roughly 600 m/gm3).

Figure 5 shows some results of the sim-ulations for the first row of burners. Airenters the furnace from the side of theouter boundary and thereby shields thefurnace wall, so slagging is avoided.

The simulations confirm the efficiencyof using a ring furnace, attributed to im-proved aerodynamics and rapid heattransfer inside the furnace.

The results also include calculated heatloads on the inner insert and outer shields(Figure 6). The calculations include the ra-diative as well as convective component ofthe heat flux. Figure 6 shows that themaximum heat loads are the same on theinner and outer shields.

CADFEM CIS performed compre-hensive simulations of the processes in aring furnace chamber. These simulationsresulted in a complete picture of the gasdynamic and thermal processes in thevolume of the furnace, including infor-mation on temperature and concentrationdistributions in the gaseous and dispersedphases, the concentration of NOx, andother characteristics of the furnace process.We believe that these results are very im-portant for the development of scientificand engineering recommendations forchoosing the design parameters of ring furnaces for boilers at thermal powerplants.

Figure 5: Computational results for the first row of burners: a, temperature distribution (°C); b, velocity distribution; c, volume fraction of oxygen; d, concentration of NOx (mg/m3).

Figure 6: Heat flux loading (radiative + convective) on the walls of the furnace chamber (kW/m2).

InfoAuthor & Contact | CADFEM

Alexey S. Fomichev, CADFEM CISE-Mail: [email protected]: +7 495 6440608www.cadfem-cis.ru



ANSYS Fluent

InfoReferences

[1] F.A. Serant, Development and Study of a RingFurnace, Its Industrial Introduction and Tests in a Boiler with a Steam Capacity of 820 tons/h. Author’s Abstract of Doctoral Thesis [inRussian], Novosibirsk (1999).

[2] L.I. Pugach, G.V. Nozdrenko, N.G. Zykova, and Yu.L. Pugach, Technological Means for Reduction of Harmful Emissions by OptimizingDust Combustion Schemes [in Russian], Izd. NGTU, Novosibirsk (1997).

[3] V.F. Konyashkin, “Three-dimensional modellingof physical processes and boiler equipment with the FLUENT program,” in: Materials from the VIIth All-Russian Conf. on Combustion ofSolid Fuels, Izd. ITSO RAN, Novosibirsk (2006).

[4] A.R. Dorokhov, A.S. Zavorin, A.M. Kazanov, and V.S. Loginov, Modelling of Heat-Generating Systems [in Russian], Tomsk (2000).


C A S E S T U D Y

rames can be constructed frommetals such as steel, aluminum ortitanium, or they can be made ofcomposite materials that are based

on carbon fiber. Traditionally, use of con-ventional simulation in the bike industryhas been limited to the metallic mate-rials. However, scientists at the Institute for Lightweight Structures (IST) at Ger-many’s Chemnitz University of Techno-logy used engineering simulation to suc-cessfully identify the stresses for acarbon-fiber–reinforced mountain bikeframe for GHOST Bikes GmbH – buildersof premium bikes of all classes and cate-gories. The research team used ANSYSComposite PrepPost software to analyzepotential failure within the complex light-weight structure.

Carbon-fiber–reinforced polymer(CFRP) is an increasingly popular materialfor mountain bikes due to its lightweightcharacteristics and ease of manufactur-ability. In addition, fibers can be oriented tobetter withstand loads and provide weight-efficient parts with high stiffness that willincrease the overall stiffness of the frame –a desirable characteristic. To optimize theuse of materials and to determine fiber ori-entation, complex calculations and nu-merical simulation methods are required.Conventional composite simulation pro-grams usually require additional work

exact loads, boundary conditions and ac-ceptable stress levels for a given com-ponent. The technical requirements andcorresponding test procedures are definedby standards from the German Institute forStandards (DIN EN 14766 and DIN Plusfor mountain bikes). However, these norms do not consider all possible loadsthe structure experiences, so IST de-veloped the current research projects toexpand the scope of these tests. The ISTteam defined three major load cases thatuse increased load levels and consider brake

F

to define fiber orientations and plies. Composite PrepPost software, integratedwithin the ANSYS Workbench environ-ment, takes advantage of outstanding fea-tures and solver technologies from ANSYS.This technology substantially simplifiesanalysis of CFRP structures using inno-vative modeling and analysis capabilities.

Assessment of Load CasesTo perform an effective numeric simu-lation, the engineer needs to determine the Pic

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ANSYS Composite PrepPost assists in efficient,cost-effective design of a carbon-fiber-based bicycle frame.

Figure 1: HTX Lector Team mountain bike from GHOST Bikes.

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Simulation in ANSYSComposite PrepPostResearchers transferred the model theycreated to Composite PrepPost usingWorkbench. For defining specific com-posites in the bike’s frame, CompositePrepPost offers a variety of capabilities forboth pre- and post-processing compositestructures. The material definitions, in-cluding parameters required for a failureanalysis, can be manually input or im-ported from a material library, such as theone available in ESAComp software (fromComponeering Inc.) for analysis anddesign of composites. These material def-initions can define fabrics, laminates orsublaminates (a combination of fabrics and

Figure 2: Segmented model of bicycle frame.

loads, saddle loads and handlebar loads. Engineers at IST created a model of the bicycle frame with Pro/ENGINEER®

Mechanism Design Extension (MDX). They used simulation to investigate tran-sient loads as well as seven quasi-static loadcases. To optimally define the local ma-terial properties, they further sliced the frame into components using ANSYS DesignModeler software. The final verifi-cation of the simulation model was made using strain gauges and a test rig at GHOST Bikes.


Figure 4: Laminate configuration pre-designed using ESAComp (left)and corresponding definition in ANSYS Composite PrepPost software (right).

Figure 3: Strain gauges used for testing.

Seat Stays Connecting Piece Top Tube

Seat Tube

Chain StaysDrop Outs Bottom Bracket Down Tube Head Tube


laminates) with various properties, in-cluding thickness and fiber orientation.

For the failure analysis of the bikeframe, the IST team compared 16 lam-inate configurations to standard carbonfiber for very high stiffness and resistance.The material assignment for the simu-lation model was applied on oriented sets.These groups of elements could overlap.For each group, the team defined theglobal draping directions as well as thedefinition of the zero-degree angular di-rection. Using Composite PrepPost madeit possible to adapt the fiber direction foreach element group using a smart com-bination of Cartesian, cylindrical orspherical coordinate systems.

The post-processing capabilities ofComposite PrepPost are impressive: Thelarge number of state-of-the-art failure cri-teria available as well as the ability toperform layer-wise analysis of the resultsallow the user to identify critical areasalong with the load case for which failuremight occur. Moreover, the use of theCuntze and Puck criteria allowed the teamto predict failure in the most critical areas.Engineers investigated several variationsof the design using different configurationsof plies. As a result of the simulations, theteam designed an optimized frame that wasable to meet the stiffness requirements butwould be cheaper to manufacture than theinitial design.

With ANSYS Composite PrepPost, thestiffness and resistance characteristics offiber-reinforced bicycle components can beoptimally adapted to meet design require-ments; furthermore, design efficiency is sig-nificantly improved. Compared to typicaltrial-and-error development methods usedin the bicycle industry, the number of cost-and time-intensive physical prototypes wasgreatly reduced.

C A S E S T U D Y

Figure 5: Definition of zero-degree fiber direction with help of a combination of Cartesian coordinate systems.

Figure 6: Inverse reserve factor using Cuntze failure criteria; critical areas in red.

Figure 7: Inverse reserve factor of optimized design.

InfoAuthors

Lothar Kroll, Joerg Kaufmann, Norbert Schramm,Institute for Lightweight Structures, Chemnitz University of Technology, Chemnitz, Germany


Matthias Hörmann, CADFEM GmbHPhone: +49 8092 7005 41E-Mail: [email protected]



ANSYS Composite PrepPost, ANSYS Workbench

MoreInformation

www.strukturleichtbau.net www.ghost-bikes.com

cmA = Cuntze: matrix tension failurecritical layer = 10th layer

pmA = Puck: matrix tension failurecritical layer = 10th layer

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Watch mechanisms include alarge number of high precisionand flexible components. Using traditional prototyping to find the best design is labor intensive and expensive. Using simulation improves the designprocess. By combining simula-tions with design optimizationand reliability analyses, themechanical components andassemblies become cost effective and reliable.

imulations are an important partof the development process at Audemars Piguet & Cie SA in Le Brassus, Switzerland. As one

of the world’s finest luxury watch ma-kers, Audemars Piguet uses ANSYS and optiSLang for virtual prototyping and re-duction of expensive test-prototypes.

In the wide range of mechanisms in-volved in a bracelet watch, three key mech-anisms are presented as an example forsimulations used in the developmentprocesses of the watch making industry.

Optimization of a DateMechanism Figure 1 shows a mechanism that allowsexact date changes of the display every 24hours. The mechanism is assembled withthree main parts,

● the display disk,● the trigger mechanism (this mecha-

nism stores energy and transfers it tothe display disk),

● and the jumper which ensures that themechanism never jumps a day.

The date changing cycle starts by loadingthe trigger spring. At the time the date has to change, the cam blocking spring releases the pin, and the stored energy inthe trigger spring rotates the cam anddrives the rotation of the display disk. Thejumper stops the disk and ensures that thedisk rotates not more than one digit or oneday.

The complexity of this mechanism isto balance the way the trigger energy isreleased and quickly dissipated by thejumper. The date change should occur in-stantaneously to the human eye, usually

Time forANSYS

Design and Optimization of Watch Mechanisms with ANSYS,LS-DYNA and optiSLang

S

The mechanisms used in this study belong exclusively to Audemars Piguet & Cie SA(www.audemarspiguet.com).



within 0.015 seconds; yet the mechanismneeds to be reliable and never jump a date.

The design of the jumper spring, thejumper, and the trigger spring were op-timized by simulations with ANSYS LS-DYNA (Figure 1). The rotational ve-locity of the display disk (Figure 2) showsa positive acceleration of the disk betweenstep a and b. This is the disk rotation drivenby the trigger mechanism. When the ro-tation is suddenly blocked by the jumper,the disk rotates back between step b and cuntil the backward rotation is blocked by the jumper between step c and d. Therotation is finally stopped by the jumperand the mechanism successfully changesthe display by precisely one day.

The loading moment of the triggerspring has been verified by tests and showsa perfect agreement with the simulationresults (Figure 3). The pre-series mech-anism that was produced based on the sim-ulation results fulfilled all requirements andallowed launching production withouttesting new prototypes.

Improving a Time SetMechanism Figure 4 shows a time set mechanism con-nected to the pull-out button of a watch.The button has a winding shaft that can bepulled out until it reaches a stop. Rotatingit allows setting the time.

The shaft is connected to a pull-outpiece which is controlled in its movementby a spring pushing on a small pin of thepull-out piece. The spring ensures a cer-tain traction force when pulling the button.The traction force is important since watchowners sense the quality of a watch by handling these precise mechanisms. Thespring mechanism had to ensure a tractionforce of 5N with very little tolerances.However, the yield stress within the designhad to stay below the materials yield stress.

A parametric model of the spring and a nonlinear simulation including a fric-tional contact was defined within ANSYS Workbench while an integrated version ofoptiSLang inside ANSYS Workbench was

used for the design improvement. The au-tomatic design optimization of the springdesign used eight design dimensions andconsidered three objectives:

● A traction force of a specific value● A pulling force of a specific value● Minimizing the structural stresses

The optimization used an adaptive re-sponse surface method. With 91 designevaluations the final design fulfilled the re-quirements in traction and pulling forceswithin a range of 2 % and reduced themaximum stress in the spring by 10 % themechanism was produced and fulfilled allexpectations.

Assembling the WatchThe tight fit between watch case and theglass of the watch is realized by a flexiblejoint (Figure 6). A Robust Design Opti-mization is used to reduce the force neededto place the glass securely into the fit, while

C A S E S T U D Y

Figure 1: Precision date mechanism (the diameter of the display disk is 12mm).

Figure 2: Rotation velocity of the display disk. Figure 3: Comparison between simulation and test.

17

maximizing the force needed to remove theglass. Plastic deformations of the flexiblejoint as well as stresses within the glass andthe watch case had to be minimized.

ANSYS Workbench in combinationwith optiSLang was used to simulate as-sembling the glass and watch casing. In aRobust Design Optimization three stepswere analyzed:

● Sensitivity Analysis● Pareto Design Optimization● Robustness Analysis

Starting with a design described by sixteendimensions, the sensitivity analysis iden-tified eight important design dimensions.While reducing the number of dimensions,these eight dimensions were still driving86 % of the force needed to remove theglass, 77 % of the stress in the glass, and 65 % of the plastic deformations in theflexible joint. Identifying the most im-portant design parameter is important fora focused optimization but the sensitivityanalysis also provides information abouthow modifications of these parameters will

influence the results. While design modifi-cations of the design improved the stresslevel within the watch casing and the glass,they also led to a smaller force needed toremove the glass.

At this point it is time for compro-mising. Increasing the force to remove theglass while also reducing the stress levelwithin the components was not possible. A so called Pareto optimization optimizedthe design and gave engineers a possibilityto weigh between both requirements.Two different objectives were defined forthe Pareto optimization. The first objectivewas a weighted function of removal forceand difference between inserting and re-moval force. The second objective wassimply a sum of the stresses in the watch-case and the glass. After 209 design evalu-ations the result of this optimization was aPareto front by designs minimizing bothobjectives (Figure 8). The choice of a bestdesign along this curve is given by the needto increase the removal force while main-taining an allowable stress level.

The best design selected from thePareto front was analyzed in a robustness

analysis. Manufacturing tolerances andvariations in material properties were in-troduced to the simulation. The failureprobabilities of the design were evaluatedby optiSLang by comparing the distri-bution of the maximum stress with a limitvalue. The failure probability providesdirect information about the reliability of adesign. The best design had a failure prob-ability of 20 % when gold material wasused, which was far away from the strictlimits of Audemars Piguet & Cie SA. How-ever, using steel material showed a perfectfailure probability near zero.

Figure 4: Time set mechanism.

Figure 6: Parts used in the simulation ofthe assemble process.


Figure 7: Plastic strain within the flexiblejoint a) while assembling the glass b) with the glass mounted c) when the glass is removed.

Figure 8: Results of the Pareto optimizationwith optiSLang. The probability distributionof the stress within the watch-case is shownin the top part of the image.

Figure 5: Different spring designs. The position and angle of thecontact surfaces to the pin determine the pulling forces.

InfoAuthors

Tiavina Niaritsiry, Audemars Piguet Cie SAE-Mail: [email protected]

Joël Grognuz, CADFEM (Suisse) AG


Roberto Rossetti, CADFEM (Suisse) AGPhone: +41 21 601 70 80E-Mail: [email protected]



C A S E S T U D Y

agor, a leading designer and pro-ducer of mining equipment inPoland, successfully used simu-lation in the development of a

Power Roof Support (PRS) produced forthe Australian market. The size of the PRSmade these analyses a challenge that requi-red additional assistance and training.Tagor brought in MESco to help. MEScospecializes in simulation and trained Tagorin using ANSYS. MESco was also asked toconsult for the performed simulations. En-couraged by the successful outcome of theproject many other heavy industry com-panies in Poland now benefit from simu-lations.

Mining, such as coal extraction, is aheavy industry activity in which the goal isto “squeeze every drop” of coal from themine. Excavating all of the material from amine is the normal activity of mining thatoften occurs under extreme environmentalconditions. These conditions require the useof the PRS to support the ceiling of themine during excavation. A combine har-vester is cutting the wall of the mine for un-

PRS moving forward, make it almost im-possible for repairs or maintenance to becompleted on the PRS while underground.

Fatigue AnalysesInternational standards specify the condi-tions and requirements the PRS needs towithstand. The mechanical parts of the PRSare designed to sustain thousands of loadcycles using simulation. With deformationsof more than 10cm and occurring plasticdeformations due to the extreme loads, allmechanical parts of the PRS need to be as-sessed thoroughly for material fatigue.

The materials used in the manufacturingprocess of the PRS are carefully consideredand selected. Mines have many elementssuch as dust and salt water that can causerust and corrosion, and all tools used in themine must have high wear resistance. Ma-terials such as high grade steels are usedand verified using mechanical analyses.However, high grade steels are difficult toweld and the welding points are the weakestpart of the PRS. A thorough fatigue assess-ment is required for all welding points of thePRS. Since international standards as BS7608 or PNEN 1993-1-8 lead to high safetyfactors and exclude high grade materialsfrom fatigue assessment they are only usedfor a brief welding assessment. For detailedfatigue assessments the design engineersdeveloped material fatigue curves for highgrade materials and used MESco’s HotSpot

derground excavation work. This makes theground extremely unstable with a highprobability of collapse. The PRS is designedto prevent this collapse by following thecombine harvester and providing imme-diate support. This makes the PRS thehighest stressed machine underground. Itsupports tons of rock and prevents collapseof the mine.

The PRS follows the combine harvesterthrough the mine, moving forward as thecoal layers are removed. As the PRS movesforward, it must do so in the straightestpath possible. Rigid body simulations areused to ensure that the PRS does notattach to the front or back wall whilemoving forward. The rigid body simulationalso provides information about forces andtorques while the PRS is moving. This in-formation is passed to the design teams re-sponsible for the various parts of the PRSmechanism.

Maintenance work on the PRS while itis in the mine is neither safe nor possible.The extreme conditions of the mine andthe immediate collapse of rock with the Pic

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Heavy machinery used in mining and other extreme conditionsmust be safe and reliable; there is no room for error in these conditions. Simulations with ANSYS assist engineers in designingevery detail of a Power Roof System used underground. Tagor performs the simulations, oversees the project, and provides inputon how to design stronger, better machinery. Load bearing, environmental conditions, and the level of quality needed in the welds are taken into account. The end result is heavy machinery, reliable under very extreme conditions.

Working Under ExtremeConditions

Optimization of the Power Roof Support with ANSYS

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Toolbar to create sophisticated meshes and carry out weld strength verifications on high grade materials.

The cylinders of the PRS are designed to support extreme loads. In these cylin-ders, large actuators expand with an enormous force of more than 6000 kN over the length of the five meter cylinder. This design is prone to buckling of the piston rod, particularly during sudden dynamic events. Simulations were per-formed to avoid buckling of the rods anda sudden failure of the PRS.

Tribological damage can occur when joints and pivots are exposed to dust over prolonged periods. Friction from the con-tinuous movement of the parts under high pressure and the addition of dust can lead to abrasions within the joints. Analyses of


the joint members with fretting damage arecompleted using sub-modeling techniques.

ANYS was also used to simulate the op-eration of the actuator. The actuator has asafety valve that opens in an incidental sit-

uation. If overpressure occurs, the valveshould be able to release hundred of litresof liquid very quickly. However, the valveis very small, releasing this amount ofliquid so quickly creates a supersonic flowthat easily cuts rubber hoses of the PRS orother machines used in the mine. The valvemust have a secure space where the liquidis released. ANSYS Fluent was used tosimulate these conditions.

Analyses of the Full AssemblyFinally, the full assembly is simulated andassessed. This is the only way to ensure asafe design under unsymmetrical loading.Computational costs can be reduced usingsub-structuring techniques. If the final sim-ulation involves high non-linearities, com-putational and engineering time is reducedby high-performance parallel computing.

InfoAuthors

Przemysław Siedlaczek, MEScoJacek Maj, MESco

InfoContact

Jacek Maj, MESco Phone: +48 32 786 36 36E-Mail: [email protected]



ANSYS Structural

The Power Roof Support is not the onlymachine used in mines, but its complicateddesign and analysis procedure for fatigueand safety is representative for productsof the mining industry. MESco’s assistanceand the use of ANSYS simulation toolsresult in heavy machinery that is more re-liable, durable, and safe, yet 20 % lighter.

Power Roof Support ready for delivery.

Figure 1 and 2: Stresses in the Power Roof Support.

Figure 3: Rigid body simulation of the Power Roof Support.


C A S E S T U D Y

ll development processes startwith an idea, first expressed inwords and drawings. While thetechnical understanding of the

idea evolves, construction first occurs inSolidWorks as a 2D draft and finally as 3Dmodel.

While the draft evolves, questionsemerge. Which design is preferable? Whichsolution offers the best combination of ac-ceptable stresses, deformations, weight,and costs?

ANSYS Workbench and bidirectionalCAD interfaces are used in product de-velopment driven by simulation. This startswith a comparison of different designs andimprovements based on simulation results.Within this cycle the simulation model andthe CAD model are always updated si-multaneously by the bidirectional CAD in-terfaces.

Although always based on the latest CADmodel, the simulation model requires somesimulation specific modifications. This socalled defeaturing is done in ANSYS DesignModeler and allows better simu-lation meshes and reduced simulationtimes. The modifications are automaticallyapplied to improved designs whenever theworkflow is updated. Additional user in-teraction is not required.

Simulations advance with the devel-opment of a design. Analyses of the conceptdesign change to in-depth simulations ofspecific details and favorite designs. Oncethe decision for a specific design has beenmade it is time for new simulations. Designassessments are required as well as fatigueanalyses of welds, screws and bolts.

Welds and bolted connections of thehigh pressure cylinders of the press requiredetailed fatigue assessments. The bolted

connections of the cover plates are assessedbased on VDI guidelines. Simulationsprovide a significant benefit for this sincetension forces within the bolted connec-tions are a direct result of simulations andanalytical calculations are not needed.

The pressure cylinder is assessed basedon the FKM guideline. The simulationcovers both, maximal loading conditionsfrom test loads and continuous loadingfrom the designs working environment.Accurate fatigue and durability analysesare possible by using submodeling tech-niques.

At this point the design will show if itdelivers the promises it made before. If not,design engineers will improve the designwith the information of the first detailedanalyses and update the simulation resultsuntil all fatigue assessments and engineersare satisfied.

InfoAuthor & InfoContact | CADFEM

Alexander Dopf, CADFEM (Austria) GmbHPhone: +43 1 587 10 13 14E-Mail: [email protected]



ANSYS Workbench

CADFEM Supports IAG in the Development of New Press Types

A

Machine ToolDevelopmentThe Austrian machine tool manufacturer IAG relies on CADFEM as their partner for the development of new friction lining presses.

Figure 1: Simulation resultsused for fatigue assessments.

IAG’s friction lining presses are used in manufacturing of high-quality brake pads. IAG tools produce morethan 200 Million brake pads in a yearworldwide. Nearly all cars are originallyequipped with brake pads producedon IAG tools.

Info: IAG

STAY Connected with Simulation Simulation contributes to true innovations, quality improvements, and savings in time and resources in industry and research. Meanwhile it keeps engineers from different industries and areas connected.

The CADFEM ANSYS Simulation Conference is the annual event where many users come together and learn from each other. Also, they can enjoy further education and connect with other professionals at the conference.

Therefore we kindly invite you to join us from 15th to 17th of November 2017 in Koblenz. The Programm will be published in july.

The conference program on simulation driven pro duct development is exten sive, the tools however, are few andconcise. The ANSYS product family with its core element ANSYS Workbench and selected complementary tools are

combined with the comprehensive services of ANSYS partners, CADFEM and ANSYS Germany.

We are excited and look forward to meeting you in Kassel.

The CADFEM & ANSYS Germany Team

www.usersmeeting.com

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C A S E S T U D Y

rake squeal is a friction-inducedvibration best explained by a sim-plified model of a brake assembly.Figure 1 shows a clockwise ro-

tating brake disk and a very simplifiedbrake pad in form of a beam. The beamtouches the rotating brake disk with a fric-tional contact. Without rotation of thebrake, any vibration ceases through dissi-pation at the contact between disk andbrake pad.

Under certain conditions, however, arotating brake disk causes instabilities with -in the brake assembly leading to increasingvibration amplitudes, brake squeal. Thismoment is shown in Figure 2. The rotatingbrake disk vibrates upwards in the exactmoment the brake pad moves clockwiseand therefore within the direction of the rotating disk. The brake pad is picked upby the brake disk through the contact andreceives additional energy from the disk.

At the maximum deformation of the brakepad the brake disk will vibrate downwardsand with loosing contact the brake padsprings back (Figure 3) and the cycle startsagain.

Simulation ProcessDevelopment times in the automotive in-dustry are short, and with growing designrequirements, engineers need reliable sim-ulations as well as efficient workflows.Simply modifying the design, materials, ortesting new brake pad properties shouldn’trequire any work on the simulationworkflow itself. ANSYS Workbench andANSYS Mechanical allow these modifica-tions in an excellent manner. The singlesolution steps are shown on the projectpage of ANSYS Workbench and simplycombined to a solution workflow (Figure4). The starting point for this workflow is

given by the materials used in the simu-lation, a bidirectional CAD interface toimport geometries and a robust meshingalgorithm.

While classic solutions require a timeconsuming mesh generation in the contactarea between brake pad and disk, ANSYSallows the use of simple nonlinear contact.This contact can not only replace the tra-ditional matrix elements required to definecontact between brake pad and disk, butalso add more accuracy to the solution.ANSYS uses a nonlinear static contactanalysis to solve the contact behavior be-tween rotating brake disc and pads, andsends the pre-stress effects to a subsequentcomplex modal analysis. Keeping develop -ment times in mind, ANSYS allows engi-neers to choose between short solutiontimes and higher accuracy by runningbrake squeal simulations as full nonlinear,partial nonlinear, or linear simulations.

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Brake Squeal Simulations with ANSYS and optiSLang

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Brakes withoutSqueal

A German daily newspaper recently published the following court decision: “Brake squeal is a significant lack of comfort of a luxury car. If the squealing noise cannot be eliminated by repair the buyer may be eligible to withdraw from the purchase of the car. This decision of a Higher Regional Court in Schleswig ...” Even without a legal decision, most automobile companies are veryaware of the unpleasant effect brake squeal has on driving comfort, drivers’ fatigue, and thus customer satisfaction. Therefore, avoiding brake squeal is a requirement by drivers and car manu-facturers. TRW relies on ANSYS and optiSLang to prevent brake squeal by simulations.

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23

important variables from friction coeffi-cient to material properties and CADdesign. The user simply defines a new setof material properties, a new friction con-dition, or brake pressure and updates thesimulation.

Brake squeal is not simple to under-stand. Improving the design of a brake as-sembly, as well as analyzing the assemblywith all uncertainties of its later workingenvironment, is an important part of brakesqueal simulations. optiSLang insideANSYS Workbench allows simulations including uncertainties as well as designimprovements. Variations within brakefriction and pressure, the material prop-erties of the brake pad, or manufacturingtolerances are included in the simulationand provide new information to design en-gineers.

Eye-opener by unexpected brake squealare avoided and brakes improved. The

Figure 1: Rotating brake disk.

Figure 2: Brake disk picks up brake pad.

Figure 3: Brake pad springs back.

While being able to respond to needs in timeframe or accuracy by choosing be-tween one of the three solution methods, engineers can also use different complex-solvers to solve the complex modal ana-lysis (QRDAMP, UNSYM and DAMP solver). Friction models to define friction between brake pad and disk as a function of brake pressure or rotating velocity of the disk provide the opportunity to add more accuracy to the simulation. In addition, stabilizing squeal damping, a specific brake squeal effect, the influence of gyroscopic effects, and mode tracking options are available within ANSYS Workbench.

While brake squeal simulations in ANSYS cover all areas from fast results to detailed and highly accurate solutions, ANSYS Workbench provides another im-portant piece of the brake squeal puzzle. The parametric environment includes all

CADFEM International JOURNAL

Figure 4: Brake squeal simulation process withANSYS Workbench andoptiSLang.

“That your brakes are not squealing is not just luck, it is a result of good

and detailed engineering.”

InfoAuthor | CADFEM

Marold Moosrainer, CADFEM GmbH


GermanyMarold Moosrainer, CADFEM GmbHPhone: +49 8092 7005 45E-Mail: [email protected]

USAMatthias Alberts, CADFEM US, Inc.Phone: +1 864 214 2160E-Mail: [email protected]



ANSYS Mechanical, optiSLang

As the world leader in foundationbrake systems and a pioneer in electronic braking, TRW continues to develop innovative systems thatcombine proven brake function withadvanced functionality, to meet CO2and fuel economy standards globally.We deliver smaller and lighter pro-ducts; further drag reduction; and efficient solutions for all powertrainsincluding hybrid and full electric vehicles.

Info: Green Thinking

combination of efficiency and technologyintegrated within one environment leadsto more comprehensive and reliable brakesqueal simulations.

You see: That your brakes are not squea-ling is not just luck, it is a result of good and detailed engineering.


C A S E S T U D Y

entaurum develops, manufac-tures and sells products fordentists, orthodontists, anddental technicians worldwide.

A family owned business, headquartered inIspringen, Germany, Dentaurum is notonly one of the leading dental companiesin the world but also the oldest, with ahistory and tradition going back for morethan 125 years.

Dentaurum provides their customerswith the highest quality by investing inmanufacturing and quality assurance. Asone of the first companies within the dental industry, Dentaurum was certi-fied according to the Eco Managementand Audit Scheme of the European Union.

tioLogic implants are a product of thedental implant division of Dentaurum. The system is characterized by maximalsafety, perfect aesthetics and simple han-dling. This article describes how simula-

tions with ANSYS played an importantpart in assuring the quality of the tioLogicproduct family.

The tioLogic Implant SystemImplants of the tioLogic family are used inthe upper and lower jaw. Dental implantsare inserted in the jaw bone and replacethe natural root of a tooth. An abutmentcarrying the prosthesis of the tooth is connected to the implant (Figure 1). The tioLogic product family includes the latestimplant technology and aesthetics. Thetransition between implant and abutmentis placed further inwards. The implantitself is a conic-cylindrical implant de-signed with a connection guaranteeingfirm hold of the prosthesis. The designuses two different threads lying upon eachother to ensure a firm hold and secure in-sertion of the implant. Both threads,coarse and fine are designed to reduce

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Innovative Dental Implants, Designed and Improved with ANSYS

tioLogic©, an innovative dental implant developed andproduced by Dentaurum, combines years of excellentknowledge in medicine andimplant technology. Driven byinnovation, the design of theimplant was analyzed usingANSYS simulations. The simula-tions allowed the design topass required internationalstandards successfully the firsttime they were tested.

A Firm Bite Figure 1: The tioLogic© implant.

Figure 2: Innovative design of thetioLogic© implant.

Structure

Screw

Implant

25

stress concentration in the implant so thatdamage to the bone is avoided.

To enhance these innovations and findany possibilities for design improvements(the tioLogic implants are compared tothe TIOLOX© product family, which has been successfully used over the lastyears), Dentaurum used simulations withANSYS. Finally, the design, optimizedwith ANSYS, had to pass a fatigue test ac-cording to DIN EN ISO 14801 standards.

The DIN EN ISO 14801standards(Dynamic fatigue test for endosseousdental implants) ensure that implants withstand a longtime use. The standardsspecify tests for the implant to withstand 2 Million load cycles successfully.

Design Optimization by SimulationSimulation was used to avoid unnecessaryand expensive test prototypes. The fol-lowing questions had to be answered tooptimize the design of the new productfamily:

● What are the deformations of the im-plant under the given loadingconditions?

● Where are the stress concentrations?● How will design modifications affect

the results?

The design engineers used the same loads the well-proven TIOLOX design had to withstand. With a proven and outstanding quality, the TIOLOX family was used as a reference design. Analyses of this product family showed stress levels significantly less than the yield stress of the used ma-terial.

Simulations of the tioLogic implants showed stress concentrations in the area where ambition and implant are con-nected. Although the risk for plastic de-formations in this area was low, the design engineers improved the design by re-moving the final groove of the fine thread, and therefore, increased the wall thickness of the implant in the critical area. This modification improved the design and lead to a stress level below yielding (Figure 3 and 4).

Simulation was also used to help engi-neers identifying the best material choice. All TIOLOX implants used Titan Grade 5,a standard material for implants. With less structural strength than Titan Grad 5, the use of Titan Grade 4 material for certain implants of the tioLogic family had to be analyzed. To avoid unacceptable implant


failure it was important to know theminimal required diameter for using TitanGrade 4.

Three design modifications were ana-lyzed, and the simulation results led to asignificant improvement of the implantstrengths. The simulation results showedcritical stresses for the use of Titan Grade4 and implant diameters less than 4.2mm,therefore, all implants with a diameter of4.2mm and less use the higher quality ti-tanium Titan Grade 5.

Biomechanical Analyses of the Bone StressesThe simulation results also focused on thejaw bones. The stress level of the newproduct family within the bone was iden-tical to the stress level of the TIOLOX designs. Actually, the new design and thenew fine threads within the implantshowed a more homogeneous stress dis-tribution of the bone stresses.

Successful Test of the First DesignThe optimized design had to prove its re-liability in a fatigue test according to theDIN EN ISO 14801 standards. The im-plant was tested with a norm-prosthesisand cyclic loads. The design had to with-stand 2 Million cycles without showingfailure and fatigue.

The results of the test remarkablyproved the concept of the new implantfamily. A design balanced between the well-proven concept of the TIOLOX implantsand new technological developments. Thedesign included new functionality andmodern aesthetics important for implantexperts and patients. Despite smaller di-mensions, all requirements were fulfilledto withstand the 2 Million load cycles andmore.

The ANSYS simulation results playedan important role in the design of the newimplant and made expensive time-con-suming prototypes unnecessary.

InfoAuthors

Jurgen Lindigkeit, Dentaurum GmbH & Co. KGTobias Sterzl, Dentaurum GmbH & Co. KG


Christoph Mueller, CADFEM GmbHPhone: +49 8092 7005 43E-Mail: [email protected]



ANSYS Workbench

Figure 3: Critical area of the implant.Higher stresses are shown in the finalgroove of the fine thread.

Figure 4: Removing the final groove of the thread reduced stresses below criticalvalues.

Figure 6: Test of the implant according toDIN EN ISO 14801.

Figure 5: tioLogic© implant with a 4.2 mmdiameter and Titan Grad 4 material. Sincethe stresses shown here were too high, allimplants with a diameter of 4.2 mm andless use higher quality titanium.

Load DeviceNominal bone marginStructureImplant bodyMount for the specimen

Load application point



vast number of engineering ap-plications include not only phy-sics of a single domain, but alsoconsist of several physical phe-

nomena, and, therefore, are referred to asmulti-physics. As long as the phenomenaconsidered are to be treated by either a con-tinuous approach, such as Eulerian, or adiscrete approach, such as the Lagrangianapproach, a homogeneous numerical so-lution concept may be employed to solvethe problem. However, numerous chal-lenges in engineering exist and evolve, in-cluding continuous and discrete phase si-multaneously, and therefore, cannot besolved accurately by continuous or discreteapproaches.

Advanced Multi-physicsSimulation Technology(AMST)The Discrete Particle Method (DPM)considers each particle of an ensemble asan individual entity with motion and ther-modynamics attached to it. The motionmodule of the Discrete Particle Methodhandles a sufficient number of geometricshapes that are believed to cover a largerange of engineering applications. Thethermodynamics module incorporates aphysical-chemical approach that describestemperature and arbitrary reaction pro-cesses for each particle in an ensemble.Relevant areas of application include fur-

A Problems that involve both a continuousand a discrete phase are important in ap-plications as diverse as the pharmaceuticalindustry, automotive, agriculture food andprocessing industry, construction and agri-cultural machinery, metals manufacturing,mining, biomedical, cement and energyproduction. Some predominant examplesare coffee, corn flakes, nuts, coal, sand, re-newable fuels and fertilizer. In particular, adiscrete approach to determine both the dy-namic (position and orientation) and ther-modynamic (temperature and species) stateof individual and discrete particles of an en-semble is not available to date. Similarly, theimpact of particles on structures or on flowof gases or liquids is largely unexplored. Pic

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The Extended Discrete Element Method (XDEM) is a numerical technique that extends thedynamics of granular material or particles described by the classic Discrete Element Method (DEM).

This extension is achieved through additional properties such as thermodynamic state, stress/strain,or electro-magnetic field for each particle. Contrary to a continuum mechanics concept, XDEM aims at resolving the particulate phase with its various processes attached to the particles. While theDiscrete Element Method predicts position and orientation in space and time for each particle, the Extended Discrete Element Method additionally estimates properties such as internal temperature inconjunction with heat/mass transfer to fluids, or mechanical impact with structures.

Simulating Particles

Adding Particles to Classic Simulations with Diffpack


naces for wood combustion, blast furnacesfor steel production, fluidized beds, cementindustry, or predictions of emissions fromcombustion of coal or biomass.

The exchange of data between con-tinuous and discrete solutions requirescareful coordination and a complex feed-back loop so that the coupled analysis con-verges to an accurate solution. This is per-formed by coupling algorithms betweenthe Discrete Particle Method to the FiniteVolume e.g. Computational Fluid Dyna-mics to structural engineering or standardFEM software with Diffpack.

AMST in ActionThe applications for multi-physics analysescover a vast amount of engineering appli-cations that involve coupling of multiplephysical phenomena of particulate andgranular materials. Many of these applica-

tions require high consumer-safety, such asthose associated with the food processingand automotive industries, where accurateanalyses are critical to understand andensure product reliability.

AMST is also to be considered avaluable tool in biomedical applications, inwhich product performance is a criticalissue in life-or-death situations. For ex-ample, intravenous drug-delivery requires

Figure 1: Tire impacting a granular ground.

Figure 2: Particles impacting a conveyor belt with subsequent deformation.

Figure 3: Temperature distribution of particles in a packed bed reactor.

InfoAuthor

Prof. Dr. Bernhard PetersUniversity of Luxembourg, www.uni.lu

InfoContact

Frank Vogel, inuTech GmbHPhone: +49 911 323843 10E-Mail: [email protected]



Diffpack

MoreInformation

www.diffpack.com, www.xdem.de, www.inutech.de

fluid-solid interaction-coupled physics. Inparticular, AMST will play an importantrole in structural engineering by suppor-ting, understanding, and analyzing loaddistribution due to impacting granular material. Figure 1 shows a simulation of atire on granular ground. The simulation ofparticles impacting a conveyor belt isshown in Figure 2.

Furthermore, AMST is widely emplo-yed in engineering applications such aspacked bed or fluidized bed reactors as atype of chemical reactors shown in figure3, fluid catalytic cracking, fluidized bedcombustion, heat or mass transfer andcoating.



lectrostatic painting is a method ofpainting used in the automotive in-dustry to apply paint to the metalsurfaces of the automobile. The

electrostatic painting process starts with abare bone car frame known as a body-in-white or BIW. The BIW has been strippedof all its moving components leaving onlythe sheet metal parts that are welded together forming the general shape of thecar. This BIW proceeds through multiplesteps in the factory including electro-deposition coating (ED-coat) and severalspray applications.

Most car drivers are unaware that theirvehicle has been through a five-step paintprocess that results different layers of paint.Starting from the surface of the car bodywe have:

● Pre-Treatment: Providing surfaceadhesion for the following layers

● ED-Coat: Offers protection fromcorrosion

● Primer Surface: Prepares the surfacefor the adhesion of the color

● Base Coat: The color layer● Clear Coat: Gives a glossy finish and

protects from weather

The ED-coat is of particular importance.This layer provides shielding from mois-ture and other corrosive elements that caneventually damage the automobile. The

the structural behavior of the car body.Therefore, the concern for many auto-motive companies is developing a way tolook inside those hidden regions to ensuresufficient coating without paint pooling onthe material within the pocket.

Working together with BMW, CADFEMcombined decades of knowledge in thesimulation business with the automakersknowledge to develop tools for simulatingthe painting procedure.

Virtual Paint Shop (VPS®) developedby CADFEM GmbH consists of two mainapplications, one to analyze the ED-coatbehavior in the paint bath (VPS/EDC) andthe other to simulate the BIW in the dryingoven (VPS/DRY). By utilizing simulation,engineers can determine the film thicknessgrowth of the ED-coat as well as tempe-rature profile and mechanical deforma-tions due to high temperature loads duringthe drying process.

It is this film thickness analysis that wasof interest to Honda R&D America’s, Inc.Working with CADFEM, Honda was ableto confirm the ED-coat simulation withVPS/EDC for their development of newcar bodies and achieve a virtual prototypein the painting area. This was validated bya stepwise approach and a detailed com-parison between simulation results andmeasurements on real structures.

Because the processing line mustmaintain a certain speed, simply leaving

E process of applying the ED-coat requiresdipping a negatively charged BIW into apositively charged bath of paint. This elec-trochemical process should result in thepaint covering the entire car body, insideand out.

But what if it doesn’t? An insufficient ED-coat can lead to poorcorrosion protection during the lifetime ofthe car. Depending on company war-ranties, this could lead to a massive recallby the auto manufacturers. In 2001 alone,three auto companies were forced to recallnearly 1 Million cars due to issues relatedto corrosion1. Along with fuel efficiency,crash safety and the overall aesthetic ap-pearance of the car, designers must takeinto consideration the BIW’s design withregard to coating.

Visual inspection on the processing lineonly tells half the story, it does not showmissed areas. Common areas of concernfor manufacturers are the enclosedvolumes and cavities within the BIW. Thelatter are the most challenging areas whereinsufficient ED-coating often occurs dueto the Faraday Effect (isolated regions withno electric current and therefore no paintdeposition). These areas can’t be visualizedduring the process. Holes in the sheet metalwill reduce the Faraday effect; however,they will have a significant influence on Pic

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Durable Paintwith Virtual Paint ShopAvoiding damage to the car due to corro-sion is understandably a high priority in the automotive industry. Honda relies on simulation to achieve a high quality of protective paint for the new Acura TL.

29

the body in the paint longer is not a viable option. However, with the results from the ED-coating simulation engineers can change the geometry of the BIW to allow for a better coating in all areas of the body. At this point the model can be ‘cut’ within the virtual environment to observe the cav-ities and volumes that are typically prob-lematic for the manufacturer during the painting simulation. In addition, simulation also has the advantage of easily showing the effects of changing voltages in the ED bath at different zones along the line.

In order to implement the Virtual Paint Shop simulation, an auto manufacturer must provide three things. The first and most fundamental is the car body CAD data. Honda provided a reduced body-in-white that consisted of the most crucial sections of the car body. Since this is the focus of the analysis, it is the most essential part required for the simulation.

The second requirement is the general paint parameters. A calibration test must be performed from the paint used on the factory line. A simple, but essential, test in-volving two plates and an anode is per-formed and the characteristic such as the conductivity, electric current and throw power (paint’s ability to grow between two adjacent metal sheets) is measured. Tem-perature and other conditions can be varied during the calibration as well. Based on these measurement results, a parameter extraction is done to obtain material pa-rameters for the specific paint line.

The third and final group of required input is the data pertaining to the pro-cessing and equipment. Aspects such as line speed, tank geometry, distribution of the anodes and voltage program are con-sidered when setting up the simulation.

To truly appreciate the complexity of this simulation one must understand the deposition process. As mentioned earlier,


the electrons flow from the anode to the carbody (cathode) and a thin layer of coatingbuilds up on the car surface. The rate ofdeposition decreases as time goes on. Thisis because the deposition rate depends onthe current density which is a function ofthe surface resistance of the car body. Thisresistance depends heavily on the thicknessof the ED-coat which is getting thickerevery moment. By calculating the integralof this deposition rate CADFEM engi-neers are able to find the precise thicknessof the coat at any point on the body and atany time step.

Those familiar with simulation andfinite element procedures are well awarethat a majority of the preprocessing ofCAE models is spent creating a propermesh. For paint simulation there is an ad-ditional effort in creating all requiredvolumes besides the meshing process. Thetimeframe of meshing a full body-in-whitemodel takes around five weeks to complete.However, by focusing on the most criticalregions of the body to be simulated Hondawas able reduce this to about three weeks.

Honda created a two step procedure forvalidation. The first step involved a rec-

tangular tube positioned in the center ofthe vehicle as the initial test for the capa-bilities of the VPS tool. After the simulationconfirmed the results from this test, a fullbody-in-white was simulated. VPS suc-cessfully predicted 100 % accuracy withinthe requisite tolerance range. There wereover fifty measurement points comparedwith simulation results, distributed all overthe car model.

Due to the importance placed on pre-venting corrosion automotive manufac-turers are looking to simulation methods topredict the ED-coat thickness for theirBIWs. The results of the simulations per-formed by CADFEM demonstrated toHonda that the VPS software was capableof predicting the ED-coat paint thicknessin body-in-white structures. By integratingVPS in their product development, Hondawas able to balance the performance ofCorrosion, NVH (noise, vibration &harshness) and Crash prior to establishingspecifications for their BIW structures.

InfoAuthors

Steven Junor, CADFEM US, Inc.Ray Hughes, Honda R&D Americas, Inc.


GermanyGerhard Zelder, CADFEM GmbHPhone: +49 8092 7005 87 E-Mail: [email protected]

USAMatthias Alberts, CADFEM US, Inc.Phone: +1 864 214 2160E-Mail: [email protected]



ANSYS Mechanical, VPS

InfoReferences1 National Association of Corrosion Engineers Inter-

national. “Vehicle Recalls due to Corrosion,” NACE.http://events.nace.org/library/corrosion/Car/recalls.asp, January 10, 2012

Figure 1: The new paint shop line at Hondas Maryville auto plant.

Figure 3: Simulation Accuracy. Comparisonbetween actual thicknesses and thick-nesses predicted by VPS for measurementpoints on the exterior of the car body.Overall, CADFEM successfully predicted all 53 measurement points.

Figure 2: ED-coat thickness after 180 seconds. View inside theAcura TL body in white, outside metal sheets hidden.


I N N O V AT I O N

ou have to admit, the idea is im-pressive: Transforming carbondioxide, or CO2, into syntheticfuel. “Our motivation is high. We

want to contribute to a carbon dioxide-neutral mobility”, says Dominique Kro-nenberg, COO of Climeworks. Rising concentrations of carbon dioxide arewarming the atmosphere, and since in-dustrialization, the concentration of carbondioxide has increased massively. Nowadayswe have 400 CO2 molecules per million inearth’s air, around 1800 it was 280.

Climeworks wants to use carbon dioxideto produce synthetic fuel and contribute toa reliable energy supply and reduction incarbon dioxide emissions. For this goal, thecompany works on a CO2 Catcher.

dioxide is added to the greenhouse.Carbon dioxide fertilizing itself is not anew development. But, until now, thecarbon dioxide is produced by burning gas.Instead of using the carbon dioxide we al-ready produce, it’s an additional use of oilor gas. Climeworks’ CO2 Catcher mainlyruns with thermal energy, generated bysolar power, or as a by-product of indus-trial facilities. The CO2 Catcher is alsosmall in size, using not more than 1 % ofthe greenhouse area.

The first prototype is planned for fall2012. But that is just the first step. Climeworks is currently looking for indus -try partners to manufacture the absorber inlarger numbers, bringing the CO2 Catcherto the market. To catch the carbon dioxide,Climeworks uses a specific filter technology.“The filters used in the CO2 Catcher arenot based on filter sheets but on a granularfilter medium”, explains Maria Maluszyns -ka, Chief Chemist at Climeworks.

That’s how you Catch Carbon DioxideHow does the CO2 Catcher work? Sim-plified, the complete system is a box filledwith absorber material. Mechanismscontrol the air flow through the box. Whilethe air flows through the box, chemical re-actions separate the carbon dioxide andmostly clean air leaves the box.

Y The First Goal: CO2 for a GreenhouseAlthough always in mind, the long termgoal of the CO2 Catcher is currently a steptoo big for the young company. The spin-off from the ETH in Zurich focusses onother niche markets for their CO2

Catcher. The beverage industry, green-houses and wastewater treatment facilitiesall use carbon dioxide. Climeworks fo-cuses on greenhouses. According toClimeworks the sales potential of carbondioxide in Europe alone exceeds $ 600Million per year. Carbon dioxide fertil-izing is especially effective when growingvegetables. The growth of cucumber, forexample, increases by 30 % when carbon

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Climeworks develops a technology to remove CO2 from our air. The young company wants to produce synthetic fuel from the gas,that transforms our earth into a greenhouse.

The CO2 CatcherTechnology for Our Environment

With CO2 fertilization, the growth of cucumbers can be increased by 30 percent.

31

To separate the carbon dioxide from the filter, the complete system is closed and heated. Solar heat, not to be confused with solar electricity produced by photovoltaic cells, can be used as a heat source. With the carbon dioxide isolated from the air, it can be used either directly on-site or stored in the form of gas, dry ice or synthetic fuel. The filter, now cleaned from all carbon dioxide, can be reused. Climeworks ex-pects a filter lifetime of up to four years. This is currently tested intensely in long time tests. The technology for the CO2 catcher has been developed within the In-stitute of Energy Technology and the Pro-fessorship of Renewable Energy Carriers, directed by Prof. Aldo Steinfeld, at the ETH in Zurich, Switzerland.

A Wider UseIn 2020, the CO2 Catcher shall be pro-duced in larger numbers and used to gen-erate the raw material for synthetic fuel. Catching the carbon dioxide out of the air has a huge advantage, the carbon dioxide can be produced nearly anywhere. In an ideal case, next to a fuel synthesis plant. The market for synthetic, or renewable, fuel is promising. Efforts to push re-newable energy sources do help. In Europe the European Union just recently passeda law that requires, until 2020, ten percent

of all fuel consumption to come from re-


newable energy sources. This is naturallyimportant for airlines. Being aware of thehigh penalties they face when these re-quirements are not fulfilled, airlines arewilling to pay a higher price for renewableenergy sources. This is where Climeworkssees its market.

The Final Goal, Synthetic Fuelfrom Carbon DioxideClimeworks will cooperate with SunFireto produce the synthetic fuel. While Climeworks CO2 Catcher produces thecarbon dioxide, SunFire produces the syn-thetic fuel. A first demonstration unit, producing a barrel of synthetic fuel a day,is planned for 2013. In 2016 Climeworksand SunFire want to open the first pilotfacility. This facility will produce five tonsof synthetic fuel a day.

Next to economic aspects synthetic fuelhas additional advantages. The fuel is ofhigher quality than fossil fuels containingsulfur and other residues. Maybe evenmore important, synthetic fuels guaranteea security in energy supply.

Although not directly improving cli-mate, synthetic fuel is carbon neutral since it has not been produced by fossil resources. The carbon dioxide taken fromthe air will, however, finally find its wayback into the air when it’s burned. This isavoidable by storing it underground or in

the sea. Although research work is donewithin this area, there are many open ques-tions, and a real solution for this will haveto wait another 10 or 15 years.

It will be a while till Climeworks willplay its role in reducing global warming.But, their CO2 Catcher will allow Climeworks to sell carbon dioxide farearlier to niche markets. “The nichemarkets allow us to bring a product to themarket early. This will help us to financethe development of larger units used toproduce synthetic fuel”, explains JanWurzbacher, co-founder of Climeworks.Currently Climeworks finances itselfmainly by participating and winning tech-nology awards and by support of differentfoundations. But, private investors also be-lieve in the innovative idea and team ofClimeworks. Next to the Zurcher Kanton-albank this is also CADFEM International.

InfoAuthor

Elisabeth FryThis article was originally published in German in the “Zurcher Wirtschaftsmagazin 1/2012”, the magazine of the Zurcher Kantonalbank inSwitzerland.

InfoContact

Dominique Kronenberg, Climeworks AGPhone: +41 44 633 75 95E-Mail: [email protected]


32 CADFEM JOURNAL International


he esocaet education programsfocus on theoretical and methodo-logical knowledge but also on prac-tical use of simulation technology.

Not related to specific software tools, esocaet is a link between industry and uni-versities. It transports knowledge learned,directly to the day to day work. Today esocaet offers

● Part-Time Master’s Degree “AppliedComputational Mechanics”

● eFEM for Design Engineers (OnlineEducation)

● CAE Related Trainings● Summer Schools for PhD Students● CADFEM Forum for CAE Manager● School Projects

Part-Time Master’s Degree“Applied Computational Mechanics”The unique and international masterprogram in Applied Computational Me-

degree is unique to the esocaet education.Companies benefit from engineers verywell educated in simulation technology andmanagement. In many other countrieswithin and outside of the European Unionthe part time education of esocaet is aunique possibility. esocaet is currently es-tablishing the master program in India andMalaysia, funded by the German FederalMinistry of Economic Cooperation andDevelopment. Other countries, Russia orthe USA for example, have also shown asubstantial interest in the program.

Today the esocaet program allows com-panies to educate students from all overthe world and combines education of thestudents with familiarizing them to theGerman industry culture. The two yearmaster degree is an ideal link within inter-national CAE groups.

Whirlpool used the esocaet program toeducate one of their Indian engineers inGermany while the engineer was employedby the Whirlpool subsidiary Bauknecht. In-tegrated into the CAE team, the student

chanics attracts students from variouscountries worldwide. The master’s degreeis a two year program, teaching studentssimulation knowledge in compact blocks,part time, next to their industrial day to daywork. This allows students to connect edu-cation and work, and bring their own tasksfrom work into the program. Next to pro-fessors from the Universities of AppliedSciences Ingolstadt and Landshut, top-class professors from other universities areteaching modules of the program. CAE ex-perts from various industries maintain thelink from education to industry and com-plete the master program. All studentsgraduating from the master program of Applied Computational Mechanics aregiven the academic title Master of Engi-neering (M.Eng.). The master program isaccredited in Germany.

The master program, organized by esocaet, offers many simulation and tech-nology oriented modules, but also man-agement related classes. This combinationof technology and management in a master

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The “European School of Computational Engineering Tech-nology”, shortened esocaet, started in 2004 as a projectfor the development of education in simulation sciences.Funded by the European Union, the project led to the parttime master program “Applied Computational Mechanics”.CADFEM, the Universities of Applied Sciences Landshutand Ingolstadt and international partners participated inthe development. CADFEM realized the importance of parttime studying opportunities early and established morepart time education next to the master program in the lastyears. Today, esocaet is a separate division at CADFEM.

Industry Related CAE Education

T

Learningand Working

33

combined the education of the master program with his day to day work. When finished with the two year program the student returned to Whirlpool in India.

The Bosch and Siemens Home Appli-ances Group (BSH) uses another inter-esting concept combining education with outsourcing. While studying for the esocaet master program the students are employed by BSH in Germany and familiarize them-selves with the simulation tasks of the BSH simulation group. When the students fin-ished the master’s degree they returned to India and are now working for CADFEM India as outsourcing partner exclusively for BSH. This new concept is explained in more detail in this edition of the CADFEM international Journal (Training at BSH Opens Doors for the Future).

CADFEM JOURNAL International

The First Step into Simulation,eFEM for Design EngineerseFEM for Design Engineers is an onlineeducation program providing interested stu-dents with basic knowledge in ComputerAided Engineering. The program is targetedat design engineers interested in simulation.The concept of the program is based onblended learning, mainly allowing studentsto teach themselves with e-learning modulesand online education. Complemented byfew onsite education days the program isbuilt of 140 learning units and completedwithin three months. The attendees canlargely decide by themselves if they arelearning at home or at work. Next to theonline education modules the days onsite,two days at the beginning, one day within

the three months and one day at the end ofthe program, ensure a consequent learningprocess for all students. It further allowsstudents to get to know each other. Theprogram uses online-meetings allowing stu-dents to exchange information and ques-tions between each other and with thecourse instructor. The instructor will alsoevaluate the tasks completed by the studentsonline. The students of the eFEM forDesign Engineers usually spend about eighthours per week for the education program.

Within the next years the online edu-cation program of esocaet will expand tospecific areas of interest. The medical in-dustry, electronics, architecture and civilengineering will complement the currentopportunities. And the program willexpand to more countries. CADFEM Indiastarted the online education in 2011 and esocaet plans to offer simulation educationwithin North-Africa starting in 2013.

More Possibilities of esocaetNext to the master’s program and onlineeducation esocaet offers technology orien-ted trainings in Germany, Switzerland andAustria. These trainings cover topics fromquality management to product liability.New topics, such as electro-mobility or en-vironment friendly product and processoptimization, are also covered by the esocaet training program. Based on de-mand, these courses are also given inEnglish. A more intense exchange ofknowledge and teaching is possible in theone week summer schools of esocaet tar-geted directly at PhD students. While thesummer schools focus on specific simula-tion areas and higher education CADFEMrealized that simulation should also ap-pear earlier in education. Together with a high school near Munich in Germany,CADFEM established and supervised aone-year school project focused on simu-lation in 2011. In 2012 this project hasbeen continued with further high schools.

Outside of simulation technology esocaet organizes the CADFEM forumsince 2007. This forum gives CAE mana-gers multiple opportunities to discussmanagement problems and ideas withinthe CAE environment.


Anja Vogel, CADFEM GmbHE-Mail: [email protected]: +49 8092 7005 52


MoreInformation

www.esocaet.com

Figure 1: Alumni’s of the esocaet master’s program “Applied Computational Mechanics”.



SH is certified by the CorporateResearch Foundation (CRF) as aleader among employers. In 2012BSH has again been ranked by the

CRF Institute among the top emplo-yers in Germany, Poland and the Nether-lands. In the category “innovation man-agement” BSH achieved the 1st place con-cerning “Top employers for Engineers2012”.

“We not only seek the most qualifiedperson for our company, we also want tohave a work environment in which theycan develop and meet their individualstrengths and preferences – now andthroughout their professional life ahead”,adds Dan Neumayer, who is now managerof oven predevelopment and was directingthe simulation group before his currentposition.

“A good example is the esocaet-conceptand its part-time Master in Engineering”,adds Dan Neumayer, who is directing the

concept was basically designed to max-imize the value of the outsourcing part-ner.

BSH develops a wide range of pro-ducts with various simulation applica-tions. “Intensive in-house trainings at BSHin Germany provided the basis for our efficient work with outsourcing partners.”The required qualification is ensured bythe esocaet master program Applied Com-putational Mechanics at the Universitiesin Landshut and Ingolstadt.

“The master course is completed par-allel to in-house training and was fullyfunded by BSH. Over two years we haveworked very close with two engineers fromIndia”, explains Dan Neumayer. “We wereable to build up a mutual cultural under-standing and develop a shared way ofthinking and working. This intense rela-tionship is a very important base for ourlong-term cooperation and we see this asa fundamental success factor. The in-house

simulation group of BSH. BSH uses esocaet to qualify their direct engineersand engineers of their outsourcing partnerCADFEM India. BSH hired two engineersfrom India for two years to complete themaster program “Applied ComputationalMechanics”. Within the last years severalengineers, while studying, employed byBSH in Traunreut, have successfully com-pleted the master course.

A Concept Attractive for BSH and Outsourcing PartnerCADFEM IndiaThe internal resources at BSH alone maynot be able to handle all simulation needs.Therefore, BSH uses external resources tosupport standardized simulation tasks.“Our goal is to achieve a sustainable out-sourcing concept for the CAE sector, andto use the experience of already com-pleted projects”, says Dan Neumayer. The Pic

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The Bosch and Siemens Home Appliances Group (BSH)produce close to 1 Million ovens and hobs in Traunreut,Germany per year. The development and production facility not only meets the latest requirements of ergo-nomic workstations but also sets new standards interms of energy and resource usage. The factory whichis today a BSH facility has existed for more than 60 years and has more than 2,000 employees. Provingthat development and manufacturing of household appliances in Germany can indeed be successful.

A Long-term Basis for Simulation

B

Training at BSH Opens Doors for the Future

35

training combined with a parallel master‘s program for Indian engineers is a very at-tractive choice of qualifications. Based on international qualifications, there are many ways to shape their future career. With these references, there are many doors open to them.”


Outsourcing Success at BSH

“Once graduated, the new experts in com-putational mechanics will work forCADFEM India with a two-year contractbinding them to BSH. We naturally assumethat they will continue to work for us with

an open contract after that”, says DanNeumayer. “Within the first two years, wewill achieve our return on investment andbenefit from financing the master courseand the trainings in advance.” Currently,two well-trained Indian professionals areperforming simulations for the productarea cooking. However, the need will growin the near future with other product categories of BSH as they desire to take advantage of the CAE outsourcing conceptas well.

Outsourcing projects is always con-nected with an increased workload whichresults in additional communication effort.A relief of local computation effort cantherefore only be realized if the share ofprojects assigned in its size is significantlylarger than the basic operating costs. Com-pensation of the “overheads” arises fromparallelization of preprocessing operationsin India.

Other employees of CADFEM Indiaare also supporting the BSH projects. Thisexpands the base for a long-term cooper-ation. In preparation for the outsourcingproject while completing the master degreein Germany, the Indian engineers havelearned not only about simulation tasks atBSH, but also about solidarity and coop-eration, joint development methods andcreative opportunities. Dan Neumayer em-phasized this, “We have created a solid andpromising long-term base for an interna-tional accomplishment of our simulationtasks.”

“We not only seek the most qualified person for our company, we also want to have a work environment in which they can develop and meet their individual strengthsand preferences – now and throughout their professional life ahead.”Dan Neumayer, manager of oven predevelopment

InfoAuthor | CADFEM

Gerhard Friederici, CADFEM GmbH


IndiaPraveen Mokkapati, CADFEM IndiaE-Mail: [email protected]: +91 40 64543579

GermanyAnja Vogel, CADFEM GmbHE-Mail: [email protected]: +49 8092 7005 52


MoreInformation

www.esocaet.comwww.bsh-group.com


J O I N T R E S P O N S I B I L I T I E S


[email protected]


n 1959, Palden Tawo, his wife and their parents, fledfrom their home country Tibet and found a new homein Switzerland. With a heart for the small children inTibet and help from close friends, Palden Tawo, his wife

and Yeshe Gonpo Khaser founded the Tadra project 35 yearsafter their journey from Tibet to Switzerland. The project im-proves the terrible circumstances of orphans and abandonedchildren in Eastern Tibet, and the utterly unsatisfactory edu-cation and health system. New children’s villages are builtwithin the project providing the small children with a newhome and education.

The Tadra project is important to the children in Tibet andit’s important to CADFEM. We are glad to support the projectin form of an orphanage, the “CADFEM-House”.

Of course, donations for the project are always welcome,and the children in Tibet will always be thankful for even thesmallest donations. Every cent goes directly to the project inTibet. Please contact us if you are interested in the project.

I

Orphans Villages in Tibet

The TadraProject

www.cadfem- internat ional .com

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