Engineering case study

ENGINEERING & CONSULTING

2015

Skills and Experience

Simulation – CAE: Modell building, meshing Structural analysis (linear, non-linear) Creep analysis Dynamic and kinematic simulations Thermal analyses Electromagnetic simulations Transient simulations Endurance calculations Seismic analyses Analysis of composite structures (CRP, GRP, …) Explicit simulations (crash, drop, airbag) Multi-body simulations Optimizations Programming for CAE applications

Design – CAD: Special equipment Robots Welding and riveting machines Assembly lines

Employees by experience CAE: 20 Employees 7 – ANSYS Classic/Workbench 2 – ANSYS/CFX, Fluent 4 – ANSYS/LS-DYNA, 4 – LS-DYNA, PAM-Crash, RADIOSS 2 – ANSYS/ACP 2 – ANSYS/Optislang 4 – ABAQUS/Standard 2 – ABAQUS/Explicit 4 – NASTRAN, Patran 2 – FEMFAT, nCode 8 – HyperWorks 3 – Optistruct 10 – ANSA 1 – MAXWELL 2 – Medina 3 – Moldex3D 2 – MoldFlow 1 – ADAMS, Simpack 3 – LMS AMESim Designers: 15 Employees 8 – SolidWorks 8 – CATIA 4 – ProEngineer

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Composite capabilities Calculations for Automotive, Railway and Aircraft


CAE Experience in Composites

• FE modeling – HyperWorks, ANSA, ANSYS Composite PrePost • Shell models

• Mixed models – Shells and Solids

• Solid models

• Sub-modeling

• Material property definitions

• Solvers – ANSYS, NASTRAN, ABAQUS • Static calculations

• Thermal and coupled thermal-structural analyses

• Dynamic calculations

• Optimization – Finding an optimal layup, based on predefined loads and boundary conditions • Minimize deflection

• Weight reduction

• Topology and Topography optimizations

• Assessment based on failure criteria • Calculations based on some major criteria: maximum stress, maximum strain, Tsai-Hill, Tsai-Wu, Hashin, Puck, LaRC

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Composite Camera Console

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High frequency dynamic analysis The model combines shell, solid and beam elements. An Orthotropic

Material model was used. The effect of the impact is a 90G load

applied in two directions

Problem: A test bench for crash experiments was equipped with high-speed

cameras. The cameras are to be fixed onto composite levers.

Shaking of the cameras due to the impact is critical

Optimization The outer shape of the arm is fixed. Design variables are the layup

and the reinforcing ribs. The goal is to keep peak deformation under

5mm in both loadcases.

Reinforcing ribs

Mesh closeup Interior structure

Displacement

Acceleration affecting the camera Model overview

Test video


Modular Sandwich Composite Autobus Development

Composite structures • Complete vehicle models

• Shell or hybrid Solid/Shell models

• Modelling and optimization of layups

• Multiple failure criteria for strength analysis

• Material model setup based on in-house and/or external measurement

results


ULTRA LIGHT aircraft


• Ultra Light category:

• max. 450kg total weight

• Geometry is based on a previous model with upper

wing configuration

• lower wing aircraft

• Non structural simulations

• Preliminary design prozess & CFD simulations

• Structural calculations

• Simulating different in-flight and landing

positions - over 10 different loadcases

• Static calculations, based on aviation standards

• Loads readily include all desired safety and

overload factors

• Composite structure is modelled using layered

shells

• Using Tsai-Wu failure criterion to assess

composite strength

ULTRA LIGHT aircraft Ply size optimization – free-size optimization result


• Ply thickness is determined by either

• Removing the ply altogether

• Placing one …

• … or more layers into the layup

• to achieve an optimal thickness

of a given orientation

• Objective:

• Minimum Weight

• no material failure

• Utilization of most utilized layer

• Improved strength 29% improvement

Optimization in

Automotive Calculations for Automotive


Topology optimization • Development for

DAIMLER

• Part

Side Support

• Material

MakroBlend KU

(Polycarbonate + PBT)

• Preprocessing:

ANSA, Hypermesh

Shell model

• Solver:

OptiStruct

Static loadcases

• Postprocessing:

HyperView


Case Study #1

Original Design Space Optimization result Engineering interpretation Wall thickness optimization


Case Study #2



Case Study #3


02. 12. 2013. http://www.econengineering.com 13

Optimization Results

Part Performance

Property Case Study 1 Case Study 2 Case Study 3

Mass reduction 0% -7% -7%

Stiffness in X direction increased +14% +22% 0%

Stiffness in Y direction increased +42% +14% +20%

Stiffness in Z direction sustained +36% 0% +12%

Mode 1 frequency increased +15% +16% +22%

Mode 2 frequency increased +11% +17% +5%

02. 12. 2013. http://www.econengineering.com 14

Organic design – Engine Bearer Optimization


• Part

Engine Bearer

• Material

Aluminum

• Preprocessing:

ANSA, Hypermesh

Solid model

• Solver:

OptiStruct

Static loadcases

• Multi level optimization:

Minimum mass w/ stress constraint

Maximum stiffness w/ same mass

• Postprocessing:

HyperView

Optimization for a

Composite bumper

concept Calculations for Automotive


Original version

Version Mass Deformation

Original (1) 1.7kg 8mm

Uniform wall thickness (2) 0.98kg 4mm

Optimized wall thickness (3) 0.67kg 4mm

1

2

3

Topology Optimization

Part performance


Optimization for a

plastic-hybrid

door concept – study Calculations for Automotive


Smart Tür A451

Projektkonzept, Aussenhaut aus faserverstärkten Materialen

Aus faserverstärkten Mateialen als eine

Platte.

In diesen Platte wird die neue Verstärkung

einsetzen/zusammenmontieren, dann

werden die Rippen eingespritzt.

Die neue Verstärkung, aus einen Teil

Kontur des Bauraums


Smart Tür A451


Lastfälle


Nondesignable steel structure

Wandicke (alle Rohre und

Blech): 1.5 [mm]

Designable skin – z.B. Organoblech

Designable solid – PA

Smart Tür A451


KONZEPT #3 - Ergebnisse


Low speed impact &

pedestrian safety Calculations for Automotive


Pendulum speed = 2.6km/h – 4.25km/h

Pendulum mass = 2048 kg

Low Speed Pendulum Impact

• Part

Complete car front

• Preprocessing:

ANSA

Shell model (with some solids)

• Solver:

LS-Dyna

Full transient explicit

• Postprocessing:

HyperView


Pedestrian Safety Calculations


Strength

calculations for

automotive industry Coupled thermal – structural analysis


Strength and CFD Calculations of Turbochargers

Structural Simulations

• Preprocessing: ANSA, Solid model

• Solver: Abaqus

Coupled thermal and structural

analysis

• Postprocessing: HyperView

• Extensive strength evaluation of the

housing using numerous loadcases

CFD Simulations

• Frozen rotor model

• SST Turbulence model

• Steady state with physical timescale


Calculations for

the Railway industry Other Industries


Railway Calculations

• Preprocessing:

ANSA, Hypermesh

Shell model

• Solver:

NASTRAN

Static loadcases

• Postprocessing:

HyperView

• Standardized loadcase

combinations for fatigue

evaluation and strength

assessment


Tram Calculations

• Preprocessing:

ANSA, Hypermesh

Shell model

• Solver:

ANSYS

Static loadcases

• Postprocessing:

ANSYS, HyperView




assessment


Strength Calculation of Motor Bogie


• Preprocessing:

ANSA, Hypermesh

Shell model

• Solver:

Nastran

Static loadcases

• Postprocessing:

HyperView




assessment

• Fatigue evaluation

Calculations for

the Autobus industry Other Industries


Static calculations

• Complete vehicle model – Chassis, body & suspensions

• Vehicle mass modelled at full load

• Static loadcases – accelerations, suspension forces and towing

• Stress evaluation in structure and in welds


Dynamic calculations

• Transient simulation of durability field testing

• Estimating results for Altoona durability test

• Transient stress signals in welds

• Complete vehicle FE model is used


Durability & Fatigue

• Varying stress in weld lines is analyzed

• Static loadcases are used to represent min/max stress states

• Transient loadcases are used to generate a transient stress signal for

rain flow analysis and damage accumulation

• Fatigue in welds is based on

• SN curves from standards

• Modified SN curves for improved reliability


Rollover simulations

• ECE-66/01-02, standard test for inter-urban buses

• Complete structure rollover or single module “static” testing

• Very strong correlation with physical test results

• Precise evaluation of Survival Space

• Prediction of local failure – break and buckling of tubes can be estimated


CFD

Calculations Other Industries


Simulation with Moving Domains

• Target

Determination of minimum and average static

pressure in chambers at given boundary

conditions.

• Method

Transient simulation with mesh deformation

Rotation of whole domain is considered

Average static

pressure in

chambers


Centrifugal Pump

• Target

Determination of moment on

turbine wheel, and efficacy.

• Method

Frozen rotor model


Cabin Heat Exhanger Device


• Model

All solid parts included

Air around the heater

Interfaces between solid-solid

and solid-fluid domains

• Solver

ANSYS CFX

• Method

Steady state simulations with

heat transfer

SST Turbulence model

• Postprocessing

comparison with experimental

results

heating performance

System simulation Other Industries


System Simulation


• LMS AMESim system simulation

software

• Experience in modeling

Mechanical

Electromechanical

Hydromechanical systems

• Valves on design level

• Calibration by CFD

• Parameter studies

• Stability analyses

Plastic injection

molding simulation Other Industries


• Goals

Reduce production losses

• Reason

Inhomogen filling

• Solution

Modify runner system

Modify cooling parameter

• Results

More even filling

Reduced shear stress in problematic region

Cable tie sumilations

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2014 eCon Engineering Kft. - http://www.econengineering.com - [email protected] – phone: +36 1 279 0320 - fax: +36 1 279 0321 Material - PA66 Vydyne


Inhaler holder

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• Goal

Show and eliminate the vacuum void

• Reason

Thick area in the part

Thin gate diameter

• Tasks – simulations versions

Oblique gate

Thicker gate diameter 0.60.9 mm

Increase Mold temperature 1550°C

Increase Mold temperature and gate diameter

• Results

None of the examined changes solved the problem

Conclusion: The void is only an aesthetic problem, it won’t break to the surface

Material – Marlex (HPDE) Increased Mold temperature and Gate

diameter

Increased Mold temperature


ANSYS Workbench – Moldex3D

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• Model desctruption

Fixed support on bolt

10 [Nm] moment on shaft.

bolt & shaft from Structural Steel

Clutch PA66: Ultramid A3EG6

Isotrop material properties Fiber orientation directly from Moldex3D

Injection molding simulation anisotrop

material properties


Rapid prototyping

capabilities


RPT capabilities – with cooperation partner

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Sand casting

Printex wax pressure tool

Special gearbox parts – gravity casting

Engineering case study

Engineering

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