engineering case study
TRANSCRIPT
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
http://www.econengineering.com 2
2 http://www.econengineering.com
Composite capabilities Calculations for Automotive, Railway and Aircraft
http://www.econengineering.com 3
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
4
http://www.econengineering.com
Composite Camera Console
5
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
http://www.econengineering.com
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
http://www.econengineering.com 6
ULTRA LIGHT aircraft
7 http://www.econengineering.com
• 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
8 http://www.econengineering.com
• 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
http://www.econengineering.com 9
Topology optimization • Development for
DAIMLER
• Part
Side Support
• Material
MakroBlend KU
(Polycarbonate + PBT)
• Preprocessing:
ANSA, Hypermesh
Shell model
• Solver:
OptiStruct
Static loadcases
• Postprocessing:
HyperView
http://www.econengineering.com 10
Case Study #1
Original Design Space Optimization result Engineering interpretation Wall thickness optimization
http://www.econengineering.com 11
Case Study #2
Original Design Space Optimization result Engineering interpretation Wall thickness optimization
http://www.econengineering.com 12
Case Study #3
Original Design Space Optimization result Engineering interpretation Wall thickness optimization
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
15 http://www.econengineering.com
• 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
http://www.econengineering.com 16
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
http://www.econengineering.com 17
Optimization for a
plastic-hybrid
door concept – study Calculations for Automotive
http://www.econengineering.com 18
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
http://www.econengineering.com
Smart Tür A451
Projektkonzept, Aussenhaut aus faserverstärkten Materialen
Lastfälle
http://www.econengineering.com
Nondesignable steel structure
Wandicke (alle Rohre und
Blech): 1.5 [mm]
Designable skin – z.B. Organoblech
Designable solid – PA
Smart Tür A451
Projektkonzept, Aussenhaut aus faserverstärkten Materialen
KONZEPT #3 - Ergebnisse
http://www.econengineering.com
Low speed impact &
pedestrian safety Calculations for Automotive
http://www.econengineering.com 22
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
23 http://www.econengineering.com
Pedestrian Safety Calculations
http://www.econengineering.com 24
Strength
calculations for
automotive industry Coupled thermal – structural analysis
http://www.econengineering.com 25
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
http://www.econengineering.com 26
Calculations for
the Railway industry Other Industries
http://www.econengineering.com 27
Railway Calculations
• Preprocessing:
ANSA, Hypermesh
Shell model
• Solver:
NASTRAN
Static loadcases
• Postprocessing:
HyperView
• Standardized loadcase
combinations for fatigue
evaluation and strength
assessment
http://www.econengineering.com 28
Tram Calculations
• Preprocessing:
ANSA, Hypermesh
Shell model
• Solver:
ANSYS
Static loadcases
• Postprocessing:
ANSYS, HyperView
• Standardized loadcase
combinations for fatigue
evaluation and strength
assessment
http://www.econengineering.com 29
Strength Calculation of Motor Bogie
30 http://www.econengineering.com
• Preprocessing:
ANSA, Hypermesh
Shell model
• Solver:
Nastran
Static loadcases
• Postprocessing:
HyperView
• Standardized loadcase
combinations for fatigue
evaluation and strength
assessment
• Fatigue evaluation
Calculations for
the Autobus industry Other Industries
http://www.econengineering.com 31
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
http://www.econengineering.com 32
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
http://www.econengineering.com 33
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
http://www.econengineering.com 34
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
http://www.econengineering.com 35
CFD
Calculations Other Industries
http://www.econengineering.com 36
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
http://www.econengineering.com 37
Centrifugal Pump
• Target
Determination of moment on
turbine wheel, and efficacy.
• Method
Frozen rotor model
http://www.econengineering.com 38
Cabin Heat Exhanger Device
http://www.econengineering.com 39
• 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
http://www.econengineering.com 40
System Simulation
41 http://www.econengineering.com
• 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
http://www.econengineering.com 42
• 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
43
2014 eCon Engineering Kft. - http://www.econengineering.com - [email protected] – phone: +36 1 279 0320 - fax: +36 1 279 0321 Material - PA66 Vydyne
http://www.econengineering.com
Inhaler holder
44
• 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
http://www.econengineering.com
ANSYS Workbench – Moldex3D
45
• 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
http://www.econengineering.com
Rapid prototyping
capabilities
http://www.econengineering.com 46
RPT capabilities – with cooperation partner
47
Sand casting
Printex wax pressure tool
Special gearbox parts – gravity casting