Your partner for demandingcalculation tasks - since 1989

Mechanical EngineeringPlant EngineeringAutomotive IndustryAerospace TechnologyShipbuilding Industry

VirtualProduct Development

Structural Analysis

Fluid Dynamics

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MERKLE & PARTNER ENGINEERING CONSULTANTS

The engineering firm MERKLE & PARTNER, which can look back on over 25 years of company history, is one of the first service providers in the field of engineering calculations and simulations in Germany.

In our headquarters in Heidenheim and our offices inHamburg, Ingolstadt and Homburg/Saarland, 50 employees work on approximately 500 customer projects per annum in the core fields of structural analysis, fluid dynamics and virtual product development. We use of state-of-the-art and high-performance hardware and software.

Our customers are well-known companies from the fields of machine and plant engineering, aerospace technology, automotive industry and the shipbuilding industry who rely on the expertise and experience of Merkle & Partner.

YOUR RELIABLE PARTNER SINCE 1989

T H E C O M PA N Y

WE DELIVER WHAT WE PROMISE

This principle is our primary motto. With our many years of experience and the necessary hardware and software, we guarantee maximum commitment and best results.Our challenges include dealing with new topics, theimplementation of solution approaches for new tasks and

Headquarters Heidenheim an der Brenz Hamburg Branch

Foundation of Merkle & Partner by Dipl-Ing. (Graduate Engineer) Stefan Merkle, after his graduation inaerospace engineering in Stuttgart

1989

Expansion of the range of services by the construction design and professional training sectors

1995

Establishment of the fluid dynamics department1998

Establishment of the product development department2005

Setting up of first branch in Hamburg anddevelopment of a computer cluster with 144 CPUs in Heidenheim

2008

Expansion of the business premises in Heidenheimto approx. 1,700 m² office space

2009

Opening of second branch in Ingolstadt2011

Opening of third branch in Homburg/Saarland2012

the continuous improvement of our solution strategies. These challenges provide us with a field of activity in which terms such as boredom and mechanical routinesdo not exist.

www.merkle-partner.de

Homburg/Saar Branch Ingolstadt Branch

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By way of simulation, potential products in the form ofvirtual prototypes can be examined for functionality,physical properties and future performance behaviour.

Traditional product development requires the production of prototypes and testing. However, this does not allow foractual product characteristics to be detected in advance.The “trial and error” approach often only reveals problems after the market launch and thus incurs high costs.

Can be applied to a variety of technical tasks

Quick (thanks to virtual prototypes)

Risk minimisation

Cost savings

Reduced development time

Graphical visualisation of computational results

Testing of new design concepts possible

Parameter studies

“What if” studies

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CAD model

S I M U L AT I O N

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GOING PLACES WITH YOUR DEVELOPMENT PROJECTS

BENEFITS OF NUMERIC SIMULATION

WORKFLOW

Idealization

Mesh generation

Definition of loads and boundary conditions

CalculationResults evaluation

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The main tasks of structural analysis include calculations, simulations and the optimisation of components and complex modules for the determination of physical properties (e.g. forces, stresses or deformations). We take on tasks from a wide variety of industries.

Buckling » Linear buckling according to Euler » Non-linear buckling » Bifurcation buckling » Elastoplastic buckling Dynamics / vibration » Modal analysis (determination of natural frequency) » Frequency response analysis » Random analysis » Harmonic analysis » Impact analysis » Spectrum analysis Earthquake simulation Strength (linear and non-linear) FSI fluid-structure-interaction

Rubber and gasket calculation Contact (with/without friction) Plastics calculations High-speed dynamics » Crash » Drop-test » Containment Life cycle analysis » High-cycle fatigue » Low-cycle fatigue Plasticity » Perfect plastic behaviour » Stress-strain dependence » Strain hardening » Cyclic plasticity

Thermal tasks » Steady » Transient » Linear » Non-linear » Radiation » Thermoelasticity » Thermoplasticity » Creep Thermal Shock

CORE COMPETENCE STRUCTURAL ANALYSISFINITE ELEMENT METHOD (FEM)

S T R U C T U R A L A N A LYS I S

AREAS OF APPLICATION

Courtesy of Leusch GmbH Industriearmaturen

www.merkle-partner.de

On the Web: www.m-cae.de/fea

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The life cycle analysis determines the maximumnumber of tolerable load changes for componentsthat are subjected to changing or cyclic loads.

The classic application range of FEM is for cases of failure; this is also a main line of business of MERKLE & PARTNER.

In case of component failures within an agreed servicelife, costs are often high due to the substitution of thecomponent itself, secondary damages as well asproduction downtimes or product recalls. Many of these damages could have already been identified in the design or construction phase through the early application ofcomputational simulations.

The aim of component optimisation is to achieve the best possible stress resistant component design. In this context, the potential for optimisation is dependent on boundary conditions such as e.g. costs and benefits. Objectivesinclude minimising material costs, testing alternativematerials or increasing the load tolerance.

LIFE CYCLE ANALYSIS

FAILURE ANALYSIS

COMPONENT OPTIMISATION

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MERKLE & PARTNER manages the complete virtual process from the formation of intermittent forces, the elasticresponse of the system based on FE computations up to the calculation of the acceleration level. Resonances can be recognised and eliminated in this way. In addition, mount rigidities can specifically be optimised.

MERKLE & PARTNER provides computational structural safety proofs based on finite-element models according to all standard earthquake codes (including UBC 97, EC 8, IBC 2006, KTA 2201, ISO 3010 and the Eurocode) for any type of systems, steel constructions and machines.

MERKLE & PARTNER focusses on the calculation of complexgeometries. Typical application ranges include the determination of the tolerable test pressure, flange analysis and footingconnections. The analysis of deformations or stresses can be performed in accordance with all common standards (e.g. AD2000, ASME).

SPECIAL TOPICS

STRUCTURE-BORNE SOUND

S P E C I A L T O P I C S

PRESSURE VESSELS AND PUMPS

EARTHQUAKE SIMULATION

Courtesy of Cofely Refrigeration Gm

bH

www.merkle-partner.de

On the Web: www.m-cae.de/spec

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MERKLE & PARTNER focusses on containment analysesof pumps, compressors, turbines and flywheels.

As a rule, in case of material failure or cracking,no fragments should exit the containment or escape tothe outside. To guarantee this, a containment must bedimensioned accordingly.

These are explicit analyses (Crash) with underlyingfailure criteria in the material. In case of overspeed, the crack of the rotating part is initiated by calculation andthe behaviour is calculated over a corresponding period

Multi-body simulation deals with all kinetic and kinematic tasks. These include motion sequences e.g. of wheelsuspensions, gears, pumps, hydraulic lifts, cranes and wipers.

By means of multi-body simulation, loads resulting from mechanisms and mass inertia of a system are determined. These loads can be used for the determination ofdeformations and stresses in structural mechanicalcalculations.

C O N TA I N M E N T S I M U L AT I O N M U LT I - B O DY S I M U L AT I O N

CONTAINMENT SIMULATION

MULTI-BODY SIMULATION

of time until a large proportion of energy is destroyed.The shape and size of the fragments is specified byrelevant standards.

Additional Application Ranges:

Protective rooms for robots Engine rotor blades Grinding wheels Axial fans Turbochargers

Typical application ranges include driving simulations, force and torque behaviour in gears and mechanisms as well as stability analyses.

Video: www.m-cae.de/mbs

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» Steady and unsteady flows

» Laminar and turbulent flows

» Incompressible and compressible flows

» Flows with (coupled) heat transfer / CHT

» Flows with chemical reactions

» Multiphase flows

» Complex geometries

Industries

Electronics

Energyproduction

Pumps &turbochargers

Aviation

Automotive industry Chemistry &

process engineering

CORE COMPETENCE FLUID DYNAMICSCOMPUTATIONAL FLUID DYNAMICS (CFD)

F L U I D DY N A M I C S

APPLICATION RANGES

www.merkle-partner.de

On the Web: www.m-cae.de/fluid

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Fi re S imulat ion

Computational fluid dynamics (CFD) has been an integral part of MERKLE & PARTNER for more than 15 years. Understanding the impact of fluid dynamics is of crucial importance for the development process and has become a fixture in today’s industry.

Saving on development costs and reducing development time, functional safety through reduction of faulty developments and “Seeing what no one else sees” are just a few of the benefits computational fluid mechanics has to offer. The ever increasing performance capacity of computertechnology results in innovative and ground-breaking advances andapplication fields for fluid dynamics.

Automotive industryVehicle aerodynamics, vehicle occupant aerodynamics, engine cooling system, engine combustion,outdoor weathering

Motor sportsVehicle aerodynamics, design and optimisation ofaerodynamic components, aerodynamic balanceadjustment, raising of aerodynamic efficiency:“more down-force, less drag” as well as time efficientdevelopment of different aerodynamic set-ups

Aerospace industryPower engineeringTurbines, compressors, combustion chambers,capacitors, wind power, and biogas plants

Process engineering / chemical industry

BiotechnologyMedical engineeringPump and valve constructionPlant engineeringShipbuilding industryCooling for electronic componentsBuilding engineering services including air conditioningHydraulics

CFD inspires new ideas. CFD reveals. CFD generates innovations.

Simulation of spreading smoke and flue gas concentration following a fire

in a building

PRACTICAL EXAMPLES

Video: www.m-cae.de/fire

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AIR CONDITIONING OF VEHICLE INTERIORSSimulation of air emission flow for different nozzle settings in a vehicle

FLOW/RADIATION IN MOTOR COMPARTMENTCoupled simulation of flow, radiation and thermal flow in the engine compartment of a vehicle

FANS AND BLOWERSAnalysis and optimisation of impeller and housing geometry, volume flow and pressure loss

DEFOGGING OF HEAD LAMPSSimulation of different ventilation options for head lamps

GEARSMulti-phase flow of oil distribution and determination of filling volumes, ventilation losses or conveying effect

VALVESCalculation of the flow coefficient and depiction of areas with danger of cavitation

CORE COMPETENCE FLUID DYNAMICSPRACTICAL EXAMPLES

F L U I D DY N A M I C S

www.merkle-partner.de

Video: www.m-cae.de/defog

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When developing new products engineers and designers often encounter new problems, for which solutions need to be found for in a manageable time frame.

This is where the method expertise of MERKLE & PARTNER comes in. With our sound knowledge of method development and many years of experience, we develop customisedcomputational solutions for innovative tasks.

Practical example: Particel packing simulationMERKLE & PARTNER’s method development department created a simulation model which allows the analysis and optimisation of different particle packing geometries. Packing particles, used e.g. in the chemical industry, were developed with a considerable amount of time and high costs in the past.

The different visualisation options offered by the simulation allows the drawing of much quicker conclusions and the optimisation of new packing particle geometries. Packing particles can now be designed quicker and more efficiently, as this process is purely virtual. Thanks to this improvedefficiency of the new packing particles, in future, systems can be built more compact or designed for larger flow volumes.

Multi-bodysimulation

3D geometry Mesh Fluid dynamics

METHOD DEVELOPMENTPRACTICAL EXAMPLE: PARTICLE PACKING SIMULATION

M E T H O D D E V E L O P M E N T

Video: www.m-cae.de/pps

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Modern product developments with ever shorterdevelopment periods and the quickest possible market launches can only be implemented with the consistent prevention of data redundancy.

We develop new products for you, from the idea to the manufacturable product, and guide you in the prototype design, the test phase and initial operation.

The individual steps that the product goes through, from the first idea to the completion of the development, must be strictly monitored through evaluation matrices. Here, various factors such as optics, design, market analyses, production characteristics, material etc. play an important role.

Assessment of feasibility and implementation

Generation of a 3D model within a defined temporal and financial framework

VIRTUAL PRODUCT DEVELOPMENTHOLISTIC SUPPORT FROM THE IN IT IAL IDEA TO COMMISSIONING

V I R T U A L P R O D U C T D E V E L O P M E N T

PRODUCT IDEA

DEVELOPMENT AND DESIGN

www.merkle-partner.de

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Analysis and interpretation of physical properties

On-time delivery to the site of operation and professional assembly

Selection of a suitablemanufacturing company and guiding of the production process through regular quality controls

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CALCULATION AND SIMULATION

PRODUCTION

LOGISTICS AND ASSEMBLY

Video: www.m-cae.de/reel

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CATIAPRO/ENGINEERUG(NX)INVENTOR/AUTOCAD

ABAQUSANSYSNASTRAN

STRENGTH/TEMPERATURE

ABAQUS EXPLIZITLS-DYNARADIOSS

CRASH/DROP TEST/EXPLOSION

MAXWELL

ELECTROMAGNETISM

CAD

AUTOFORMPAM-STAMP

DEEP DRAWING SIMULATION

MATLAB / SIMULINKMATHEMATICAMDESIGN

TECHNICAL CALCULATIONS

STAR-CCM+CFXFLUENTOPENFOAMVECTISTOSCAKULIRADTHERMAURAICEM CFDANSA

ADAMS

MULTI BODY SIMULATION

SYSWELD

MATERIAL CONVERSION

OPTISTRUCTOPTISLANG

OPTIMISATION

ANSAENSIGHTHYPERWORKS

PRE-/POST-PROCESSOR

FEMFAT

LIFE CYCLE

CADMOLD

INJECTION MOULDING SIMULATION

STAR-CD

FLUID DYNAMICS

SOFTWAREOVERVIEW OF SOFTWARE TOOLS USED

S O F T WA R E

www.merkle-partner.de

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• Allweiler GmbH

• AUDI AG

• BERU Electronics GmbH

• BSH Bosch und Siemens Hausgeräte GmbH

• Cofely Refrigeration GmbH

• DAIMLER AG

• DIEFFENBACHER GmbH

• Dr. Schneider Kunststoffwerke GmbH

• EADS Deutschland GmbH

• EMCO WHEATON GmbH

• FTE automotive GmbH

• General Dynamics European Land Sys. Germany GmbH

• Handtmann-Systemtechnik GmbH & Co. KG

• INA-Schaeffler KG

• Johnson Matthey Catalysts GmbH

• Kayser-Threde GmbH

• KSB AG

• Leuze electronic GmbH & Co. KG

• MAGNA STEYR Fahrzeugtechnik AG & Co KG

• MAN Diesel SE

• NuCellSys GmbH

• Pollrich Ventilatoren GmbH

• Quattro GmbH

• RENK AG

• Robert Bosch GmbH

• Robert Bürkle GmbH

• Rütschi Fluid AG

• Thales Electron Devices GmbH

• Trützschler Nonwovens GmbH

• VOITH Turbo GmbH & Co. KG

• Volkswagen AG

• ZF Friedrichshafen AG

... and many more.

REFERENCE CUSTOMERSIMPLEMENTING INNOVATIVE IDEAS, TOGETHER

R E F E R E N C E C U S T O M E R S

In the area of conflict between safety and sustainability on the oneside and costs and weight aspects on the other side, FEM and CFD calculations have long been established in modern developmentprocesses.

Undoubtedly, you are also looking for a service provider who hasaccess to state-of-the-art hardware and innovative software tools. However, MERKLE & PARTNER offers you a whole lot more:experienced calculation engineers who not only achieve reliableresults, but also know how to evaluate these in a scientifically sound manner. It is not without reason that we are one of the oldest service providers of our industry in Germany.

Complex tasks, far from standard calculations, the development of new calculation methods as well as national andinternational code-checks - all these are our specialties. You can rely on our expertise!

Stefan MerkleFounder and Managing Director of Merkle & Partner

MERKLE & PARTNER OFFERS MORE!

Ingolstadt Branch

Lilienthalstrasse 4885080 Gaimersheim / Germany

Phone: +49 8458 60366-11Fax: +49 8458 60366-19

ingolstadt@merkle-partner.de

Hamburg Branch

Behringstrasse 28a22765 Hamburg / Germany

Phone: +49 40 3037766-00Fax: +49 40 3037766-09

hamburg@merkle-partner.de

MERKLE & PARTNER GbRHeadquarters Heidenheim

Friedrichstrasse 189518 Heidenheim / Germany

Phone: +49 7321 9343-0Fax: +49 7321 9343-20

info@merkle-partner.dewww.merkle-partner.com

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Homborg/Saar Branch

Saarpfalz-Park 1766450 Bexbach / Germany

Phone: +49 6826 93318-11Fax: +49 7321 9343-20

homburg@merkle-partner.de

www.facebook.com/femberechner www.twitter.com/MerklePartner www.youtube.com/MerklePartner

Please also visit us on the Internet:www.merkle-partner.com