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Company:

Tesat-Spacecom

Products:

MSC Apex Generative Design

Industries:

Aerospace

Overview:

The enormous efforts needed to send technical equipment into space require a particularly high degree of lightweight construction. Generative design allows these complex optimisation processes to be significantly simplified and automated. The potential offered by this approach is demonstrated by a case study from German satellite specialist Tesat-Spacecom.


 
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Company:

Vellore Institute of Technology

Products:

Adams

Industries:

Automotive

Overview:

In automotive design, the seat plays an important an important role in ensuring passenger comfort, especially in the case of long-distance drives. Most OEMs today focus on static comfort of seats, while paying limited attention towards dynamic comfort. This project by the students of VIT helped shed some more light on importance of dynamic comfort.

Using simulation tools from Adams, the students designed a model to scrutinize the performance of a semi-active seat suspension system using a PID controller and a newly designed magneto-rheological fluid damper. The software helped the students to test their model seamlessly and cost effectively on real time basis, using virtual prototyping and virtual testing, before physical prototyping and testing.


 
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Company:

SABIC

Products:

Digimat

Industries:

Medical Devices

Overview:

For short fiber reinforced composites, SABIC uses Digimat to define nonlinear strain rate dependent material model for accurate prediction of part performance under impact loads


 
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Company:

SABIC

Products:

Digimat

Industries:

Medical Devices

Overview:

SABIC uses Digimat for high-fidelity anisotropic simulation, considering manufacturing effects and non-linear material behavior


 
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Company:

Thai Steel Cable

Products:

Adams
MSC Nastran

Industries:

Automotive

Overview:

MSC Software helps Thai Steel Cable apply Multibody Dynamics & Finite Element simulations to design the structure of a Robotic Arm with Polyamide


 
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Company:

The FormulaStudent Team from Paderborn University

Products:

MSC Apex Generative Design
Simufact Additive

Industries:

Motorsports

Overview:

From load simulation via generative design to manufacturing and verification – optimisation of a wheel carrier for FormulaStudent with MSC Software


 
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Company:

Avio

Products:

Actran Acoustics
MSC Nastran

Industries:

Aerospace

Overview:

Using MSC Nastran and Actran – engineers at Avio were able to accurately predict the effect of noise vibrations on the structural integrity of its launchers.


 
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Company:

Northrop Grumman Mission Systems

Products:

MSC Apex

Industries:

Aerospace

Overview:

Lacking a productive tool for taking advantage of hex mesh in product development missions, engineers reviewed and benchmarked MSC Apex versus their legacy workflow and tools, and found quite a few benefits from using the new workflow.


 
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Company:

Meritor

Products:

Adams

Industries:

Automotive

Overview:

Regulators are continually increasing the performance standards required of automobile manufacturers. An example is FMVSS 105 and 121 which define the performance of braking systems and are intended to ensure safe braking performance under normal and emergency conditions for heavy trucks and trailers. A typical change in these regulations is to reduce the distance required to stop the truck under emergency conditions. This can be achieved by designing bigger, heavier, more expensive brakes. Ragnar Ledesma, Principal Engineer for Meritor, took a different approach by addressing the algorithms used to control anti-lock braking systems used in nearly all mediumand heavy-duty trucks.

Results Validation:

The simulation showed the proposed control system brings the vehicle to a complete stop in less than 4 seconds in a stopping distance of 177 feet (54 meters), demonstrating a way to meet the requirements of a tougher regulation without major changes to braking hardware. The results show a nearly constant deceleration response at the driver seat as opposed to the cyclical response with conventional ABS braking. The explanation for the improved performance is explained by the simulation results. The wheel angular velocities and tire slip ratios do not fluctuate from their desired values; hence the new ABS control system can sustain maximum braking forces almost over the entire braking cycle.

Benefits:
  • Leveraged Adams-Controls Integration to provide virtual testing of the new braking algorithms used in the ABS system
  • Achieved a reduction in truck stopping distance by over 30% using current disc braking systems
  • Evaluated the truck braking performance without many expensive prototypes iterations
  • On-demand access to the Adams Controls module via the MSC One token licensing system

 
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Company:

Aerospace Industry

Products:

MSC Apex Generative Design

Industries:

Aerospace

Overview:

The aerospace industry is one of the most demanding industries in terms of quality and reliability. There is an enormous potential for the use of additive manufacturing as this technology gives the opportunity to create function-oriented part designs for a highly purpose-oriented geometry.

In a research project of the Direct Manufacturing Research Center in combination with an industrial partner, such a function-oriented component optimisation was developed using MSC Apex Generative Design. A fixture has been identified and selected for redesign which is installed less than 100 times per year. The previous design consists of a two-part assembly in which the individual components are milled from a solid aluminum block and then connected to each other by several rivets. This produces a correspondingly high amount of waste in the production process.


 
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Company:

Tyvak Nano-Satellite Systems, Inc.

Products:

MSC Apex

Industries:

Aerospace

Overview:

Tyvak considered and evaluated MSC Apex because of its “smart” nature, ease of use, and seamless compatibility with MSC Nastran. When utilizing MSC Apex for pre-/post-processing an FE model, engineers conveniently achieved firstrun- success in simulations.


 
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Company:

Inteva

Products:

Digimat

Industries:

Electronics

Overview:

The collector box ground cable retention feature was improved over the earlier design further for better performance. An economical and reliable feature was to be redesigned to meet the requirements of the intended retention force which ensures that the feature is always under pre-stressed condition. In the process of design modification of this existing feature, several parameters like length of the arm, width and thickness at the root, etc. were considered. The retention forces were estimated through a structural simulation using non-linear isotropic material properties (glass-filled Polybutylene Terephthalate material). The extracted retention force for this redesigned feature was found to be exceeding the intended force value which in turn caused the failure of the feature. However, the physical test results showed that the features were safe, and the retention forces measured were also in the acceptable range. Hence to understand the influence of fibre orientation in such glass-filled components; extended FEA studies were carried out using Digimat software.


 
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Company:

GreenDwell

Products:

scSTREAM | HeatDesigner

Industries:

Architecture

Overview:

GreenDwell provides design and consultancy services for buildings based on the principles of sustainable design. Rather than the conventional approach of looking at sustainable design purely from an energy and environmental perspective, GreenDwell also considers the human aspect of sustainability. The company believes that how people experience space through time defines their well-being.

The company uses a Green Research-Integrated Design (g.r.i.d) process to hypothesize the various senses that people might experience after the building is constructed. Computer simulation tools are used as the ‘sensual experience tester’ to help architects check for the sensual performance early in the design phase. The design is analysed for visual, thermal, and acoustic comfort, alongside checking the building’s environmental impact. Thus, the company creates an experience that is a delight to the senses, while minimizing negative effects on the environment.

Given the unconventional approach, the work process often takes longer than the typical design process. The company uses simulation to demonstrate to clients the impact of various environmental factors on the design. Using the additional layer of site and context-specific information enables the creation of a better design.

Given that the company caters primarily to clients in Thailand, which is a hot and humid country, shade and natural ventilation play a very important role in design. Also, for projects set in urban areas, the design needs to consider existing obstructions and their impact on wind flow on the site. The most efficient way to achieve this is by integrating ventilation simulation throughout the design process.


 
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Company:

Composites Technology Research Malaysia Sdn Bhd (CTRM)

Products:

Adams
MSC Nastran
Patran

Industries:

Aerospace

Overview:

Composites Technology Research Malaysia Sdn Bhd (CTRM) is part of the global supply chain in Composites Aero structures for major commercial and military aircraft manufacturers in the world. The company plays a strategic role in the Aerospace and Composites industries and has also diversified its business into composites aircraft interiors, aircraft seats and transportations.

As part of the production process, the company is required to run thorough physical tests on each of the components that it manufactures to ensure that they meet the stringent standards. This is especially true in the case of components made of composite materials. In order to guarantee that the testing process is extremely meticulous and accurate, each component needs to undergo the required scans/tests from all possible angles. This means that each component needs to be flipped over by 180 degrees, rotated etc. to ensure that each portion of this component is accessible to the scanning machines and also to guarantee that all data and measurements are physically captured and recorded.

Flipping these components can be quite a challenging process, especially since some of them such as the aircraft fan cowl can weigh upwards of 70 kilograms. Flipping these is not easy even if there are 5 persons deployed to physically flip each part.

Doing it manually can damage the product since there is a possibility that it might get dropped or might touch or scratch some surface thereby damaging the part. Since these parts are not ergonomically designed to be held or flipped, they can be quite unwieldy. Yet, testing and certification of each component before it is sent to the OEM is extremely important.

The company was keen to mechanise the process by designing a ‘flipper’ device that could be used to physically flip the components as required for testing.


 
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Company:

Simusolve Australia

Products:

MSC Apex

Industries:

Automotive

Overview:

Simusolve Australia was tasked with the structural evaluation of the preliminary design of a fabricated “road registered” supercar. The structural system involved various vehicle sub-assemblies, comprised of over 100 individual components made from metallic, carbon composite and elastomeric materials. The data was supplied as a single structured Parasolid assembly file – generated from SolidWorks. Simusolve was required to do internal load and stress surveys, torsion and beaming stiffness assessment, as well as modal response and confirmation of internal load paths.

The assignment was quite challenging due to several factors. First, the sheer scale of the mesh creation activity would have been sufficiently challenging on its own. However, when combined with the need to manage and organise such a large number of components and subassemblies, their structural interfaces and properties, and the problem became even more difficult. Traditional pre-processors struggle to handle problems of this magnitude. In addition, the team needed to make rapid changes to the geometry in order to assess design changes arising from analysis insights.


 
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