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Company:

ITW Delfast集团

Products:

Industries:

Machinery

Overview:
ITW Delfast集团为汽车行业设计和生产工程用塑料和金属紧固件。典型的塑料紧固件通过插拔式卡扣起到固定作用。由于紧固件存在多个接触体、大变形和滑移接触等多个非线性因素,因此带来了很大的设计难度。过去主要由有经验的分析工程师进行有限元分析,成本昂贵。
 
 
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Company:

Pratt&Miller

Products:

Industries:

Automotive

Overview:
作为一家非常成功的赛车设计者和制造者,Pratt&Miller学会了如何在紧张的工期中进行赛车研发,并第一时间取得成功。2005年,公司成立了工程服务部门将这些技术推广到其他工业领域。在工期只有几个月的时间里,为国防客户开发出了全面设计的展示车辆,MSC Software公司的ADAMS软件进行的车辆动力学仿真起到了关键作用。
 
 
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Company:

Leading Edge Engineering

Products:

Industries:

Overview:
许多公司已经使用FEA分析他们的结构,使用一系列静力或者惯性载荷和模态分析来验证他们的产品。这些载荷通常可以有效的工作,成功避免灾难性事件。因而,大部分公司就不再进一步仿真和预测疲劳失效。然而,在开发周期的早期就进行疲劳失效预测,可以节省数次物理原型反复测试过程所造成的时间和金钱的花费。进行疲劳失效仿真可以减少长期保修成本,可以用来优化产品结构。
 
 
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Company:

クヌーズEハンセン社

Products:

Adams

Industries:

Energy
Shipbuilding

 
 
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Company:

Fokker Space

Products:

Adams

Industries:

Aerospace

Overview:

The subject of this case study was an effort undertaken within Fokker Space to lower the volume and mass of solar panel array designs. This culminated in the Curwin solar panel array concept which used a curved arrangement of solar panels (like a tape measure) instead of a separate backbone structure to reduce both volume and mass while retaining the required stiffness and high frequency response.

Challenge:

The goals for the simulation of the deployment were:

  • Determine the important factors in a successful deployment
  • Evaluate the initial design of the solar panel array
  • Validate design changes to meet the requirements of a successful deployment
  • Final validation of a design that resulted in a controlled and reliable deployment
Solution:

MSC Software’s Adams was chosen to analyze the multibody dynamic process during the deployment. In the past, Adams has been successfully used within the spacecraft industry to model solar panel deployment.

Benefits:
  • Lower volume and mass of solar panel array design
  • Reduce costs from $10,000 per pound for a single satellite launched via heavy rockets to below $3,000 with new approach
  • Realistic simulation to replicate on-orbit conditions during deployment

 
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Company:

Big Tyre

Products:

Marc

Industries:

Heavy Equipment

Overview:

Designing the right tire for large wheeled vehicles used to haul coal and other materials in underground mines presents an enormous design challenge. Pneumatic tires present risks because of the danger of an explosion in a confined space while solid tires are associated with relatively large vibrations experienced by the driver. Big Tyre, a company that specializes in producing solid tires for mining vehicles, is developing a unique alternative which uses arrays of leaf-springs, typically made of composite materials, to provide performance similar to pneumatic tires without the risk of blow-outs.

Challenge:

Big Tyre is a manufacturer of solid wheels that are primarily used in underground mining vehicles. “Many mining companies have switched from pneumatic tires to solid wheels because of the dangers presented by pneumatic tires underground,” Louden said. “Mines underground have bolts sticking out of the walls that can easily cause punctures. Tires on heavy vehicles are inflated as high as 170 psi, so when they are torn or punctured a considerable amount of force is released. Due to space constraints underground, workers are often in close proximity to the tires so the potential for injury when a tire is torn or ruptures is a major concern.”

Solution:

The design concept provides the flexibility and challenge of defining various design parameters including the number of springs in an array, thickness of springs, curvature of springs, length of springs, material properties of springs, geometry and material properties of the segments that the springs attach to on the outer diameter of the wheel, as well as many others. The design criterion is to provide a very efficient vertical loading for the size of the wheel while providing similar if not equivalent suspension to a pneumatic tire, with excellent torque capacity and lateral stability.

Results Validation:

Compumod first conducted a nonlinear static analysis on one spring to correlate the model material properties with experimental data. The material properties were tuned to replicate the measured reaction force in the experiment. Then a nonlinear analysis was performed on the entire wheel to assess its strength. The wheel was given an enforced displacement of 150 mm which was solved in 100 nonlinear increments. The reaction force was then measured on the ground and graphed against displacement. The first negative slope indicated failure of the wheel at 252 kiloNewtons or 25.7 metric tons, which is well over the target of 16 metric tons. After the first collapse of the wheel, the contact between the springs and between the springs and segments added stiffness to the wheel and the reaction force increased again for increasing displacements.

Benefits:

“After seeing the benefits of the software, we decided to purchase Patran and Marc,” Louden said. “Compumod organized training for us in their Sydney office and handed over the models they created in the consulting project. We very quickly began designing the second full-size version of our design, and have been able to improve the design at a much faster pace than in the past. It even allows us to simulate driving maneuvers of the vehicles, including obstacles on the road.


 
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Company:

Comtes FHT

Products:

Marc

Industries:

Machinery

Challenge:

Pilsen Steel, a leading producer of castings, ingots and forgings experienced difficulties with ingots cracking in a forging operation. The company contracted with COMTES FHT to investigate and determine the root cause of the formation of longitudinal cracks in 34CrNiMo6 steel ingots.

Solution:

Traditional process involved cooling of the ingots after casting to between 500oC and 600oC, after which the ingots are placed in the forging furnace at temperature of 1100oC to 1200oC. COMTES used MSC Software’s Marc nonlinear finite element analysis (FEA) software to analyze the process of heating the ingots in the furnace and confirmed that heating the ingots in the furnace generated thermal stresses that later caused cracks to form during forging. Additional simulation studies also showed that increasing the temperature of the ingots by 100oC prior to putting them into the furnace reduced thermal stresses to acceptable levels. Pilsen Steel implemented this change and it eliminated the cracking problem.

Benefits:
  • Realistic Simulation of the Multiphysics behavior of metal during manufacturing
  • Elimination of cracking in final product reducing reject rate and improving product quality

Performing thermal analysis on the complete ingot workload requires determining the radiant heat transfer between the furnace and each of the each ingots with shading effects taken into account. Marc excels at this type of challenging multiphysics problem which is why it is our finite element analysis tool of choice

Tikal, COMTES FHT


 
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Company:

Medicrea

Products:

Digimat

Industries:

Medical Devices

Overview:

Spinal injury and the gradual deterioration of spinal discs that lead to back pain or spinal disorders can be treated surgically. One of the most promising surgical options under continuous development is the use of artificial discs to replace the patient’s natural spinal disc. The materials used in these artificial discs are an important factor in the development of this technology. The discs must be made from materials that are safe to be implanted in the human body, do not cause allergic reactions, but also wear resistant and compatible with medical imaging (MRI for example). Fiber reinforced plastic composites are used more and more in today's orthopedic implants because of their resistance to wear and improved mechanical properties.

Challenge:

The challenge when designing implants that take advantage of reinforced plastics is predicting the manufactured material performance. The mechanical properties of an implant designed with fiber reinforced plastics can vary widely depending on the use of the material and how the implant is manufactured. The injection or compression molding process used to manufacture the implant will affect the fiber orientations throughout the part. Typical analysis assumes the material is isotropic for simplicity, but in reality the fiber alignment is continuously changing throughout the implant, resulting in a heterogeneous, anisotropic material. Poorly aligned fibers or not appropriately accounting for the fibers’ effect on material performance can lead to a softer or stiffer implant than designed, and even premature failure.

Solution:

MSC Software’s Digimat produces a much more accurate prediction of the composite behavior for materials such as fiber reinforced plastics. The process is simple. Start with the same finite element model of the implant that is used for the existing analysis. Digimat will work with any major finite element solver. Next, request the injection mold simulation results from the manufacturer. This analysis is done to assure the implant’s mold has been designed properly for manufacture, but the results can also be used in the finite element analysis of the implant itself. To do this, use Digimat to map the fiber orientations, residual temperatures and residual stresses onto the structural analysis model.

Select or create an intelligent material model of the reinforced plastic using the tools provided by Digimat. The intelligent material model is a function of fiber orientations instead of a static value, allowing Digimat to adjust the material stiffness at every location throughout the implant. Finally, conduct the analysis as normal with one exception, the static value for material stiffness will be replaced by a Digimat material model.

Digimat takes care of tying the intelligent material into the analysis solution so that the analyst can focus on designing the implant’s performance, not guessing at which material property might give the best results.

Results Validation:

The attention to material details result in much more accurate simulations that reduce test/ analysis iterations and improve performance predictions. In the case of the Medicrea design, the original isotropic simulation over-predicted the implant’s stiffness by as much as 170%.

The same simulation using a Digimat material model that accounted for both changes in fiber orientations as well as plastic deformations matched the test results almost perfectly.

Benefits:
  • Cost and time savings
  • Reduce test/analysis iterations
  • Improve performance predictions by 170%

 
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Company:

Airbus

Products:

Actran TM

Industries:

Aerospace
Sustainability

Overview:

Noise is becoming a major obstacle to growth in air transport as increasing numbers of airports place restrictions on the amount of noise that can be generated by an aircraft during various phases of flight. Airbus is working hard to reduce aircraft noise such as by improving the nacelle acoustic liners used to minimize the fan noise radiated from the engine. The company has dramatically reduced the time required to design and evaluate optimized acoustic liners by moving to a simulation-based process using Actran acoustic simulation software developed by Free Field Technologies (FFT), MSC Software Company.

Challenge:

The acoustic liners that are built into the engine nacelle are fundamental in controlling fan noise. Acoustic liners present a major design challenge because they must address a large number of conflicting design requirements. Liners must provide high levels of noise reduction over a wide range of engine operating conditions and frequencies. Liners must also meet tight space restrictions and need to be as light as possible in order to limit fuel consumption. The liner is typically designed at a point when aspects of the airframe and engine are not completely defined so the liner design must be flexible enough to adapt to changes. The liner must be able to survive exposure to heat, cold, water, oil, and maintenance operations. Finally, the liner must be durable enough to deliver decades of service in the highly demanding aircraft engine environment.

Solution:

Liners are typically manufactured in two or three curved segments that are assembled with longitudinal splices. Simulation with Actran and other numerical tools helped to reveal the substantial impact of splices on forward fan noise and these simulations were confirmed with physical testing. These simulations made it possible to compute the radiated noise fields under all relevant engine operating conditions and predict the noise reduction in certification conditions. The design of the zero-splice concept, through numerical simulation, made it possible to significantly reduce the fan noise and the acoustic discomfort.

Results Validation:

Airbus developed an integrated numerical chain for Actran in order to streamline its use by acoustics engineers who are not numerical experts. The chain, called Automated Liner Optimization Chain for Nacelles Air Inlets and Exhausts (ANaNax), automates the simulation process from engine geometry to Actran results including prompting the user for all required information and performing validation checks on the data entered by users. “A typical optimization loop for the nacelle liner requires evaluation of 80 liner iterations and three flight conditions at a frequency range from 125 Hz to 5650 Hz which means we need to simulate several thousand different cases,” Suratteau said. “Robustness and accuracy of the simulations is critical so realistic 3D shapes, flows and boundary conditions are a must. ANaNax greatly reduces the time required for non- analytical experts to perform simulations and to check their work to be sure inputs are realistic. Computation time has also been drastically decreased by the implementation of a high performance computing (HPC) platform based on Westmere X5670 Infiniband technology with 5312 cores combined with the high scalability of Actran.

Benefits:
  • Reduce product development costs by avoiding expensive post-design changes.
  • Reduce test/analysis iterations
  • Improve performance predictions

 
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Company:

Scania

Products:

Adams

Industries:

Automotive

Overview:
Scania uses simulation to evaluate a much greater number of vehicle configurations than was possible in the past. “We selected MSC Adams/Car because Adams provides the premier solver technology and has become the de fact standard in the automotive industry..MSC Adams/Car supports Scania’s modular vehicle configuration strategy by enabling us to model and simulate different vehicle configurations in a small fraction of time that would be required to build and test them.”
Benefits:
  • Significantly improve the handling, comfort and fatigue life of vehicles
  • Reduced stress levels in many parts, resulting in improvements in component life
  • Identify potential problems early in the design process and make corrections on the virtual model

 
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Company:

Knud E. Hansen

Products:

Adams

Industries:

Renewable Energy
Shipbuilding

Overview:
The Anholt Offshore Wind Farm is a Danish wind farm currently under construction, located in Kattegat, between Djursland and Anholt Island. Knud E. Hansen was contracted by MT Højgaard A/S to assess the Drill Rig’s waves induced motion while transported by HLV SVANEN, and to calculate the maximum tensions on the lashing cables for a maximum operational wave height.

“Adams Software helped us to understand the motion and forces involved by capturing the full gamut of real world complexities including rigid bodies, flexible bodies, springs, dampers, joints and all others mechanical components. The software never placed any limits on what I wanted simulated, yet it made it possible to assemble the complex model very quickly. ”

Mirco Zoia, Navel Architect & Offshore Eng., Knud E. Hansen A/S

Challenge:
Accurate assessment of complex mechanical systems that require a dynamic analysis
Solution:
Initially, the 3D Multi-body Dynamic model of the system composed by HLV SVANEN, the Drill Rig and its crane lifting components (Lifting Spreaders, Lifting and Lashing Equipment), was created in a CAD software and then imported to Adams. Densities and other material properties were given to the parts of the 3D Model. All the parts in motion were joined together with translation, revolving, spherical and cylindrical joints to simulate as close as possible the real behaviour of the system. The steel and fibre ropes of the system were defined as flexible dynamic bodies with the same material properties (density, young’s modulus, poisson’s ratio, and damping coefficient) as the actual ropes. The winch pretensions were defined using preloaded spring-dampers. Motions, constraints, wind forces and winch pretension loads were then applied to HLV SVANEN. The motion analysis was based on the HLV SVANEN maximum response motion previously assessed.

The dynamic analysis was carried out to assess the maximum displacement of the Drill Rig, and the minimum required winch pulling force to fulfill the requirements of the client and to safely carry out the necessary marine operations.
Benefits:
  • Ensure the safety of the marine operations
  • Reduce risks and costs of the wind turbines installation
  • Anholt offshore windfarm to become the biggest offshore windfarm in Denmark

 
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Company:

BioSimulations, LLC

Products:

Marc

Industries:

Medical Devices

Overview:
The ability to control, modify or block the signals from the receptors to the brain may be accomplished through selective electrical stimulation of a specific nerve path. MSC Software’s Marc nonlinear simulation solution was selected to generate the model, perform the analysis and post-process the results.
Challenge:
To evaluate a proposed design concept for an electro-mechanical device
Benefits:
  • Successfully check the model components and generate a final assembly of the model.
  • Performed model pull-off loading using incrementally applied large displacements.
  • Make results plotting easy using Marc post-processing features.

 
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Company:

University of Cassino

Products:

Dytran

Industries:

Medical Devices

Overview:
The detachment or tearing of the retina in the human eye as a result of a collision is a phenomenon that occurs very often. The project was aimed at understanding the actual processes of dynamic deformation taking place in the human eye when subjected to blunt impact. For this project an FEA model was developed in MSC’s Dytran software starting from 3D measurements of real human eyes. The results of the model were then compared to measurements with respect to the deformation at different times and to the residual velocity of the projectile during the rebound phase.

Challenge:
  • Over 60% of all eye injuries are caused by blunt impact, i.e. impacts with objects of various kinds that do not cause a perforation of the globe.
  • Based on evidence of a patient who, despite having undergone the removal of the vitreous, had a clear macular hole resulting from a blunt impact, it was decided to investigate this phenomenon in more detail in order to validate the various hypotheses of damaging mechanism with the help of a MSC Dytran simulation.
Solution:
  • The computational model of the ocular globe was generated starting from an average size human eye represented with the help of the code MSC Dytran.
  • The preliminary results of the project indicate that the laceration of the retina mainly occurs due to the tension resulting from the reflection of compression waves in the moments immediately following the impact, and not necessarily due to the deformation of the whole eye.
Benefits:
  • The availability of a reliable and validated model for the simulation enabled the research team to understand in detail the pathogenesis of the blunt impact phenomenon, which is particularly difficult to reproduce in a controlled and instrumented manner through physical tests in the laboratory.
  • Practical applications of this study are to be found especially in the military industry, for example in the design of advanced security systems for personnel and for helicopter pilots in the event of a crash landing.

 
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Company:

NASA/JPL-Caltech

Products:

Adams

Industries:

Aerospace

Overview:
NASA Jet Propulsion Laboratory (JPL) engineers simulated this final sky crane landing sequence of the Curiosity Mars Rover using MSC Software’s Adams multibody dynamics software. The simulation identified problems with the initial concept design and guided engineers as they resolved these issues and made the design more robust. The simulation was also used to validate the landing sequence and determine loads on subassemblies and components. The controls software code that guides the mission through the sky crane landing sequence was integrated into the Adams environment to validate and tune its performance. The accuracy of these simulations was proven by the success of the mission.

Challenge:
Validate the landing sequence and determine loads on subassemblies and components on the Curiosity Rover during its historic landing sequence on Mars.
Solution:
The engineers at JPL were not able to test most of the critical mission events on Earth so they had to rely upon MSC Software simulation technology to design most of the hardware and control sequences for this mission.
Benefits:
  • Optimize the design of every component to ensure their ability to withstand loads and successfully perform their mission.
  • Determine the bounding limit design loads that could be expected on every component.
  • Ensure that there was no possibility of contact between the flight hardware.

 
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Company:

General Dynamics Land Systems

Products:

Adams

Industries:

Defense

Overview:
The gun turret drive on a combat vehicle presents a very complex design challenge. When the vehicle travels over rough terrain, the gun turret drive compensates for the vehicle’s motion and keeps the gun pointed precisely at its target with 99.5% accuracy. In the past, General Dynamics Land Systems (GDLS) engineers used separate simulations to evaluate different aspects of the gun turret drive design, such as the rigid body structures, flexible bodies and control system. But engineers were not able to evaluate the performance of the gun turret drive as a complete system until they built and tested prototypes.
In the last few years, GDLS engineers have begun using a multidisciplinary-based co- simulation process to model the operation of the gun turret drive system while taking into account all of the key physics involved in its operation. The centerpiece of this simulation effort is the use of Adams dynamics software to model the rigid bodies, nonlinear joints and contacts in the gun turret drive.
Challenge:
Create the multidiscipline model for the gun turret drive. Early prediction of the jamming condition in the gun turret drive.
Solution:
In this highly complex weapons system, the ability to account for nonlinearities is critical to accurate simulation. The key advantage of Adams is that it accounts for the nonlinearities in this system through its ability to model nonlinear on/off contacts, large displacements associated with part deformations and nonlinear materials.
Benefits:
  • Quick verification of results
  • Shorter product development cycle
  • Cost saving

 
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