Company:Benelli Armi S.p.A. Products:Adams Industries:Aerospace | Overview: This case study shows the process of virtual prototyping applied in the development of the VINCI project. After experimentally characterizing the phenomenon of the shot, a complete multibody model of the gun was built using MSC Software’s Adams ™ to determine a satisfactory configuration of the weapon. This configuration was then used to develop the first physical prototype, on which kinematic and dynamic parameters were measured in order to calibrate its behavior with respect to the Adams multibody model. Challenge: To develop a conceptually new weapon designed as a modular system and an integrated system of recoil reduction.Solution:
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Company:System Design Evaluation Ltd. Products:Adams Industries:Aerospace | Overview: In the design of any new high explosive ammunition, the most complex and often problematic component is the fuzing system. The fuze must incorporate a Safe and Arm device to ensure that the projectile may only enter the armed state following exposure to firing forces and after reaching a safe distance from the muzzle of the weapon. Engineers at System Design Evaluation Ltd. (SDE) in Hertfordshire, UK have constructed rigid and flexible body MSC Adams models to study the motion and strength of the design of fuze mechanisms to identify potential design issues and assist with analysis of trials results. “Conducting live firing ammunition trials is an expensive business,” said Eva Friis, Project Manager for the APEX ammunition development programme at Nammo Raufoss, Norway. “Analysis of recovered fuzes to determine the cause of failure is little short of forensic science and it is difficult to know how the forces imposed during recovery of the projectile affect the results. The Adams simulations have provided an insight into the operation of the fuze and enabled the team to highlight and address weaknesses with the design before manufacture and physical testing.” Challenge: The Nammo 25mm APEX projectile is a next
generation armour-piercing, high-explosive
ammunition designed for use with the US F-35
Joint Strike Fighter aircraft. The projectile leaves
the muzzle of the 4-barrelled GAU-12 weapon
system with a velocity of around 1,000m/s and
experiences a peak setback acceleration of
almost 80,000g. Under these conditions, coupled
with severe space restrictions, it is almost
impossible to instrument the fuze in order to gain
an understanding of the operation and interaction
of components inside. Therefore, while physical
testing can be used to confirm functionality of
the fuze, it often offers only limited information for
post analysis in the event of a failure to function.Solution: Adams modeling has proven invaluable in providing information to assist with the diagnosis of evidence gained from recovery tests. In one case, examination of the internal components of the fuze after recovery tests showed markings which indicated a malfunction had occurred. A detailed flexible body Adams model of the design was developed, and analysis confirmed the nature of the problem and sequence of events within the fuze mechanism; huge centrifugal forces due to projectile spin resulting in deformation of internal components sufficient to result in the unlocking of two retaining gears. Computer modeling of ammunition fuzes has not been without challenges. Safe and Arm devices are often mechanical and operate using clockwork escapement mechanisms, similar to those found in wrist watches. Such mechanisms rely heavily on 3D contact, leading to extended run times. Further, fuze arming times are largely dependent on the definition of frictional algorithms within the models. SDE has worked closely with fuze manufacturers to overcome this and validate models against static spin tests thereby providing a firm basis from which to investigate further design permutations. Results Validation: The Adams results have not only
successfully predicted the failure of
components on numerous occasions
within various fuze designs, but have also
facilitated in the redesign of components
to achieve suitable strength. Importantly,
by quantification of stresses within
components, Adams has assisted in
proving compliance with required safety
factors, information which is not possible to
glean from live firing trials results.
Benefits: •Cost Reduction •Invaluable Diagnostic Evidence •Design Optimization |  DOWNLOAD |
Company:Schneider Electric Dupont Products:Digimat Industries:Electronics | Overview: Government regulation and unexpected fluctuations in raw material price levels create new challenges for many companies. DIGIMAT offers the perfect combination of material modeling platform to optimize the performance of our reinforced thermoplastic components and DIGIMAT has demonstrated its ability to provide robust and accurate prediction of materials behavior. Challenge:
Solution:
Results Validation: "…From REACH legislation to unexpected fluctuations in raw material price levels, our products are more than ever challenged, in this context DIGIMAT offers the perfect combination of material modeling platform to optimize the performance of our reinforced thermoplastic components and DIGIMAT has demonstrated its ability to provide robust and accurate prediction of our materials behavior." M. Oubahmane Innovation & Technology Specialist Schneider Electric
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Company:JSOL Corporation Products:Digimat Industries:Automotive | Overview: “Fiber reinforced plastic becomes major material for intake manifold because of lightweight and heat resisting properties. Detecting the correct high stress concentration area is important to predict fatigue properties of manifold. DIGIMAT helps us to predict correct stress distribution by taking into account the fiber orientation coming from injection molding. " Challenge:
Solution:
Results Validation: "Fiber reinforced plastic becomes major material for intake manifold because of lightweight and heat resisting properties. Detecting the correct high stress concentration area is important to predict fatigue properties of manifold. DIGIMAT helps us to predict correct stress distribution by taking into account the fiber orientation coming from injection molding. " Noriyo Ichinose, Sales engineer, JSOL Corporation, JapanBenefits:
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Company:Ticona GmbH Products:Digimat Industries:Automotive | Overview: Digimat was used to model the plastic injection of a sun roof bearing part, taking into account fiber orientations predicted by injection molding. There existed very good correlation with experimental failure data. Digimat was able to predict critical failure location in the part. Challenge:
Solution:
Results Validation: "Ticona’s intent is to provide solutions to our customers. Speed and quality of CAE predictions are key factors when we work on new components. Customers expect working solutions based on detailed structural response predictions and optimized mold design. From the results of our practical tests, the use of DIGIMAT to link Moldflow with Ansys structural analysis proved to be a very good way to fulfill these customer needs." Ulrich Mohr-Matuscheck, Leader Design CAE, Ticona GmbH
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Company:Sovitec Products:Digimat Industries:Consumer Products | Overview: This study allowed Sovitec to obtain the arguments necessary in order to be more effective in the prospection of new markets, but also to consolidate its image of serious in the presentation of technical results in the plastic industry. Clearly a Plus. Challenge:
Solution:
Results Validation: "This study allowed Sovitec to obtain the arguments necessary in order to be more effective in the prospection of new markets, but also to consolidate its image of serious in the presentation of technical results in the plastic industry. Clearly a Plus." Frederic Juprelle, Business Unit Manager, Sovitec
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Company:RHODIA Products:Digimat Industries:Consumer Products | Overview: Being predictive in crash simulation is the dream of CAE engineers. The use of short fiber reinforced materials was putting this target out of range, because such materials have a variable anisotropy all over the part, associated to complex matrix behavior. No material model implemented in a code is able to capture this complexity level. Digimat to LS DYNA does. Associated with the Rhodia material database MMI confident Design™, Digimat CAE/LS DYNA is providing the best predictability level available on the market today. Challenge:
Solution:
Results Validation: "Being predictive in crash simulation is the dream of CAE engineers. The use of short fiber reinforced materials was putting this target out of range, because such materials have a variable anisotropy all over the part, associated to complex matrix behavior. No material model implemented in a code is able to capture this complexity level. Digimat to LS--DYNA does. Associated with the Rhodia material database MMI confident Design™ , Digimat--CAE/LS--DYNA is providing the best predictivity level available on the market today. Rhodia is proud to offer this reliability to its customers." O. Moulinjeune, Simulation Expert at Rhodia Engineering Plastics
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Company:bime Products:Digimat Industries:Aerospace | Overview: The application of Digimat MF and Digimat FE gave insight into the influence of microstructure on the overall mechanical and brittle damage behavior of highly porous sound absorbing ceramics. Digimat gave the engineers at bime key in-sight into the elastic properties of these porous sound absorbing ceramics, that was necessary to reduce production cost and increase the material's strength. Challenge:
Solution:
Results Validation: "The application of Digimat--MF and Digimat-- FE paved the way for me to give an insight into the influence of microstructure on the overall mechanical and brittle damage behavior of highly porous sound absorbing ceramics. I was able to contribute to the improvement of material strength by new material design while keeping the good sound absorption." Reza Malekmohammadi Research Assistant, bime
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Company:European Space Research and Technology Center Products:Digimat Industries:Aerospace | Overview: Digimat offered the engineers at the European Space Research and Technology Center the tools they needed to bridge the gap between the Micro world and the Macro world. Using Multi scale modeling of advanced woven composite material Digimat can support a virtual design of an ultra light satellite antenna. Challenge:
Solution:
Results Validation: “DIGIMAT is able to bridge the micro to the Macro world. A great example of high--quality european know--how” Dr Julian Santiago Prowald, TEC--MSS Structures Section ESA/ ESTECBenefits:
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Company:L&L Products Products:Digimat Industries:Automotive | Overview: Digimat provides L&L Products with state of the art simulation methods which aid engineers in product development. The key advantage provided by Digimat coupled to Radioss and other CAE software is a drastic predictability improvement for glass filled polyamide materials. With an improved predictability, optimal and robust lightweight design is possible in the future. Challenge:
Solution:
Results Validation: "The key advantage provided by DIGIMAT coupled to Radioss and other CAE software is a drastic predictivity improvement for glass filled polyamide materials. With an improved predictivity, optimal and robust lightweight design is possible in the future." F. Braymand, Simulation Manager at L&L Products
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Company:Integrative Simulation and Engineering of Materials and Processes Products:Digimat Industries:Aerospace | Overview: “Digimat enables the engineers at ISEMP to perform in-depth studies of complex and realistic microstructures. As they continue to invest into the future they now base their simulation approach on the Digimat software, improving their own research method as well as the education of a new generation of simulation engineers." Challenge:
Solution:
Results Validation: "DIGIMAT enables us to perform in depth studies of complex and realistic microstructures. As an invest into the future we base our simulation approach on the DIGIMAT software, both for our research and the education of a new generation of simulation engineers who will be experts in the modeling of materials." Prof. Vasily Ploshikhin, Airbus endowed chair for Integrative Simulation and Engineering of Materials and ProcessesBenefits:
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Company:CADF Products:Digimat Industries:Energy | Overview: Digimat assisted the engineers at CADFEM to develop a more efficient wind turbine by closing the gap between advanced modeling of heterogeneous anisotropic and nonlinear materials. The possibility of taking into account the micromchanical properties of fiber reinforced plastics in wind turbines is another area Digimat can aid in the production process of green energy. Challenge:
Solution:
Results Validation: "DIGIMAT enhances our product portfolio and closes the gap towards advanced modeling of heterogeneous anisotropic and nonlinear materials. We see a large potential for taking into account the micromechanical properties of fiber reinforced plastics." Martin Kracht, Product Manager DIGIMAT at CADFEM GmbH - ANSYS Competence Center FEM in GermanyBenefits:
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Company:SOLVAY Speciality Polymers Products:Digimat Industries:Consumer Products | Overview: By using DIGIMAT the engineers at Solvay could clearly demonstrate the tight link between geometry, flow of material, fiber orientation and mechanical behavior. They successfully used the approach to evaluate the endurance of a number of different bow limb designs. Challenge:
Solution:
Results Validation: "By using DIGIMAT we could clearly demonstrate the tight link between geometry, flow of material, fiber orientation and mechanical behavior. We successfully used the approach to evaluate the endurance of a number of different bow limb designs." Laurent Hazard, CAE Senior Specialist, SOLVAYBenefits:
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Company:Optimec Consultants Products:Industries:Machinery | Overview: Based in the Greater Montreal area in Quebec, Canada, Optimec Consultants is an advanced engineering consulting firm offering Computer Assisted Engineering (CAE) services and complete Finite Element Analysis (FEA) solutions, and is a certified reseller of the MSC Software product line. For the past year, major efforts have been directed towards maximizing the potential uses of templates for building and analyzing FEA models. Templates are powerful macros that allow automation and improve productivity. Template building is a very promising capability within the MSC SimXpert multidisciplinary simulation environment. The goal of developing templates is to use them internally and to offer personalized simulation solutions to existing clients and new industries looking to implement the Finite Element Method in their design process. This case study presents four key templates that have been developed specifically for the large machinery industry and for work in future developments. Challenge: Automating the modeling and analysis of large FEA models.Solution: The SimXpert template building capability permits
the creation of templates aimed at automating
repetitive processes. Building templates can be
done using actions library or via macro recording.
Specific scripts can also be coded using Python
programming language. SimXpert’s main
advantage over its competitors is its ease of use
and straightforward interface.Benefits:
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Company:Patrick Air Force Base Products:Adams Industries:Aerospace | Overview: Ejection seats must work perfectly every time they are used in an enormously wide range of altitudes, aircraft motion profiles, wind conditions and pilot weights while at the same time taking manufacturing variation into account. Physical testing of course plays a pivotal role in ejection seat design but time, cost and safety limit the number of situations that can be tested to far fewer than the number of potential ejection scenarios. Analysts at the Naval Surface Warfare Center (NSWC) at Indian Head, Maryland, and the 45th Space Wing at Patrick Air Force Base, Florida, have developed a model of an ejection seat using MSC Adams rigid body simulation software. During the model’s initial 5-year joint-force development process, Adams was the first professional dynamics software used to completely model the complex physics involved in the deployment of an ejection seat. Challenge: Improve ejection performance and safety.Solution: Adams was used to model the complex physics involved in the deployment of an ejection seat.Benefits:
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