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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:
  • Design of bigger turbine blades with low weight & high rotational inertia
  • Optimal use of expensive high-­-end composite materials
  • Flexible & realistic simulation approach to investigate design concepts
Solution:
  • Multi-scale analysis based on ANSYS Composite PrepPost™ model
  • Describe GFRP and CFRP composites via a unique material modeling approach using the mean field homogenization on the microscopic scale in DIGIMAT
  • Fiber description taking into account isotropic or transversely isotropic properties
  • Systematic analysis of failure directly in the Epoxy and the fiber phases
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 Germany
Benefits:
  • Failure indicators are in general much lower for carbon fiber than for glass fiber reinforcement Carbon fiber reinforced blade fails on different ply level compared to the glass fiber design
  • The usage of a transversely isotropic description for the carbon fibers is critically important for a realistic simulation approach

 
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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:
  • A manufacturer injection-molded plastic bows set the goal to produce the best bows for recreational archery on the market based on SOLVAY material
  • A new and apparently improved design of the bow limbs showed a reduced fatigue lifetime as compared to an existing geometry
  • The question arose whether the premature failure of the new design is directly connected to the change in the processing of the bow limbs
Solution:
  • Reverse engineering of an elasto-plastic DIGIMAT material model
  • Computation of 1st principles stresses for preload and load cases based on fiber orientation data coming from Moldflow
  • Life time prediction using a Haigh diagram
  • Comparison between the two different designs for the bow limbs
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, SOLVAY
Benefits:
  • The lifetime in fatigue of the original design should be slightly longer than the new design
  • The higher stress level for the new design could be connected to a higher local stiffness in the critical region in the bow limb
  • The higher local stiffness could be explained by a “better” fiber orientation due to a change in the melt flow in the processing step (combination of two “converging” flows)

 
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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:
  • Quick verification of results
  • Shorter analysis time
  • Ease of use

     
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    Company:

    Patrick Air Force Base

    Products:

    Adams

    Industries:

    Aerospace
    Defense

    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:
    • Accurate Simulation
    • Reliable Analysis
    • Improved Design Process

     
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    Company:

    Setforge Engineering

    Products:

    Patran

    Industries:

    Aerospace
    Automotive
    Heavy Equipment

    Overview:
    When Setforge joined the group, Farinia took the opportunity to review its simulation resources. Nicolas Behr, Chief Project Engineer at Setforge Engineering explains: “We realized the limits of the tools we were using and that their maintenance cost was too high relative to their capacities. What’s more, because of some of the methods used by the group – especially electro-upsetting – we had to model and simulate the nonlinear multiphysics phenomena that characterize these technologies.”
    Challenge:
    Simulate the electro-upsetting process used to make very long sectional parts
    Solution:
    • Patran to develop simulation model.
    • Marc to simulate the nonlinear multiphysics phenomena that characterize electro-upsetting technologies.
    Benefits:
    • Achieve Best Cost/Performance Ratio
    • Process Optimization

     
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    Company:

    Sikorsky Aircraft Corporation

    Products:

    Dytran

    Industries:

    Aerospace

    Overview:
    Sikorsky, a world leader in the design and manufacture of advanced helicopters, reduces design bottlenecks with MSC Nastran Advanced Nonlinear.
    Challenge:
    Sporadic use of advanced finite element (FEA) software, such as nonlinear analysis by design engineers, can result in either excessive refresher training time or a bottleneck while in the queue for an analyst. The cause is a result of different types of solvers requiring different models. Commercially available translators can help, but still require significant amounts of cleanup.
    Benefits:
    • Accurate FE Model Reproduction
    • Reliable Analysis
    • Improved Design Process

     
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    Company:

    Meritor

    Products:

    MSCOne

    Industries:

    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:

    Transmisiones y Equipos Mecánicos S.A. de C.V.

    Products:

    Adams

    Industries:

    Automotive
    Motorsports

    Overview:
    Joel Ortiz is a Concept Engineer at Transmisiones y Equipos Mecánicos S.A. de C.V. (TREMEC) in Querétaro, Mexico. TREMEC is a leading producer of rear wheel drive light duty manual transmissions. Ortiz and other TREMEC engineers are responsible for ensuring that the performance of TREMEC transmissions matches up to demanding customer expectations. In the past, the only method available to resolve performance issues in prototypes was to go through the time-consuming and expensive process of making modifications to the prototype and hoping for the best.
    Challenge:
    In testing an early prototype of a six-speed manual transmission, jumps were seen in the force applied to the shifter lever and felt by the driver of the vehicle. These jumps in shifting effort, called nibble by transmission manufacturers, do not affect the performance or durability of the transmission, but they are important because the reaction force against the gear shift helps define the shift quality of the transmission for the driver.
    Solution:
    Ortiz created a virtual prototype of synchronization mechanism in Adams with 17 parts including the shift rail, fork, roller detent, gear synchronizer cone, inner synchronizer ring, blocker ring, strut, sleeve, intermediate ring, clutches and gears. The geometries of these parts were based on the measurements of the prototype transmission.
    Benefits:
    Ortiz used a virtual prototype to reduce nibble by 93% from the early prototype to the production model, contributing to rave reviews from automotive journalists.

     
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    Company:

    Diagnostic Simulations, Inc.

    Products:

    Marc
    Patran

    Industries:

    Medical Devices

    Overview:
    Dr. Paul Buscemi was the VP of Research and Development at Restore Medical Inc. in Medina MN, now a part of Medtronic. Paul and his team were responsible for conceptualization and realization of a new tongue implant to treat sleep apnea.
    Challenge:
    Restore Medical’s challenge was to build a simple, innovative, minimally invasive, palatal implant. The R&D group needed to get insights beyond airway closure to study the effect of the implant on critical tongue functions such as speech and swallowing.
    Solution:
    Using MSC.Software’s CAE products Paul and his team were able to perform a complete analysis of a new human tongue implant design.
    Benefits:
    Using MSC.Software technology, Paul’s R&D team created an accurate model of tongue musculature and motion. The model was used to design and test a virtual prototype for a new tongue implant and its effects.

     
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    Company:

    Products:

    Dytran

    Industries:

    Defense

     
     
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    Company:

    TI Automotive

    Products:

    SimManager

    Industries:

    Overview:
    When leadership at TI Automotive—a global supplier of fuel storage and delivery systems for cars and trucks— evaluated the company’s product development process, it discovered repeated design and test cycles. MSC gave the engineers at TI Automotive the essential tools they need to save time and money, by reducing prototyping.
    Challenge:
    The problem that TI faced was that simulation was disconnected from the design process. Compounding the situation was that in going from CAD geometry to simulation models, many data translations or fixes were necessary. TI really only had one simulation expert in the company, which kept analysis from being scaled across the enterprise.
    Solution:
    Using design simulation to support its product development process would enabled TI to account for complexities of manufacturing upfront, and, additionally, would move simulation from the desktop of one expert engineer to that of many engineers.
    Benefits:
    Since TI implemented an engineering simulation solution from MSC Software, the supplier of enterprise simulation solutions. The benefits have been significant.
    • TI Automotive now is able to run virtual tests without having to rely on the one in-house expert, which eliminates the previous bottleneck.
    • TI reduced physical prototyping, and analysis time went from two weeks to four days per design. With less than a half hour of user effort, engineers are able to create a new design, run all of the simulations, and receive results.
    • The new simulation capabilities have driven notable enterprise savings.
    • The use of simulation has aslo brought gains to the top line, by demonstrating significant engineering expertise and competitiveness to end customers early in the sales cycle.

     
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    Company:

    BMW Group

    Products:

    Industries:

    Overview:
    In early 2007 the computer assisted engineering process chain at BMW was reviewed in order to identify possible bottlenecks in the future caused by the increasing size of simulation models. Under the name “Model of The Day After Tomorrow” the group of functional design body and fitting developed the largest known FEM model for a system-benchmark.
    Challenge:
    Identify the theoretical limits and bottlenecks of today's computing rsoruces

     
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    Company:

    Sogeti

    Products:

    SimManager

    Industries:

    Overview:
    SOGETI Group (member of the Cap Gemini Group), a leader in IT services and R&D outsourcing, offers professional services that focus on three key complementary business areas: IT Application Management, IT Infrastructure Services and High Tech Consulting. Sogety enables their clients to leverage global technological innovations, and achieve above average results from their IT programs. The company employs more than 18,000 people in over 200 lcoations in Europe, the US and India. Around one third of the High Tech Consulting division's 3,000 employees are dedicated to engineering research and development.
    Challenge:
    As its simulation business grew, Sogeti realized that effective management of simulation content is critical to its ability to profitably and reliably offer services to its customers. In addition, increased globalization is driving compliance in R&D efforts in the aerospace sector.
    Solution:
    Sogeti selected SimManager, MSC Software’s simulation content and process management solution that eliminates time wasted in searching for data and streamlines the process of distributing standard methods, processes, material properties, and other content.
    Benefits:
    • Creation of a simulation knowledge base that facilitates collaboration and streamlines content distribution
    • Managed simulation processes that improve consistency and reliability
    • Automation of methods and processes to dramatically reduce repetitive, manually intensive work
    • Open support of existing simulation investments including third-party CAE tools, HPC hardware, and methods

     
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    Company:

    John Deere Welland Works

    Products:

    Adams
    MSC Fatigue

    Industries:

    Heavy Equipment

    Overview:
    With the help of MSC Software Professional Services and products such as ADAMS/Durability and FE-Fatigue, John Deere Welland Works completed the design and testing of their new rotary cutter system within two weeks instead of several months. Thanks to the implementation of durability analysis, John Deere could reduce the number of the required physical prototypes and was able to try out several design concepts. As a result, the total development time on one cutter was reduced from four years to two, and John Deere is on track to produce another cutter in one year.
    Challenge:
    One of the most time-consuming aspects of the cutter systems’ development in the past was the lengthy process of building physical prototypes, testing them for durability, then redesigning several parts and starting all over again.
    Solution:
    Utilizing ADAMS/Durability enabled complete integration of key virtual prototyping techniques such as finite element analysis, multibody simulation, and fatigue life prediction. The implementation of durability analysis at John Deere Welland Works was one of the key factors in reducing development time for their rotary cutter systems.
    Benefits:
    Development on a 20-foot cutter was reduced from about four years to two, and most recently, to one year. Compressing the time cycle also meant that the company was able to evaluate many more design concepts than previously possible, which leads to more innovative approaches.

     
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    Company:

    Hollandsche Beton-en Waterbouw bv

    Products:

    Marc

    Industries:

    Heavy Equipment
    Shipbuilding

    Overview:
    The design/build engineering company Hollandsche Beton-en Waterbouw bv (HBW) investigated and validated the concept of a new, very large, inflatable dam with the help of MSC.Software Professional Services and products such as MSC.Marc. Using MSC.Marc nonlinear simulation software, HBW could understand the dam’s performance and the inflation/deflation procedure, as well as ensure that stresses were within the specified margin of safety. Thanks to the implementation of VPD tools, HBW realized design improvements in the inflatable dam’s flexible structure and completed the design. When a heavy storm hit the Netherlands in 2002, HBW’s dam automatically deployed within one hour -as predicted by MSC.Software tools.

    Challenge:
    Because an inflatable dam of this size had never been built before, the concept had to be validated before it could be built.
    Solution:
    MSC Software Professional Services was engaged to investigate the concept, as well as to make design improvement recommendations, using MSC Marc nonlinear simulation software.
    Benefits:
    The simulation performed by MSC Software Professional Services gave the customor as well as the government of the Netherlands an accurate prediction of the behavior of the rubber dam.

     
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