Company:

Anadolu Isuzu

Products:

Adams

Industries:

Automotive

Adams Helps Reduce Time and Cost of the Fatigue Test

Overview:

Andolu Isuzu’s new 12 meter long bus, called the Citiport, is equipped with a ZF 6-speed full automatic transmission and a 6 cylinder common rail turbo diesel Cummins engine that produces 283 horsepower at 2100 rpm. The bus can be configured to hold up to 103 people. A wheelchair ramp and kneeling system simplify entry and exit for passengers with disabilities. The bus uses an independent air suspension powered by an electric or engine-driven air pump or compressor. This compressor pumps the air into a flexible bellows made from textilereinforced rubber. The air pressure inflates the bellows, and raises the chassis from the axle. There are two air suspensions in the front of the bus and four in the rear.

Results Validation:

With the aid of simulation results, Anadolu Isuzu engineers were able to dramatically improve the initial design concept. For example, the optimized suspension design parameters developed in the simulation reduced the rollover risk by 8.37%. The fatigue life predictions highlighted excessive stress in several body components. These components were redesigned to meet design specifications. “The use of simulation reduced the cost of the product development process because fewer physical prototypes and less physical testing were required,” Sert said. “Simulation also reduced the time required to bring the new product to market. The product was introduced about one year ago and has become a major success in the export market.”

Benefits:
  • The optimized suspension design parameters developed in the simulation reduced the rollover risk by 8.37%
  • Simulation also reduced the time required to bring the new product to market, which is a major success
  • The predictions of the simulation model closely matched the results of actual measurements

 
DOWNLOAD

Company:

Framework Construction

Products:

MSC Apex
MSC Nastran

Industries:

Energy

Static Simulation for Framework Construction in Power Plant Using MSC Apex

Overview:

Many structures in plant engineering are characterized as thinwalled. The Finite Element Method (FEM) is a common method used to assess the performance of such thin structures. Creating a FEM model of a thin structure involves midsurfacing models and meshing with shell elements. However, the process for creating FEM models is time consuming often requiring hours and days. The use of MSC Apex can help produce midsurface models significantly faster than with other traditional CAE pre/post processors. In addition to FEM creation, MSC Apex can be used to perform strength analysis.

Benefits:
  • Geometry is easily edited to construct FEM models rapidly
  • FEM models are validated for materials, properties, mesh congruency, connections and boundary conditions
  • FEM models may be exported from MSC Apex and used in a separate pre/post processor

 
DOWNLOAD

Company:

KTH Royal Institute of Technology

Products:

Adams

Industries:

Machinery

Evaluating New Forestry Machines in a Fraction of the Time

Overview:

The predominant forest harvesting method used in northern Europe is cut-to-length logging (CTL). CTL is based on a two machine solution – a harvester is used for felling, delimbing and bucking trees and a forwarder carries the logs from the harvesting area to a roadside loading area where they can be picked up by a truck. These are both off-road machines with a frame mounted crane that operate in areas not accessible by conventional wheeled vehicles at low speed. In order to stay competitive, the Swedish logging industry needs to increase productivity by 2% to 3% per year.

Results Validation:

“Now that we have validated the ability of Adams to accurately simulate the performance of forwarders, we will be able to evaluate new design alternatives and optimize the performance of concept configurations in a fraction of the time required by the build and test method,” Ismoilov said. “The ability to evaluate more designs in less time will make it possible to optimize the suspension and other components of the vehicle in order to provide higher productivity without causing discomfort to the operator or damage to the soil.”

Benefits:
  • The Adams simulation verified different suspension configurations in terms of operator comfort and impact on the soil
  • The analyses results correlates well with physical tests on roll rate and other parameters
  • Adams provides the ability to evaluate more designs in less time to optimize the suspension and other components of the vehicle

 
DOWNLOAD

Company:

CNH Industrial

Products:

Actran Acoustics

Industries:

Heavy Equipment

Actran Helps Reduce Time to Qualify Wheel Loader for Tough New Noise Standard from 1 Year to 3 Months

Overview:

Noise regulations in a key Latin American country were revised to a lower level, forcing CNH and other construction equipment manufacturers to reduce the noise footprint of their products.

Results Validation:

“Simulating the acoustic performance of alternative approaches to noise remediation helped us meet the tighter noise specification in about three months,” Tamamidis said. “If we had to rely on physical testing for this project, it would have taken at least a year to reduce noise to the levels needed to meet the new spec. Due to successful projects such as this, we have integrated Actran into our product development process and use it on a regular basis to help ensure the acoustic performance of new designs and solve problems with existing designs.”

Benefits:
  • Quicker understanding of noise contributors
  • Simulations proved more comprehensive than physical test
  • Met noise specifications faster
  • Able to ensure acoustic performance of new designs

 
DOWNLOAD

Company:

Ashok Leyland

Products:

SimManager

Industries:

Automotive

MSC Software's SimManager Enables Improved Engineering Productivity and Lifecycle Management at Ashok Leyland

Overview:

Many design targets must be achieved before commercial vehicles such as trucks and buses are released to the market. An optimal design is one that best balances the many competing project targets: performance, regulatory, ergonomics, time to market, cost, warranty and others. Exploring potential design alternatives by building and testing physical prototypes is extremely time-consuming and costly. Instead, Ashok Leyland engineers use Multibody Dynamics (MBD), durability, crash and safety, Computational Fluid Dynamics (CFD), and Noise Vibration and Harshness (NVH), Computer Aided Engineering (CAE) tools to evaluate the performance of a wide range of design alternatives. After identifying the optimal virtual designs that meet the design targets, engineers move forward to build and validate the vehicle for the launch. This approach reduces engineering expenses, accelerates delivery to market, and meets or exceeds customer requirements.

Results Validation:

With respect to the savings for the overall activities of the CAE across all the domains, there is realization of savings of 15% on Preprocessing, 80% in Post-processing in Crash, CFD, Durability and NVH with the automation implemented through SimManager. About 60% savings in human effort is achieved in durability studies.

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

 
DOWNLOAD

Company:

Kiekert

Products:

Adams

Industries:

Automotive

Adams Dramatically Reduces Time to Design Child Safety Latch

Overview:

Latches with child safety locks are built into the rear doors of most automobiles to prevent the passengers in the rear seats from opening the doors of the vehicle while the vehicle is moving or at rest. The child safety lock is a mechanism that temporarily disables the operation of the inside door handle. When the child safety lock is engaged, the rear doors can only be opened from the outside. On newer models, this safety lock is activated or deactivated electronically utilizing a small motor within the side door latch by a switch, typically located near the driver’s side door lock switch.

Results Validation:

Using multibody dynamics simulation, Kiekert engineers dramatically reduced the time required to design the child safety lock mechanism to only about three weeks. The child safety lock is part of a side door latch that is still in the development process but previous projects have demonstrated that the use of simulation – including finite element analysis and tolerance analysis in addition to multibody dynamics – can substantially reduce the time required to bring a new latch to market to less than 18 months.

Benefits:
  • The Adams simulation dramatically reduced the time required to design the child safety lock mechanism to only about three weeks
  • Kiekert accurately characterized the performance of proposed design iterations using engineering simulation prior to the prototyping phase
  • Using Adams flexible body, they precisely captured the deformation of the plastic levers and how that affects the system performance

 
DOWNLOAD

Company:

Saab

Products:

Adams

Industries:

Aerospace

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle, Saving At Least 6 Months by Reducing Physical Testing

Overview:

The Saab Skeldar V200 is a unique entrant in the unmanned aerial vehicle (UAV) market which is dominated by fixed wing aircraft. As a rotary wing aircraft, the Skeldar does not require runways to take-off or land from and can hover in one position. Skeldar is designed for land- and sea-based patrol, light transport, electronic warfare and surveillance applications. With dimensions of 4 meters long by 1.3 meters high by 1.2 meters wide, the UAV flies at speeds up to 130 km/h with a range of 150 km.

Results Validation:

After validating the model, Persson applied it to the issue that had been experienced with the prototype and discovered that the simulation model accurately duplicated the behavior seen in the prototype. The simulation model provided far more detailed information than could be obtained by instrumenting the prototype, such as the aerodynamic forces acting on each section of the blades. The model also made it possible to evaluate the performance of the UAV under a much wider range of conditions than could ever be evaluated with the prototype due to the time, cost and risks involved in actual test flights.

Benefits:
  • Leverage Adams simulation to accurately capture the interactions between the lifting forces on the rotor blades and downwash
  • Use multiple-flexible part method to capture the large deformation of the rotor blades during the flight
  • The aerodynamic forces and moments acting on the UAV are incorporated into the Adams model as a user-defined function
  • Adams analysis results correlates well with physical tests regarding flight behavior
  • Adams simulation saved the team at least 6 months compared to the traditional approach

 
DOWNLOAD

Company:

Volvo Car Corporation

Products:

Adams
Marc

Industries:

Automotive

Adams-Marc Co-Simulation Provides Efficient and Accurate Method of Simulating Misuse Load Events

Overview:

A vehicle might be subjected to misuse, peak load or strength events such as driving over a curb or skidding against a curb a few times during its life. These durability load cases play a major role in the product development process since they potentially drive the design for several components. At Volvo, the “driving over a curb” and “skid against a curb” strength events are classified into two categories, Level 1 and 2. Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle. Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode. Structural deformations are acceptable but there should be no separation or breakage. For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components, a design principle known as chain of failure.

Results Validation:

The ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process. “From the early stages of the development process, we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loads,” Wirje said. “The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle. At the same, we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required. Of course, full physical verification will be performed at the end of the project.”

Benefits:
  • Leverage Adams-Marc to capture plasticity and buckling of flexible lower control arm in the suspension system
  • The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests
  • Be able to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle
  • Reduce the prototype verification cycles by performing product development more accurately from the beginning

 
DOWNLOAD

Company:

Belgian Building Research Institute

Products:

Actran Acoustics

Industries:

Consumer Products

Actran Helps Improve Predictions for Room to Room Vibration Transmission

Overview:

The stringent acoustical requirements imposed by the Belgian standard for dwellings (NBN-S01-400-1 (2008)) present a major challenge for architects. In particular the standard defines strict requirements for the global sound insulation between rooms which is mainly determined by the direct transmission and flanking transmissions in which sound waves produced in one of the rooms excite the flanking structure and generate structural waves which are transmitted through the structure.

Results Validation:

BBRI researchers evaluated the incumbent and new prediction formulas over a wide range of surface mass ratios in the case of the old formula, and ratio of characteristic moment impedances in the case of the new formula. The results showed that for in-line and corner transmission in T-junctions, X-junctions and H-junctions the new formula more accurately predicts Kij. This work shows that a best prediction of Kij can be obtained by using the ratio of the characteristic moment-impedances “A” instead of the ratio of surface masses. It seems logical that the attenuation of vibration depends on this new ratio since during a change of direction only moments and angular velocities can participate in energy transmission.

Benefits:
  • Accurate vibro-acoustic modeling of room to room vibration transmission
  • Reduce product development costs by avoiding expensive tests

 
DOWNLOAD

Company:

Alson E. Hatheway Inc (AEH)

Products:

MSC Nastran

Industries:

Aerospace

Mechanical Design of Optical Systems using MSC Nastran

Overview:

A common mechanical failure in optical systems is inadequate stiffness in the supporting structure. Stiffness is crucial for maintaining the alignment of the optical elements and achieving adequate optical performance. It is the responsibility of the mechanical engineer to provide adequate stiffness in the mechanical design.

Solution:

In the first days the mechanical engineer analyzed the optical performance of the proposal’s mechanical design, identified and implemented needed refinements and validated that the resulting conceptual design could be developed into a detailed design that would meet the project’s optical requirements. Further, by working in simple, early structural models (lumped mass, beam and shell elements) as well as the large models of a more mature design (meshed and CAD joined tetrahedral solids), AEH/Ivory provides the project a continuous and traceable record of the adequacy of the structural stiffness supporting the optical system.

Benefits:
  • Saved months of schedule time on projects
  • Hundreds of thousands of dollars saved
  • Assurance from the very beginning of the mechanical engineering effort that the structure is designed correctly

 
DOWNLOAD

Company:

Meritor

Products:

Adams

Industries:

Automotive

Adams Used to Simulate New Control Strategy that Reduces Truck Stopping Distance by over 30%

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 medium- and 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

 
DOWNLOAD

Company:

Comat Aerospace

Products:

Adams
SimXpert

Industries:

Aerospace

Developing the 3POD Antenna Pointing System

Overview:

Comat Aerospace is in the process of developing the 3POD Antenna Pointing System (APS) in collaboration with the Centre National d’Etudes Spatiales (CNES), the French national space agency. The role of the 3POD APS is to keep the antenna pointed at ground stations regardless of the satellite’s orientation while maintaining low mechanical jitter to ensure line of sight stability. For its first projected deployment on the OTOS satellite, the 3POD ATS will be required to provide a 74° pointing domain with a worst case pointing precision of +/- 1° at a pointing speed of about 5° per second.

Results Validation:

Comat engineers originally used Adams to perform kinematic simulation of the motion and piloting functions of the robot and to complete a parametric study on the various design parameters and their impact on the overall performance. But incorporating flexibility into the Adams model required a long design loop between the CATIA model, Adams model and Nastran/Patran model. By the time this design loop could be completed, the design had often been changed so the results were outdated. Going further in the process, Comat engineers built a prototype of the robot that highlighted the importance of the flexibility of the elements on its overall rigidity in certain positions.

Benefits:
  • Study various design parameters
  • Accelerate the design cycle
  • Modify the design and validate the performance in about 4 hours

 
DOWNLOAD

Company:

Dynetics Technical Services Inc.

Products:

MSC Apex

Industries:

Aerospace

MSC Apex Used to Reduce Geometry Cleanup of Fuel Pump Components from Two Days to One Hour

Overview:

The National Aeronautics and Space Administration’s (NASA’s) Space Launch System (SLS) will be the most powerful rocket in history, launching crews of up to four astronauts in the Orion spacecraft to explore multiple, deep space destinations. The SLS is designed around an evolvable architecture that will support versions ranging from 77-metric-ton (77 ton) to 130 metric ton (143 tons) lift capability. The SLS core stage, more than 200 feet tall with a diameter of 27.6 feet, will store cryogenic liquid hydrogen and oxygen that will feed four RS-25 engines. The RS-25 served as the Space Shuttle main engines and operated with 100% mission success during 135 missions. The RS-25 is being modified to serve on the SLS by increasing its power from 491,000 to 512,000 pounds of vacuum thrust among many other improvements.

Benefits:
  • Identify and remove all undesirable boundary edges in a single step
  • Create new surface boundaries by sketching lines in place
  • Create a global solid element mesh while maintaining curvature based refinement and topological congruency

 
DOWNLOAD

Company:

University of California, Irvine

Products:

MSC Nastran

Industries:

Consumer Products

MSC Nastran Helps Perfect New Nondestructive Testing Method for Adhesive Bonded Composites

Overview:

Compared to other joining methods, bonding composite structures with adhesives distributes the load over a larger bond area, reduces weight, joins dissimilar materials and provides higher stiffness and toughness. Bonding also generally reduces manufacturing costs. However, when using adhesive bonding for composites it can be very difficult to determine if the bonded joint meets structural requirements without destroying the part.

Solution:

UCI researchers used MSC Nastran and Patran to simulate the operation of quantitative percussion testing to reduce the need for physical testing and eliminate the potential for manufacturing errors.

Benefits:
  • Reduce the need for physical testing
  • Eliminate the potential for manufacturing errors
  • Perfect the use of percussive testing in a wide range of applications.
  • Evaluate the ability of the test to clearly distinguish between well bonded and kiss bonded panels.

 
DOWNLOAD

Company:

Italian Institute of Technology

Products:

Adams

Industries:

Machinery

Accurately Simulating a Four-Legged Walking Robot with Adams

Overview:

Search and rescue is extremely hazardous work and there are some areas which cannot be reached by humans because the danger is too great. A new generation of robots is being designed to address these challenges. While there are a number of different potential search and rescue robot designs, one of the most interesting is a four legged robot being designed by the Dynamic Legged Systems Lab led by Dr. Claudio Semini (Italian Institute of Technology) to perform dynamic tasks such as walking in rugged terrain, carrying heavy loads, climbing hills and even jumping and running.

Solution:

Advanced Industrial Automation Lab engineers instead used Adams and MSC Nastran to simulate the performance of the robot in a fraction of the time that would have been required for the analytical approach. Each robot leg contains about 450 parts. IIT engineers merged these components into just a few rigid bodies, one for each moving part of the structure

Benefits:
  • Up to 90% correlation between physical tests and simulations on both robot displacements and contact forces
  • Researchers are now able to evaluate different folding methods and new package designs with the simulation model
  • Including flexibility into Adams model further increases the accuracy of predicting complex robotic behavior

 
DOWNLOAD

Pages