Company:

BAY-LOGI

Products:

Marc

Industries:

Energy

Marc Simulates Welding of Nuclear Pressure Vessel Reactor Nozzles

Overview:

The reactor pressure vessels make up the heart of a nuclear power plant, containing the core, core shroud and coolant. In water-cooled water-moderated energy reactors type power plants, nozzles on the ferritic steel pressure vessel are welded to primary coolant pipes made of austenitic steel. These nuclear power plants were built and started operating 20 to 30 years ago. The company operating one of these power plants needed to know how these welds can be expected to perform after a long period of service. It’s not practical to perform measurements on the reactor itself because of the complex geometry and the presence of radiation. Building and testing a duplicate structure would be expensive and it would also be very hard to replicate the effects of 20-plus years of operation. So the operator of the power plant agreed with the Department of Structural Integrity at Bay Zoltan Institute for Logistics and Production Engineering (BAY-LOGI) to simulate the manufacturing process to better understand the characteristics of the welded joint.

Benefits:
  • Model coupled thermomechanical effects of multi-pass welding process
  • Gain insight into residual stress distributions
  • Save on costly physical testing

 
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Company:

Litens Automotive Group

Products:

Adams
Marc

Industries:

Automotive

Adams-Marc Co-simulation Makes System Analysis 15 Times Faster than Pure Nonlinear FEA Analysis

Overview:

Litens Automotive Group’s patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional vibrations. The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia. Because the spring stiffness is softer than traditional rubber isolators, vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt. This results in isolation of all components in the accessory drive, and any accessory drive resonance has very small peak amplitudes, since there is very little excitation.

Results Validation:

The Marc simulations have previously been found to be very close to physical measurements. The co-simulation results for key values, such as the inner drive angle as a function of input torque, were found to vary by less than the 10% from the Marc simulation over two revolutions of the input shaft.

Benefits:
  • Adams-Marc Co-simulation Makes System Analysis 15 Times Faster than Pure Nonlinear FEA Analysis
  • The solution maintains high accuracy of the simulation
  • Enables engineers to run many design iterations in a short period of time to optimize in a practical fashion

 
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Company:

Infosys

Products:

MSC Nastran
Patran

Industries:

Medical Devices

MSC Nastran Provides More Accurate Solution to Assess Bone Fracture Risk

Overview:

Humans lose bone mass with age because their bones lose calcium and other minerals and become lighter, less dense and more porous. As this process continues, our bones become weaker, increasing the risk of bone fracture. A patient is said to have osteoporosis when bone mineral density (BMD), the concentration of minerals in a unit volume of bone, falls below a threshold value.

Results Validation:

This innovative solution to osteoporosis developed by Infosys uses computer-assisted design and FEA for the evaluation of fracture risk of the vertebrae quantitatively. Stresses computed through the simulation provide more accurate assessment than traditional BMD measurements in the determination of fracture risk. It applies best practices in mechanical engineering to understand the biomechanics of vertebrae.

Benefits:
  • Using MSC Nastran to study the mechanics of vertebrae while taking into account various factors such as the shape, density distribution of cortical/cancellous bone and other material properties of bone tissue and porosity.
  • The solution helps practitioners to study bones in a detailed and non-invasive manner, and quantitatively analyze the fracture risk of vertebrae
  • Stresses computed through the simulation provide more accurate assessment than traditional BMD measurements in the determination of fracture risk

 
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Company:

Ford Motor Company

Products:

Adams

Industries:

Automotive

Ford Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Overview:

Noise/vibration/harshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process.

Challenge:

When developing a new vehicle model, engineers are responsible for meeting a wide variety of often conflicting performance targets. Fuel economy and NVH are two of the most important categories of targets.

Benefits:
  • This case study successfully demonstrates the FMI integration approach for vehicle lugging NVH assessment
  • Effectively coupled AMESim Converter Controller model with Adams Driveline and Vehicle model
  • An Optimum Torque Converter slip speed was determined meeting lugging target requirement while balancing with fuel economy
  • Simulation results showed drivetrain torsional vibration along with vehicle vibration (steering wheel & seat track) were effectively reduced with converter slip

 
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Company:

Deggendorf University

Products:

Adams
Adams Car
MSC Nastran

Industries:

Automotive

Quick as Lightning - MSC Software supports 'Team Fast Forest' from Deggendorf

Overview:

Young university students make use of Adams multi-body simulation software to construct a vehicle for entry in the Formula Student competition. ‘Team Fast Forest’ from Deggendorf is using the software to study tires and chassis. Breaking conventional car design, the team will focus on electric vehicles.


 
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Company:

Mahindra Two Wheelers

Products:

Adams

Industries:

Automotive

Adams Multibody Dynamics Simulations Help Bring Two Wheelers to Market 7-21 Weeks Faster

Overview:

In the past, the design of new two wheeler models at Mahindra was based on building prototypes and driving them on a test track. The limitations of this approach were that prototypes took an average of five weeks to build and had to be run for about two weeks to evaluate component durability. A major improvement came when test rigs were introduced and used to recreate the conditions of the test track using automated equipment that eliminated the need for a driver and could be operated 24X7. This approach saved time, however, a complete vehicle prototype iteration was still required for each major design change.

Solution:

Mahindra selected MSC Software’s Adams, the most widely used MBD software for over three decades. MSC Software is the world leader in both MBD and FEA software. Speaking the language of both domains gives MSC the capability to develop the rich data transfer required to fully integrate them. Mahindra has evolved a new virtual testing design process that uses Adams to simulate the performance of new designs and accurately predict their performance prior to the prototype phase.

Results Validation:

Basing the design process on simulation rather than testing provides substantial time and cost savings. The largest savings come from being able to evaluate alternative designs without having to build a prototype. The number of prototypes required to bring a new two wheeler to market has been reduced from 4 or 5 in the past to 2 or 3 now. The time to build and test a new prototype is about 7 weeks so the company has been able to bring new two wheels to market at least 7 to 21 weeks faster than was possible in the past.

Benefits:
  • Simulation provides much more diagnostic information than can be obtained from physical testing
  • Engineers perform parametric analyses to investigate the influence of design variables such as the location of hard points on accelerations
  • Excellent correlation between simulation and measurements on suspension systems
  • The number of prototypes required to bring a new two wheeler to market has been reduced from 4 or 5 in the past to 2 or 3 now
  • Adams bring new two wheels to market at least 7 to 21 weeks faster than was possible in the past

 
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Company:

Scania

Products:

Adams

Industries:

Automotive

Advanced Powertrain Dynamic Analysis and Development Using Adams

Overview:

Scania transmission components are developed as part of Scania’s integrated powertrain with a perfectly matched specification for each individual demand. The gearboxes are designed to suit the high-torque Scania engine range. The multitude of drive axle and bogie options provide optimum strength without inducing a weight penalty. Integrated powertrains are offered to customers on a modular basis in which nearly any gearbox can be combined with nearly any engine.

Challenge:

The traditional approach to the design of gearbox and powertrain components involves creating an initial design based on one-dimension powertrain models and engineering calculations and then building and testing a prototype. With this approach, undesirable properties are identified during physical testing at a late stage in the design process when changes are expensive. Another concern was that the cost involved in building and testing different gearbox-engine combinations can be very high, especially if prototypes have to be rebuilt and retested because the design did not match what was intended the first time.

Solution:

Scania has addressed this challenge by making extensive use of MSC Software’s Adams multibody simulation (MBS) 3D powertrain models that accurately predict transmission dynamic behavior. Scania powertrains are now developed in a virtual environment in which a large number – often thousands – of design alternatives are simulated and evaluated as software prototypes. Simulation predicts the performance of design alternatives prior to committing to the time and cost involved in building and testing physical prototypes.

Results Validation:

Simulation enables Scania engineers to quickly evaluate functional virtual prototypes of power transmission assemblies and components. Working in the MSC Software Adams simulation environment, Scania engineers can exercise powertrain designs under a wide range of conditions using the same tests they normally perform in a test lab but in a fraction of the time. Modifications are validated in the virtual world, which saves a significant amount of time and money in the design process. In some cases engineers have solved quality issues 30 percent to 40 percent faster when running simulation and measurements in parallel due to better understanding of the product.

Benefits:
  • Quickly model and evaluate power transmission assemblies and components
  • Excellent correlation between simulation and measurements in NVH and gear rattle
  • Solved quality issues 30 percent to 40 percent faster than using physical test alone

 
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Company:

CNRS-LAM, France

Products:

Marc

Industries:

Aerospace

The Laboratoire d’Astrophysique de Marseille

Overview:

Astronomical telescopes and instruments enable astronomers to see into deep space and unravel the mysteries of the universe. Freeform mirror surfaces – surfaces with a shape more complex than a symmetrical conventional mirror surface (as for example, sphere, parabola, hyperbola, etc.) - offer substantial benefits by providing additional degrees of freedom that make it possible to improve the optical performances of the instrument, reducing the overall instrument mass and size.

Challenge:

The hydroforming process is difficult to design and optimize because the mirror undergoes plastic deformation to provide a freeform optical surface. While the elastic behavior of materials is well known and frequently modeled in optical manufacturing, the analysis of materials under stress in the plastic domain is much more difficult because it involves both material and geometric nonlinearities. One particular importance is the quantifying of the springback effect, in order to control the final shape of the mirror.

Benefits:
  • Reduction of time and cost of physical testing
  • Ability to produce a higher quality mirror surface
  • Accurate modeling of material and geometric nonlinearities

 
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Company:

VTT Technical Research Centre of Finland

Products:

Actran Acoustics

Industries:

Machinery
Shipbuilding

Finding the Solution to a Noise Problem

Overview:
A night time noise complaint was issued from the residential area near one of Wärtsilä’s main large 4-stroke medium speed engine factories located in downtown Vaasa. This factory produces the Wärtsilä 32 ship engine which provides higher unit power, enhanced fuel consumption, significantly reduced componentry and integral computer control to a fiercely competitive sector of the engine business. The Wärtsilä facility produces about 500 engines per year and every engine is subjected to a test run. An investigation found that the likely source of the intolerable noise was from the exhaust from a W6L32E engine 1000 hour endurance test which was running continuously at 750 rpm and full load.
Challenge:
An environmental noise study was conducted in the middle of the night when the test engine was running, with measurements taken at three locations between the test facility and the nearby residential area. Sound pressure level measurements indicated a peak in the sound spectrum at the 100 Hz 1/3 octave band at approximately 94 Hz in narrowband, which corresponds to the crankshaft rotation frequency (CRF) order of 7.5. Typically the exhaust noise of the W6L32E engine should have the highest peaks at CRF orders 3 and 4.5. The measured noise was found to be well under the nighttime environmental noise limit. The annoyance levels were presumed to be high because of the dominant half order modulated low frequency noise components.
Benefits:
  • Accurate vibro-acoustic modeling of exhaust gas pipe system
  • Reduction of environmental sound levels with minimal physical testing

 
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Company:

4Subsea AS

Products:

Marc

Industries:

Energy

Extending the Life of Subsea Drilling Equipment

Overview:
Subsea drilling is conducted through a string of steel pipe called a rigid riser that runs from the oil rig to the blowout preventer (BOP). The primary purpose of the BOP is to cut off the flow of oil in the event of an emergency during drilling. The BOP may be connected to the subsea well directly, which consists of a string of vertical pipe running into the seabed down to the reservoir. The part of the well above (2-5 m) the seabed is called the wellhead system. This is the interface to the equipment to be connected to the subsea well. Alternatively, the BOP may be connected to a valve tree, which in turn is connected to the subsea well. The valve tree is used to control the flow of oil, and is usually called a Christmas tree.
Challenge:
The traditional approach to estimate fatigue life for underwater applications is based on the nominal stress at a given location. The calculated stress is related to test results through S-N curves, which give a required amount of stress cycles to cause fatigue failure. The results from a fatigue test are plotted as stress (S) versus number of cycles to failure (N), which gives the S-N curve. However, fatigue testing is expensive and time consuming so it is usually possible only in certain cases.
Benefits:
  • Greater understanding of crack growth
  • More accurate prediction on part life-cycle
  • Increased uptime of drilling rig

 
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Company:

Uponor GmbH

Products:

Simufact
Simufact Forming

Industries:

Consumer Products

Process optimization through forming simulation

Overview:

One of the most important factors for efficient manufacturing was considered to be the experience of the blacksmith. This includes the knowledge of and the feeling for the temperatures in the blank as well as the right selection of the workpiece sizes and the correct angle for putting them into the die. Entering the forging business seems to be quite difficult for a company because it has to gain the required experiences to realize an efficient forging process.


 
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Company:

Schmiedag GmbH & Co. KG
Wildauer Schmiedewerke GmbH

Products:

Simufact
Simufact Forming

Industries:

Shipbuilding

Forming simulation streamlines manufacturing process of large forgings

Overview:

Crankshafts for large diesel engines that are used in container ships are usually forged in middle and small series. Because every crankshaft has specific features, their manufacturing and design is a challenge. This is where the forming simulation comes into play.


 
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Company:

Neumayer Tekfor Holding GmbH

Products:

Simufact
Simufact Forming

Industries:

Automotive

Forming simulation in the automotive industry – quality and cost efficiency at Neumayer Tekfor

Overview:

An optimal manufacturing process for automotive components is essential for the quality and the cost efficiency of these components. This is the reason why the use of simulation tools prior to the production has increased. With simulation, the process can be planned in detail to save material or increase the uptime of the machines.


 
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Company:

LuK USA LLC, Schaeffler Group Automotive

Products:

Simufact
Simufact Forming

Industries:

Automotive

LuK innovates manufacturing processes through forming simulation with Simufact

Overview:

In the automotive supplier industry, innovative product design and manufacturing solutions are essential for being competitive. Components and subsystems are engineered to achieve highest quality standards and must be offered at a competitive price. As those parts are usually produced in large quantities, a failure of only one component can lead to very expensive recalls, let alone the damage of the manufacturer’s reputation. Design and simulation solutions are required to offer an environment that delivers a mature and robust way to archive a greater knowledge about the optimal design and the manufacturing process, while giving the engineers the ability to find innovative solutions.


 
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Company:

Fokker Space

Products:

Adams

Industries:

Aerospace

Meeting the Challenge: Engineering for a New Class of Satellite

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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