Company:

Fokker Aerostructures

Products:

MSC Nastran
SimXpert

Industries:

Aerospace

In Summa Innovation & Fokker Aerostructures - New Methods for Simulation Automation

Overview:
In May 2011, MSC Software, In Summa Innovation, and Fokker Aerostructures entered into a close partnership. In the so-called “Fokker Virtual Lab” the three companies started to do serious research with MSC Software products SimXpert and MSC Nastran.

The goal of this first project was twofold:

1) Familiarization and testing of MSC Nastran

2) Familiarization with SimXpert to create a prototype for a process to automate the creation of a QA-sheet, the quality assurance of FEM models.
Challenge:
Investigate new simulation technologies for future use.
Benefits:
  • Created a prototype for a process to automate the creation of a QA-Sheet.
  • Researched new technologies in a joint effort between suppliers and users.
  • Developed the process of how to use SimXpert & MSC Nastran in the complete design process outside the production environment.
  • 50% reduction in report generation
  • Identification and reduction of errors

 
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Company:

Schindler

Products:

MSC Nastran
SimXpert

Industries:

Machinery

Schindler - The Ups and Downs of Finite Elements

Overview:
Schindler is a concern with business activities in all five continents and a market leader in the lift and escalator sector. Schindler’s offering ranges from passenger lifts suitable for small blocks of flats to sophisticated transport solutions for skyscrapers. Service lifts ensure the stress-free movement of goods and people in shopping centres, office buildings and railway stations. Bed lifts provide for the smooth and vibration-free movement of patients and equipment in hospitals. In industrial buildings, many of the hoists and small goods lifts in use are supplied by Schindler, while glass cabin lifts in tall buildings offer both a novel experience and a feeling of safety.
Challenge:
Find reliable & energy efficent solutions which make the optimum use of materials for complete lift systems
Benefits:
  • Simulate wall fixings of lifts and determine whether deformations and loadings remain within the permissable range
  • Model and evaluate a greater number of design variants using automated processes
  • Carry out static (strength) calculations, dynamic and vibration analyses with the aid of FE methods.
  • Construct consistent model

 
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Company:

TLG Aerospace, LLC

Products:

MSC Nastran
MSC Nastran Desktop
Patran

Industries:

Aerospace

TLG - Making Better Aircraft Everyday

Overview:
TLG Aerospace, LLC (TLG) is an aerospace engineering services company founded in 2008 in Seattle, Washington. TLG, ‘The Loads Group’ specializes in full vehicle analysis and optimization including static and dynamic loads, flutter, stability and control, aerodynamic design, Computational Fluid Dynamics (CFD) analysis, FAA certification and aircraft performance and handling qualities. TLG provides design, analysis and certification for new and modified aircraft and related aerospace products.

TLG’s primary customers are OEMs, thirdparty modifiers, and other companies who design, analyze, build and sell aircraft, aircraft modifications, and related products. TLG’s focus is on helping these customers get those products to the marketplace and in service as efficiently as possible. TLG routinely works with hardware-related groups such as manufacturing and test organizations. TLG engineers specify flight test instrumentation requirements and test conditions, act as engineering test crew for test flights, and prepare flight test reports within their disciplines.TLG also provides overflow capability for OEMs needing extra capacity, and helps new aircraft companies develop and validate their own loads and dynamics capabilities. TLG engineers have analytical and hands-on experience with over 100 aircraft models from more than 40 different manufacturers.
Challenge:
Determine design loads by involving a full aircraft analysis of the air pressure and inertia forces during prescribed maneuvers, either in the air or on the ground.
Benefits:
  • Faster design iterations
  • Efficient use of capabilities for aeroelastic analysis is used in all parts of the design process
  • More efficient aircraft design & analysis

 
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Company:

DEMA

Products:

MSC Nastran

Industries:

Aerospace

DEMA - Stamping Out Waste

Overview:

Design Manufacturing SpA (DEMA) is a major tier-one aerospace supplier to Bombardier, Alenia Aermacchi, AgustaWestland and other leading aerospace original equipment manufacturers. The company recently faced a challenge with an aluminum acoustic barrier which is part of a jet engine nacelle. DEMA performed finite element analysis (FEA) with the MSC Nastran implicit nonlinear solver which identified two problems in the initial design. These included a stress concentration around a radius and excess material beyond the dimensions of the finished part which would have required an expensive secondary operation.

Challenge:
  • Maintaining allowable stress concentrations during metal stamping procedure
  • Reducing expensive secondary operations
Benefits:
  • Reduced prototyping and manufacturing costs
  • Substantial reductions in design time

 
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Company:

University of Cassino

Products:

Dytran

Industries:

Medical Devices

Understanding Eye Injuries as a result of Blunt Impact Trauma

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

Only One Chance to Get it Right - NASA/JPL-Caltech

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

General Dynamics Land Systems

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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Company:

BL Advanced Ground Support Systems

Products:

Adams
FEA, AFEA and TFEA
MSC Nastran
MSC Nastran Desktop
SimXpert

Industries:

Defense

BL Advanced Ground Support Systems

Overview:
BL Advanced Ground Support Systems specializes in developing vehicles used by air and ground forces. In the past, when the company relied on outside consultants for simulation support, it found that considerable time was wasted in communications and waiting for simulation results. Building the internal capability to do multibody dynamics and multidiscipline simulations with MSC Software’s Adams and SimXpert has been key to developing the capacity to design vehicles to its own specifications that can later be configured to meet a range of specific customer requirements.
Challenge:
Develop a robotic vehicle platform that will handle a wide range of military missions without requiring a human driver.
Solution:
Support provided by MSC Software was crucial to BL’s success. With the help of SimXpert, the engeneers at BL were able to sped less time translating and fixing CAD data, and more time devoted to developing new vehicle concepts and bringing them to the market faster.
Benefits:
  • Cost & time savings
  • Design optimization
  • Greater understanding of design behaviors

 
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Company:

ITW Delfast group

Products:

SimXpert

Industries:

Automotive

ITW Delfast group

Overview:
The ITW Delfast group designs and produces engineered plastic and metal fasteners for the automotive industry. The plastic fasteners typically are secured by a clip snapping into contact with a serrated shaft. These fasteners present a difficult design challenge because of the complexity involved in multiple contacting bodies undergoing large deformations with sliding contact.
Challenge:
  • Bringing non-linear finite element analysis to the designers
  • Automation of CAE processes including model setup, analysis and report generation
Solution:
Ostergren and MSC worked together to develop a template that provides a high level of automation while enabling users to interact with the analysis in order to ensure that it accurately represents the current design. The template fully automates the process of defining and naming parts and properties, generating symmetry constraints, defining contact bodies, load set generation, analysis setup, job submission and report generation.
Benefits:
  • Automated simulations and report generation make engineers more efficient
  • Substantial reductions in analysis time
  • Improved design performance
  • Reduced prototyping and manufacturing costs

 
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Company:

Polestar Racing/Volvo

Products:

Adams

Industries:

Automotive
Motorsports

Polestar Racing/Volvo - Racing to Win

Overview:
Polestar engineers spend months over the winter offseason struggling to squeeze a few extra tenths of a second per lap out of their cars. One of their most valuable tools is MSC Software’s Adams/Car which they use to evaluate different vehicle designs in critical areas of the track such as the corners.

Before we used Adams/Car we found that only 40% to 50% of what we tried at the test track turned out to be effective. Since we began using Adams/Car, 80% to 90% of the ideas that we try on the track succeed.”

Per Blomberg, Manager Chassis Development, Polestar Racing
Challenge:
In the past Polestar used hand calculations and spreadsheets to perform some very rough estimates of vehicle performance to attempt to select the best designs for testing. “These tools provide some value in sharing knowledge but contribute little towards predicting the performance of a prospective design,” Blomberg said. “We have long used simulation at the component level to, for example, evaluate stress and deformation in suspension components, but we were not aware of the possibility of predicting the performance of the complete vehicle until the MSC representative introduced us to Adams/Car.
Solution:
Engineers create a model of the vehicle in Adams/Car to match a configuration that they are interested in evaluating. One of the key aspects of the vehicle is the pickup points in the suspension, the points where the suspension link arms attach to the chassis. The front end of Polestar’s current vehicle has a Macpherson strut with a damper that attaches to the body under the hood and a lower link arm that attaches to the hub. The rear end uses a multilink suspension. The locations of the pickup points are limited by the rules of the racing series. Polestar sometimes simulates vehicles outside these limits in order to get a better understanding of the sensitivity of the vehicle performance with respect to certain design parameters. Other parameters whose impact is evaluated during simulation include the spring thickness, anti-roll bar thickness, camber angles, tire properties and weight distribution in the vehicle
Benefits:
  • Quickly Build & Test Virtual Prototypes
  • Analyze Events
  • Evaluate Small-Scale Improvement

 
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Company:

Litens Automotive Group

Products:

Marc

Industries:

Automotive

Litens Automotive Group - Optimizing Engine Performance

Overview:
Litens Automotive Group’s patented TorqFiltr crankshaft vibration control technology uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional vibrations.
Challenge:
To determine the magnitude, location and direction of the action-reaction forces and stress and deformation/deflection on each component and to investigate the contact mechanism in order to achieve an optimal design.
Solution:
Marc accurately predicts how the design behaves, how components move and react against each other and what happens under dynamic loading conditions.
Benefits:
  • Cost and Time Savings
  • Design Optimization
  • Greater Understanding of Design Behaviors

 
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Company:

Race-Tec Sealing Limited

Products:

Marc

Industries:

Automotive
Motorsports

Race-Tec Sealing Limited - High Performance Seals

Overview:
Race-Tec Sealing Limited is a leading supplier of high performance seals and precision elastomeric products such as constant velocity (CV) joint boots and gaskets. CV boots used in racing, military and off-road vehicles undergo large amounts of deformation as the vehicle is steered and the suspension moves up and down. Boots must be designed to withstand the deformation without damage while keeping the size of the boot as small as possible to present a reduced area for flying object strikes. Virtually any geometry can be made out of rubber but the cost of building a prototype of and testing a proposed boot design is high.
Challenge:
To design a CV boot that will be able to withstand articulation angles without excessive stress, deformation or contact.
Solution:
Marc for nonlinear finite element analysis to quickly evaluate alternative designs and iterate to an optimal solution.
Benefits:
  • Consistent and Reliable Problem Solving
  • Accurate and Robust Nonlinear Analyses
  • Considerable Cost and Time Optimization

 
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Company:

Benelli Armi S.p.A.

Products:

Adams
Marc

Industries:

Aerospace
Defense

Benelli Armi S.p.A. - Developing New Customizable Armaments

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:
  • Adams assisted in determining a configuration of the weapon and to calibrate its behavior.
  • Marc was used to ensure the mechanical strength of the weapon.
Benefits:
  • Optimize the Parameters
  • Test Reliability and Durability
  • Contributed to the development of a conceptually new design based on a modular system
  • Reduced the number of physical prototypes and experimental tests
  • Time and Cost Reduction of Project Development

 
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Company:

Sigmadyne

Products:

MSC Nastran

Industries:

Aerospace

Sigmadyne - Temperature Effects on Optical Systems

Overview:
When optical systems become exposed to a non-ideal environment, their optical performance degrades. For example, a lens system which was designed to produce high quality images may produce poor quality images when subjected to the thermal effects of a laser beam. Some of the energy in the beam is absorbed by each lens, causing temperature gradients throughout each lens that deform the lens surfaces. A second effect of the temperature gradients is a change in the indices of refraction, optical material properties that are dependent on temperature. A third and less important effect is that the temperature gradients induce stresses that also change the indices of refraction. These combined effects cause image quality to decline.
Challenge:
To predict the effects of the environment on optical systems in order to optimize design and minimize its effects
Benefits:
  • Reduction of weight be a factor of 2 while maintaining the required optical and structural performance metrics.

 
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Company:

Aeros

Products:

MSC Nastran
Patran

Industries:

Aerospace

Aeros - Developing A Revolutionary Vehicle Buoyancy Air Vehicle

Overview:
The Aeroscraft is a unique variable buoyancy air vehicle developed by Worldwide Aeros Corp. that combines elements of lighter-than-air crafts such as airships with conventional heavier-than-air aircrafts. The unique design of the Aeroscraft requires high weight efficiency (low ratio of weight over hull surface area) and provides advantages compared to conventional airships but also creates significant challenges in the design and optimization of the structure.
Challenge:
Building a variable buoyancy air vehicle
Solution:
MSC Nastran and Patran were used to build an FE model which generated detailed structural performance information for the preliminary design including displacements, strains and stresses. This information not only characterized the performance of the preliminary design but also provided insights into how the performance could be improved.
Benefits:
  • Reduced Weight
  • Design Optimization
  • Time Savings

 
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