Company:

Bombardier, Inc.

Products:

MSC Nastran
Patran

Industries:

Rail

Bombardier Transportation - Passenger and Fright Rail

Overview:
Bombardier Transportation is a market leader in the rolling stock industry for short- and long-haul, passenger, and freight rail transportation. Its wide range of products includes passenger rail vehicles and complete rail transportation systems.
Challenge:
Need to consolidate multiple engineer software packages
Benefits:
By doing analysis early in the project, Bombardier can eliminate a significant amount of physical testing. Sometimes as a result of early analysis, the engineers set up a physical fatigue test on particular components, especially bogies. This testing runs in the background as analysis continues. Each new product series is monitored throughout its life to measure and document its fatigue response.

 
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Company:

Fimtextile

Products:

Adams
MSC Nastran

Industries:

Machinery

Fimtextile - Complex Kinematic Simulation in the Textile Industry

Overview:
Fimtextile designs, manufactures, and sells shedding motions (called dobbies andcam motions), which are fitted to weaving machines with rapier, projectile, or air- and water-jet weft thread mechanisms. The shedding motion is the device that moves the frames holding the warp thread in weaving machinery. These frames and their threads are reciprocated for ever pass of the weft mechanism. For maximum weaving efficiency, the motion of the frames must be as fast and as smooth as possible.
Challenge:
One of the main challenges in designing rotary dobbies is arriving at a good selection mechanism. There is a significant dynamic problem to solve for the selection mechanism: stopping the loom at a specific locked configuration in a quadrilateral frame moving at high speed. Also, significant inter-part impacts involved in this locking mechanism can cause problems in use.
Solution:
MSC.ADAMS and MSC.Nastran are essential tools to simulate the precise way these impacts between the flexible components of our machines affect their performance,
Benefits:
Virtual analysis and simulation allow Fimtextile to produce significant virtual test data in a very short time, which reduces development time, improves product quality, and eliminates the need for many intermediate physical prototypes.

 
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Company:

Pilatus Aircraft Inc.

Products:

Adams
MSC Nastran

Industries:

Aerospace

Pilatus Aircraft - Bring New Turboprop Aircraft to Market Faster

Overview:
Pilatus Aircraft Inc. is highly regarded due to the excellent performance and reliability of their products, which they owe to their turboprop engines. The flagship of the company’s reputation is the Pilatus PC-6 Porter, in production for more than 40 years. The civil program has been supplemented since the mid- 1990s by a single-engine business aircraft, the PC-12. In 1945, the company produced its first military training aircraft and to date has sold more than 750 Pilatus trainers to customers in more than 20 countries. In order to secure their leadership role in the trainer market of the future. Pilatus’ high-tech specialists worked at full speed on a new project. The PC-21, which undertook its maiden flight in 2003, was planned to be certified in 2004 and released to the market. For the first time in the history in Pilatus, the most advanced development methods and tools were used to implement this ambitious project.
Challenge:
Achieve three core objectives for the PC-21 project: Superior aerodynamic performance when compared with any other turboprop trainer currently on the market; a more powerful, flexible, and cost-effective integrated training system than any other turboprop or jet trainer; and a lifecycle support cost that did not exceed current turboprop benchmarks.
Solution:
MSC ADAMS was used for the design of control kinematics. In order to increase the use of multi-body simulations in the future, Pilatus engineers used MSC.ADAMS as part of its Multiphysics Applications in which kinematic simulation is combined with structural mechanics data.
Benefits:
  • Shorter time-to-market
  • lower investment cost
  • lower lifecycle costs
  • minimization of technical risk

 
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Company:

Hollandsche Beton-en Waterbouw bv

Products:

Marc

Industries:

Heavy Equipment
Shipbuilding

HBW/Netherlands - Simulation Leads to Successful First-time Operation of Inflatable Dam

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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Company:

Germanischer Lloyd

Products:

Patran

Industries:

Shipbuilding

Germanischer Lloyd - Pattern-based semi-automatic modeling of ship structures

Overview:
The German classification society Germanischer Lloyd is using MSC Patran as the foundation for their industry-specific solution GL/ShipModel. Through customization based on the MSC Patran pre-processor, GL/ShipModel enables pattern-based semi-automatic modeling of ship structures while taking into account specific shipbuilding modeling needs. Tailored to the shipbuilding engineering process flow, the program's functionality is saving time-up to 30%-and cost, and increasing quality. VPD tools from MSC Software are helping Germanischer Lloyd meet safety requirements, and tight schedules while maintaining acceptable profit margins.
Challenge:
Scenarios such as hurricanes and other extreme weather situations are codified in technical regulations and considered in the design and construction of a vessel.
Solution:
MSC Patran from MSC Software was used as a foundation for the targeted solution, providing both a high basic functionality and, with its open architecture, the best conditions for GL’s plans. The result is a system that offers scheme/pattern-based semi-automatic modeling of ship structures while taking into account specific shipbuilding modeling needs.

 
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Company:

Newman/Haas Racing

Products:

Adams
Adams Car

Industries:

Automotive
Motorsports

Newman Haas Racing

Overview:
Newman/Haas Racing uses the ADAMS/ Motorsport toolkit and ADAMS/Insight for vehicle system modeling and design of experiments (DOE) to optimize the setup trade-offs required to deliver a more competitive car. The methods provided by MSC.Software have produced a more intuitive understanding of the model and significant gains in runtime, and helped Newman/Haas Racing discover opportunities to further improve efficiency and output. Using test chassis set-up options in a virtual environment, Newman/Haas Racing can take best advantage of limited on-track practice and testing time.
Challenge:
With a winged, ground-effect racecar producing a large amount of downforce, a constraint for a given spring rate and static ride height must be set high enough to avoid excessive contact with the ground at high speed. Conversely, for a given spring rate, the static ride height must be set as low as possible to produce maximum downforce. Therefore, the design space results in a band matrix factor that defines the area of normal operation and combinations not physically possible and not meaningful.
Results Validation:
Correlation between physical test data and analysis results ensures models represent the real world.
Benefits:
ADAMS/Insight for vehicle and system modeling has proven to be an effective tool for efficiently producing a complex yet quantifiable understanding of model behavior. These methods have produced significant gains in runtime and understanding.

 
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Company:

NASA Glenn Research Center

Products:

MSC Nastran

Industries:

Aerospace

NASA Glenn Research Center - Rotor Dynamics Simulation

Overview:
NASA Glenn Research Center is using the new Rotor Dynamic capability in MSC Nastran for engine performance analysis. MSC Nastran Rotor Dynamics provides a standard rotor dynamics code, enabling much faster transfer of data models, and a more streamlined capability for rotor dynamic analysis. With MSC Nastran Rotor Dynamics, NASA Glenn engineers can calculate maneuver loads for microgravity experiments and perform blade-out analysis, ensuring that the physical test is passed the first time, saving millions of dollars.
Challenge:
Testing rotor dynamics is a critical function for ensuring safety, as well as cost and time-to-market Reductions for builders of aerospace engines and turbines, air frame manufacturers and NASA, which collaborates with them. Until recently, software codes for simulating rotor dynamics – a necessity because of the tremendously high cost of physical tests – have been largely home-grown. This has created an environment that slows the transfer of simulation data and models between customers and vendors.
Benefits:
  • A single analysis platform for rotordynamic studies
  • Able to analyze large rotorydynamic models millions of degrees of freedom in size

 
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Company:

Lego

Products:

Marc
Patran

Industries:

Consumer Products

Lego - Engineers Stretch Their Own Creativity

Overview:
Since 1932, the LEGO Group has been making a reputation for delivering quality products and experiences that stimulate creativity in children around the world. Today, LEGO makes software, watches, and clothing, as well as operates LEGOLAND them parks, but its core products are still the plastic bricks that made it famous. More than 1.4 million LEGO parts are produced every hour making up the 100 million LEGO sets produced annually. With this many parts, every part and every change, even small changes in material usage, have a tremendous impact on costs.
Challenge:
Need to maximize safety, while minimizing time-to-market and costs.
Benefits:
  • Reduced overall cycle time, from concept to finished part
  • Reduced dependency on physical prototyping
  • Eliminating costly changes to tooling
  • Substantially reducing manufacturing costs

 
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Company:

Matrix Applied Computing

Products:

Patran

Industries:

Shipbuilding

Matrix Applied Computing - Designing Racing Yachts Using MSC Laminate Modeler

Overview:
The New Zealand company Matrix Applied Computing has successfully used Patran Laminate Modeler to generate flat patterns for strips of material quickly and effectively from a CAD model of a racing yacht. For racing yachts where stiffness and mass are of paramount importance, the draping simulation provides accurate material directions and hence more reliable stiffness optimization. The use of MSC Laminate Modeler is now an integral part of the company's design offerings.
Challenge:
High-performance yachts are often made from expensive carbon-fiber reinforced pre-preg materials. These are typically supplied in rolls and are laid on male or female molds to form the skins of the boat hull. Because hulls are typically of compound curvature, the strips will overlap when laid over the hull unless they are trimmed. This trimming is typically done using preliminary paper patterns which are themselves draped over the hull and cut to size. This process is difficult and expensive, and introduces errors.
Solution:
A New Zealand company, Matrix Applied Computing, has successfully used MSC Patran Laminate Modeler to generate these patterns quickly and effectively from a CAD model. The specifications called for accuracies on the order of +/-1mm. With advice from experts at MSC Software, Matrix developed flat patterns for strips of material to be draped on a 16m hull section using MSC Patran Laminate Modeler.
Benefits:
The draping simulation provided accurate material directions and hence more reliable stiffness optimization.

 
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Company:

Guardian Europe S.A.

Products:

Marc

Industries:

Automotive
Machinery

Guardian Automotive - Simulation of Automotive Glass Components

Overview:
Guardian Automotive uses Marc and MSC Software Professional Services in the development of glass products such as windows for the automotive industry. Simulation with MSC Software products enabled Guardian to try different temperature situations without interrupting the actual production process and to predict the behavior of the various materials both in different production stages and in their final use mounted in cars. The validated Marc simulations showed Guardian what the layout of the window should look like, and enabled them to demonstrate to their customers whether a certain heating system was suitable. As a result, Guardian benefited from increased efficiency and significant time savings.
Challenge:
The manufacture of car windows is a complex production process, since several variable factors are involved.
Solution:
Manufacturer Guardian Automotive is developing simulation techniques to obtain an accurate prediction of how these factors will interact. These simulations are made with the aid of MSC Software. At a later stage MSC Marc was also used to simulate the glass bending process.

 
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Company:

Invernizzi Presse

Products:

Marc
Patran

Industries:

Aerospace
Machinery

Invernizzi Presse - Simulation Drives Manufacturing Press Inovation

Overview:
The Italian manufacturer Invernizzi Presse employed Marc and Patran to improve existing presses and to develop new custom-made presses. They also used MSC Software tools to illustrate the functional performance of the presses to their customers. The combination of Marc and Patran was used for various contact analysis, mechanical safety structure analysis, and load calculations. Invernizzi engineers could try more design variants in less time and gained more accurate results than by using traditional mathematical calculation methods. As a result, Invernizzi realized significant time savings, and, while optimizing material usage, saved production costs.
Challenge:
  • Before using MSC Marc, the development department of Invernizzi Presse used mathematical methods to do the calculations for the presses. These methods were time-consuming and less precise because only a certain number of design variations could be tested.
  • The production of a physical prototype would be impossible due to cost and time restraints.
Solution:
Invernizzi Presse now uses the combination of MSC.Marc and MSC.Patran in a variety of applications, including:
  • Contact analysis between pivot, bearing, and connecting rods to evaluate the flex/bending stresses in the pivot, the contact pressure on the bearing, and the resulting rod stiffness.
  • • Contact analysis between the presses’ pivot, bearing and rod, along with the backlash of the pivot, in order to understand the thermo-mechanical behaviour of the bearing. Invernizzi engineers found that the heat generated by the friction between the parts increased the temperature of the mechanical components, breaking the oil film and seizing the mechanism. With this knowledge, the design was modified to improve performance.
  • • Mechanical safety structure analysis. The MSC.Marc model allows engineers to study the mechanical behaviour of the safety system used on all types of presses. The analysis uses flexible contact elements and an external force representing the oil pressure.
  • Epicycloidal analysis (study of a multi-stage gear transmission system). This simulation allows Invernizzi engineers to evaluate the stresses in complex gear systems in order to optimise the gear dimensions, avoid gear failure during duty cycles, and extend the life of the mechanism.
  • Load calculation during the bending process in order to understand the correct force needed to obtain the correct bending of the material.
Benefits:
Using the results of these simulations, Invernizzi can demonstrate the functional performance of a press without having to build a physical prototype, illustrating to its customers that the press will fulfill the requested tasks.

 
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Company:

Draper Labaratory

Products:

Easy5

Industries:

Aerospace

Draper Labs

Overview:
Draper Laboratory used MSC EASY5 to provide the graphical user interface (GUI) and infrastructure for a collaborative Virtual Product Development environment in the development of missile guidance systems. The open architecture of MSC EASY5 improved the collaboration by providing a direct link to other popular simulation tools, such as MATLAB/Simulink. Using MSC EASY5, Draper Labs reduced the high costs of testing very complex electromechanical systems by cutting simulation time from weeks to hours.
Challenge:
Physically testing a missile guidance system is time-consuming and expensive. Add to this the need for collaboration between prime contractors and subcontractors, and the process becomes very complex and even more time-consuming.
Solution:
The simulation uses very detailed processor models, accepting binary code like an embedded processor and replicating its behavior. The rest of the system can be modeled around the processor. When a simulation is run, the software developer can actually look at how many clock cycles it takes to execute the code.

 
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Company:

Automotive Systems Laboratory, Inc. (ASL)

Products:

Dytran

Industries:

Automotive

Automotive Systems Laboratory (ASL) - Vehicle Occupant Restraint Systems

Overview:
In order to reduce the cost of testing their airbag restraint systems, ASL is using Virtual Product Development tools such as MSC Dytran. MSC Dytran offers the advantage of coupled Euler-Lagrange analysis, allowing combined structural and gaseous fluid simulation. Contact analysis is very important in simulating an airbag deployment, and MSC Dytran provides a number of options for defining contacts. For ASL, MSC Dytran has proven to be a robust tool that can be applied to the design optimization of vehicle occupant restraint systems for both crash and out-of-position scenarios, which are relevant to the restraint system designs of the future.
Challenge:
The cost of testing airbag restraint systems is growing, because government and industry regulatory groups are phasing in testing requirements for a wide group of drivers and occupants including large males, small females, and children. Some of these tests involve out-of-position (OOP) testing without safety belts.
Solution:
MSC Dytran provides coupled Euler-Lagrange analysis, allowing combined structural and gaseous fluid simulation. The Lagrangian method is used for structural components that may undergo large deformations and for which the dimensions, deformed geometry, and residual stress state are of major importance.
Benefits:
  • The benefit of the Lagrangian solver is that the displacements, deformations, and stresses in structures can be monitored with a high degree of precision.
  • The benefit of the Eulerian method is that complex material flow can be modeled with no limit to the amount of deformation.

 
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Company:

Autoliv, Inc.

Products:

Dytran

Industries:

Automotive

Autoliv - Side-curtain Airbag Simulation

Overview:
Autoliv, the world's largest manufacturer of automotive safety equipment, has developed side-curtain airbag systems by using MSC Dytran to similate the dynamic events that occur during inflation, such as gas flow and enclosure impact stiffness. MSC Dytran provides Autoliv with an effective tool to study OOP (out-of-position) scenarios, enabling engineers to identify and quantify the impact of numerous design variables. The software provides real value in terms of reducing the time and overall development effort required, compared to conventional prototype build and test methods.
Challenge:
Simulating airbag deployment is a complex and labor-intensive process, including meshing of the material and folds, analysis of fluid flow, and dynamic stresses on the enclosure.
Solution:
Using MSC Dytran, the engineers at Autoliv were able to pinpoint the key contributing variables and isolate them for optimization.
Benefits:
The software provides real value in terms of reducing the time and overall development effort compared to conventional prototype builds and testing.

 
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Company:

The Boeing Company

Products:

Adams

Industries:

Aerospace

The Boeing Company

Overview:
Boeing is responsible for design, development, construction, and integration of the International Space Station (ISS) - Integrated on-orbit from a series of segments transported up to the Station by the Shuttle. MSC ADAMS was used for functional verification of the attachment interface mechanisms, which required a thorough representation of the contacting geometry. The MSC ADAMS solid-to-solid contact force statement allowed simulation of the segment-to-segment attachment including various combinations of contact feature misalignment. The analysis reduced contact model development and helped Boeing minimize the possibility of introducing an error by providing stable, accurate solid-to-solid models.
Challenge:
The segment-to-segment attachment interface includes ready-to-latch indicators, coarse and fine alignment guides, a capture latch, and supporting interface structure. Each of the contacting elements was idealized as one or more of the following contact representations: sphere to plane, line to line, line to arc, sphere to cone, sphere to torus, sphere to cylinder, arc to interior of cone, and arc to exterior of cone. Each of the contact equations was resolved to a pair of points representing the minimum distance between any two contacting elements.
Solution:
Model validation was accomplished using component-level tests of the contacting features. Testing was performed on the coarse guides, fine guides, and the capture latch. Testing was performed by slowly moving the contacting elements together while measuring test table strut displacement and force. The results of the tests were then compared with simulation results.

 
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