Company:

Sikorsky Aircraft Corporation

Products:

Dytran

Industries:

Aerospace

Sikorsky Aircraft Corporation - Certifying Helicopter Components

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:

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

Products:

Adams

Industries:

Automotive
Motorsports

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

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:

PROTON

Products:

Adams
FEA, AFEA and TFEA
MSC Nastran
Patran

Industries:

Automotive

PROTON - Driving Engineering Innovation

Overview:
PROTON develops mechanical and structural components, sub systems and complete vehicle systems.
Challenge:
In developing complex mechanical and structural automotive components, going through multiple build-and-test hardware prototype cycles to verify performance, stress and fatigue life is just too timeconsuming and expensive. This issue can be addressed by evaluating and refining designs with analysis tools up front in development, reducing test cycles later in the development process. PROTON’s pioneering spirit naturally has led Mr ismail to not just stop at traditional methodologies in computer-aided engineering for design analysis. As the risk of failure in any design was becoming more and more significant and he was constantly looking at areas to assess risk parameters and minimize any risk factors, he needed to turn to industry-leading simulation analysis tools that would be able to provide him with the necessary accurate foundation to progress his methodology. Mr. Ismail realized that conventional virtual development approaches are no longer sufficient to meet the increasing standards of accuracy required at PROTON. Conventional approaches do not take into consideration the variations that affect finite element analyses. Mr. Ismail needed proven tools that produced the most accurate results, allowing him to capture the potential failures and provide the nature of failures so that these can be mitigated in the process. With resource efficiency on his mind, Ms Ismail also needed to manage test accuracy while reducing the dependency on running too many variations.
Solution:
With MSC, Mr. Ismail was able to conduct multi- run design improvement studies which can be used to assess design sensitivity to product and environment variability, discover unknown design variable interactions, and provide a global view of the overall design space.
Benefits:
  • Visible quantification of design risk or reliability
  • Identifies areas of high risk in a design
  • Provides the ability to modify design variables relative to reliability
  • Provides a means to compare differing designs

 
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Company:

Triple Eight Race Engineering Ltd.

Products:

MSC Nastran
Patran

Industries:

Automotive
Motorsports

Triple Eight Race Engineering Ltd. - Racing to Win

Overview:
Graham Lawrence is a Race Engineer for Triple Eight Race Engineering Ltd. in Greatworth, Banbury, Oxfordshire, United Kingdom. Triple Eight Race Engineering designs, builds and races Vauxhalls on behalf of the UK arm of General Motors (GM). Lawrence and his team are responsible for designing cars that race in the British touring Car Championship (BTCC). In the past, very little simulation was performed. Instead, components were physically manufactured and run on race cars during costly test sessions to evaluate their reliability and optimize their design.
Challenge:
2007 saw the start of a new era for the BTCC as the series adopted the S2000 regulations that are used in the World Touring Car Championship. The changes in regulations meant that Triple Eight’s Vauxhall Astra Sport Hatch had to be replaced by a Vauxhall Vectra. Lawrence and his team were faced with the challenge of designing a new vehicle to meet unfamiliar regulations from the ground up. There was no time to field a competitive vehicle using traditional build-and-test methods.
Solution:
Patran pre/post-processor and MD Nastran multidiscipline simulation software.
Benefits:
Despite limited development time the new Vauxhall Vectra proved an almost instantaneous success, winning its second race and winning both the driver and manufacturer’s title in 2007. 2008 was even more successful for the new car as it won all three championship titles: driver, manufacturer and team.

 
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Company:

Products:

Dytran
FEA, AFEA and TFEA
MSC Nastran
MSC Nastran Desktop
Patran

Industries:

Defense

Agency for Defense Development - Improving the Survivability of Airframes

Overview:
Jong H. Kim is Senior Engineer for the Agency for Defense Development (ADD) in Daejeon, South Korea. Kim and other members of the Aircraft Structural Team are responsible for, among other things, improving the survivability of airframes so that aircraft will be able to return to base after being hit by enemy fire. The primary method of assessing design alternatives in the past, live fire testing, is so expensive and time consuming that aircraft could not be tested for all of the likely damage scenarios.
Challenge:
ADD needs to evaluate various wing fuel tank designs for their ability to withstand a high velocity projectile impact. Their goal is to predict and quantity the damage from impact so that subsequent survivability analysis, such as residual strength and structural/flutter stiffness can be performed on the remaining structure. This also provides understanding of how the aircraft should be flown to enable it to safely return to base. In order to accomplish these objectives, it is necessary to simulate the very complex phenomena of hydrodynamic ram which occurs when a projectile impacts a structure containing fluid and penetrates it or detonates near it to produce a blast wave.
Solution:
Patran, MSC Nastran, Flightloads, and Dytran finite element analysis software
Benefits:
ADD has demonstrated the ability to simulate the damage to the airframe caused by the penetration and detonation of a projectile. This is expected to reduce the amount of live fire testing required and to make it possible to evaluate the effect of far more damage scenarios.

 
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Company:

Diagnostic Simulations, Inc.

Products:

Marc
Patran

Industries:

Medical Devices

Diagnostic Simulations, Inc. - Designing Palatal Implants

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:

Cleveland Golf

Products:

Dytran
MSC Nastran
Patran

Industries:

Consumer Products

Cleveland Golf - Virtual Prototype for Golf Clubs

Overview:
Cleveland Golf, leading manufacturer of equipment in the $7.5 billion golfing equipment industry, launches new golf club designs on an annual basis in a highly competitive, performance-driven market.
Challenge:
Cleveland Golf has its sights set on becoming the #1 golf equipment manufacturer in the world. The company needed to evaluate many design possibilities thoroughly and quickly in order to produce best-in-class clubs for golfers of every skill level. In order to do this, they needed Jeff and his team to create, build, and test many prototypes each month to optimize golf club designs quickly. Considering the lead time and costs required for tooling to build prototypes, traditional “build & test” design methodologies could not meet this requirement.
Benefits:
Cleveland Golf can now create and test a virtual prototype for new or modified golf club designs within a day – a 3000% improvement in design cycle time.

 
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Company:

Products:

MSC Nastran

Industries:

Shipbuilding

Rina - Reducing Noise and Vibration of Ship Vessels

 
 
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Company:

Products:

Dytran

Industries:

Defense

Agency for Defense Development - Airframe Survivability Research

 
 
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Company:

TI Automotive

Products:

SimManager

Industries:

Defense

TI Automotive - Focus on design simulation

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:

SimManager

Industries:

Defense

BMW Group - High Performance Computing

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:

Defense

Sogeti Group - Simulation Process and Data Management

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

John Deere - Durability Analysis

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:

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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