AEROELASTIC
ANALYSES IN "PZL-MIELIC" USING MSC/NASTRAN (Acrobat
293K) #2199, 13 pgs.
Wojciech Chajec--Aircraft Factory "PZL-MIELEC" Ltd.
ABSTRACT: Presented here is implementation of MSC/NASTRAN system in aerolastic computation practice in "PZL-Mielec". This computation system is compared with our own old flutter calculation programs. Discussed are advantages and also difficulties caused overcoming of old habits and the fact that MSC/NASTRAN is an universal system not only for flutter calculation. PC programs which were created specifically to overcome the difficulties are presented additionally. A few interesting results of calculations are also showed.Contents
1. Short view on flutter calculation methods in "PZL-Mielec" before MSC/NASTRAN based on calculated (beam-like structural calculation model) or in GVT measured modes.
2. Implementation of MSC/NASTRAN system.
3. Description of additional programs for PC - useful for aeroelastic calculation in MSC/NASTRAN, prepared in "PZL-Mielec"4. Examples of aeroelastic calculation in "PZL-Mielec" and problems
- programs for natural mode and flutter mode animation and drawing
- program for drawing and sorting flutter calculation results: g(V), f(V)
- graphic preprocessor for aerodynamic data generation and static pressure distribution drawing (for static aeroelasticity calculation)
- some modification of propf.for program (in propa.v68 - alter) for aerodynamic forces in whirl-flutter calculation
5. Conclusions
BALANCED
CONTINUOUS TURBULENCE GUST LOADS USING SOLUTION 146(Acrobat 195K)
#2099, 13 pgs.
James E. Locke, Sr. Technical Specialist--Raytheon Aircraft Company
ABSTRACT: This paper describes and illustrates a method to obtain balanced (time-correlated) continuous turbulence gust loads using MSC/NASTRAN Solution Sequence 146 (SOL 146). Continuous atmospheric turbulence is modeled in the frequency domain as a power spectral density (PSD) function using the von Karman gust PSD. SOL 146 is used to obtain the complex frequency response for each load quantity. Balanced loads are determined using the equations of random process theory. Maximized load quantities correspond to RMS values determined from response PSD functions. Balanced loads for each maximized load correspond to scaled cross-correlation functions. Results are presented for a typical gust load condition.
COMPUTATION
OF DYNAMIC LOADS ON AIRCRAFT STRUCTURE DUE TO CONTINUOUS GUST USING MSC/NASTRAN,
(Acrobat 819K) #0797, 17 pgs.
Eduardo A. Rodrigues and Mauro
T. Kamiyama--EMBRAER S.A., Brazil
ABSTRACT: The computation of gust loads on the structure of an aircraft is part of the engineering work during the development and certification phases of a new project. The present work describes the methodology used at EMBRAER to compute dynamic loads caused by atmospheric continuous gusts. The mathematical formulation assumes that the gust phenomenon is described as a stationary random process and that the aircraft dynamics is linear. MSC/NASTRAN is used for obtaining the dynamic system modal data by means of SOL1O3 (normal modes solution), and the modal amplitudes necessary to generate the dynamic system frequency-response functions by means of S0L146 (aeroelastic response solution). An example is given in which the methodology is applied to a modern jet aircraft.
COUPLED
AEROELASTIC ANALYSIS OF A FREE FLIGHT ROCKET(Acrobat 228K) #2399,
11 pgs.
D.S. Livshits, S. Yaniv--IMI - Israel Military Industries
M. Karpel--Technion - Israel Institute of Technology
ABSTRACT: Aeroelastic analysis of rockets is an essential part of their design procedure. In most cases, the analysis is limited to calculation of the divergence velocity, sometimes leading to unrealistic prediction of the rocket response. The coupled dynamic aeroelastic analysis approach is established to allow for the consideration of coupling effects between the rocket spin, its imperfection parameters and the airflow. The approach is based on integrated dynamic aeroelastic/CFD modeling methodology
ABSTRACT: This paper presents development of a procedure to include flight control system dynamics with aeroelasticity in MSC/NASTRAN. The specific application is on flutter analysis of a twin engine propeller aircraft with the yaw damper flight control system ON. The flutter analysis is performed using the PK-method.
The yaw damper transfer functions are introduced into the aeroelastic equations of motion through a combination of EPOINT and TF entries. One of the extra-points represents the rudder deflection resulting from the yaw damper system. The additional generalized unsteady-aerodynamic forces due to this extra-point are provided with down-washes supplied on DMI entries in the Bulk Data.
The analysis results are presented on V-G and V-F diagrams for two configurations, nominal and yaw damper ON.
AN
ENHANCED CORRECTION FACTOR TECHNIQUE FOR AERODYNAMIC INFLUENCE COEFFICIENT
METHODS
(Acrobat 488K) #2299, 12 pgs.
Ioan Jadic, Dayton Hartley and Jagannath Girl--Raytheon Aircraft Company,
Kansas
ABSTRACT: The present Enhanced Correction Factor Technique (ECFT) is intended to provide an improved solution to the classical problem of correcting the Aerodynamic Influence Coefficients (AIC) formulation produced by panel methods, such as the Doublet Lattice Method (DLM). In the case of MSC/NASTRAN aeroelastic analysis methods, provisions are made for inclusion of correction matrices which premultiply the AIC matrix in order to provide a level of accuracy of the aerodynamic forces consistent with experimental and/or CFD data. Classical techniques use a diagonal correction matrix allowing for limited correction capabilities: typically, one mode. By contrast, the present ECFT uses a full correction matrix that can handle multiple modes simultaneously, allowing a complete correction capability including any interference effects. Further, it is possible to define by means of ECFT several correction matrices that tackle nonlinearities for a given Mach number.Several comparisons are presented which cover a wide range of application cases. The results obtained with ECFT are shown to match the input data.
ABSTRACT: In the design of aircraft, it is important to have an accurate simulation of both the structural characteristics and the aerodynamic characteristics of the vehicle. For static aerodynamic loads, MSC/NASTRAN uses unsteady aerodynamics at zero reduced frequency. To utilize the accurate structural representation of MSC/NASTRAN in the computation of aeroelastic loads, it is desirable to incorporate aerodynamic and aeroelastic data into the MSC/NASTRAN solution sequence that better represents the actual geometry of the vehicle. This entails importing data that replaces or augments the unsteady data. The Boeing Company, in conjunction with MSC personnel, has prototyped an interface procedure that allows the static aeroelastic loads computations in MSC/NASTRAN to use the rigid aerodynamic forces and aeroelastic corrections from the A502 High Order Panel Method.
THE
MSC FLIGHT LOADS AND DYNAMICS SYSTEM, (Acrobat 54K) #1197, 8 pgs.
Douglas J. Neill and Greg Sikes--The
MSC.Software Corporation
ASTRACT: The MSC.Software Corporation (MSC) developed an aeroelastic analysis and design capability in the late 1970's and 1980's as part of MSC/NASTRAN. This capability includes flutter analysis, gust analysis and flight loads calculations. The latter is more suited to preliminary and conceptual design. As aerospace companies move to simulate the aeroelastic behavior of the vehicle early in the design cycle, however, there is a need to augment these capabilities to better fit within the current design processes. This augmentation includes new system architecture concepts, enhanced data management and model management and integrated visualization tools that understand aeroelastic models. Finally, new engineering tools need to be implemented that can better model aeroelastic phenomena at an appropriate level of fidelity for use in both vehicle design and production analysis.This paper will present the critical requirements of the system as understood from numerous discussions with aerodynamicists, loads analysts, dynamicists and aeroelasticians in the aerospace community. Results from this work-in-progress will be presented where appropriate to illustrate the basic architecture, data flow and usage paradigms and their interaction with the aircraft design process.
LOCAL
STRESS ANALYSIS OF STIFFENED SHELLS USING MSC/NASTRAN'S SHELL AND BEAM
p-ELEMENTS, (Acrobat 68MB) #4797, 10 pgs.
Sanjay Patel, Claus Hoff, and Mark Gwillim--The MSC.Software Corporation
ABSTRACT: In large finite element models of aircraft structures, traditional h-elements give sufficient accuracy for most purposes, for example in vibration analysis. However, for local stress analysis of stiffened shells, h-elements may give inaccurate answers at shell-stiffener connections. The paper shows how to use p-elements at those locations where more accurate stresses are required. P-elements work with the existing h-element mesh. A few modifications of the input are necessary to convert local parts of the model into p-elements. The p-version elements improve local stresses significantly. The increase in accuracy is demonstrated on two examples of stiffened shells.
MSC
DEVELOPMENTS IN AEROELASTICITY, (Acrobat 41K) #4497, 9 pgs.
Erwin H. Johnson--The MSC.Software Corporation
ABSTRACT: The MSC.Software Corporation has a long history of involvement with aeroelasticity. This paper briefly reviews past development efforts and the current capabilities in this area. Recent developments that have not been incorporated into standard documentation are given somewhat more emphasis. This paper concludes with a discussion of ongoing development activity.
MSC/SUPERMODEL
A CAE DATA MANAGEMENT AND ADVANCED STRUCTURAL MODELING SYSTEM
(Acrobat 1.2MB) #4597, 11 pgs., color
Greg Sikes--The MSC.Software Corporation
ABSTRACT: MSC/SuperModel supports the processes typically used in the design of large structures comprised of multiple components, typical of aircraft, jet engines, satellites, and launch vehicles. The engineering design and analysis of these large assembly structures is often conducted at the component level with multiple project engineers or project teams each responsible for a given component. In addition to modeling and simulating the performance of each individual component, the assembled vehicle performance must be verified as well. MSC/SuperModel provides an integrated engineering environment that greatly facilities the coordination and communication of engineering modeling and analysis results data among the project team(s). MSC/SuperModel is a powerful CAE process and data management system with engineering tools for advanced modeling and simulation.
RANDOM
ANALYSIS USING MSC/NASTRAN ISHELL MODULE, (Acrobat 1.5MB) #4897, 13
pgs.
Mohan Barbela--The MSC.Software Corporation
ABSTRACT: MSC/NASTRAN version 70 has a new DMAP module called ISHELL that allows users to execute an external program from within MSC/NASTRAN. This module is very powerful and can be used to perform various tasks; for example, sorting, margin of safety calculation, and any data block manipulation using an external user written program. This paper briefly describes the ISHELL DMAP module and the procedure to perform random analysis using MSC/NASTRAN ISHELL DMAP module and an external program.
CHARACTERIZATION
OF MSC/NASTRAN & MSC/ABAQUS ELEMENTS FOR TURBINE, (Acrobat 379K)
#2097, 15 pgs.
Lt. Jeff Brown--Air Force Research Lab
ABSTRACT: An accuracy study of MSC/NASTRAN and MSC/ABAQUS three dimensional element types was conducted for turbine engine blade natural frequency analysis. Linear, quadratic, hexahedral, and tetrahedral elements were used with different mesh densities in the frequency and mode shape predictions. These results were compared to bench test data and laser holographic mode shapes. Recommendations are made on the selection of finite element meshes for future analyses.
DEFLECTION
ANALYSIS OF AERO GAS TURBINE STRUCTURE DURING PROTOTYPE DEVELOPMENT,
(Acrobat 525K) #2197, 10 pgs.
M.Chandrasekaran and K.Ramachandra--Gas Turbine Research Establishment,
Bangalore, India
ABSTRACT: This paper presents a refined finite element procedure to obtain the cold dimensions of aero engine structural assembly from the dimensions of larger hot gas flow path and also establish the operating clearances between rotor blades and casings. The effects of stiffness distribution on the circularity of casings-frames assembly and its weight optimization are also discussed.
DYNAMIC
ANALYSIS OF FLEXIBLE TURBO-ROTOR SYSTEM USING SUPER-ELEMENTS
(Acrobat 130K) #1799, 14pgs.
A. Surial and Dr. A. Kaushal--Rolls Royce, Montreal
ABSTRACT:The approach presented in this paper will give an overview on the dynamic analysis of gas turbine engines. It will help a user to prepare an input file for MSC/NASTRAN in order to perform the critical speed (SOL 107) and forced response analysis (unbalance response — SOL 108) of any size rotating structure(s), taking into account gyroscopic effects using MSC/NASTRAN DMAP, ridgyroa.v705.
FINITE
ELEMENT ANALYSES OF A LAMINATED BLADE RETENTION SYSTEM, (Acrobat
456K) #2297, 18 .pgs.
Dennis K. McCarthy and Robert T. Fort--McDonnell Douglas Helicopter
Systems
ABSTRACT: Design of a helicopter main rotor blade retention system is a challenging problem. This critical system must reliably carry large blade loads while allowing extreme blade motions. Several different methods for blade retention systems are currently in service including laminated metallic stacks (LMS). Due to the lack of precise analytic methods laminated metallic stack systems have historically been developed through test. A methodology, developed by the authors, is presented herein to accurately predict the behavior of a LMS blade retention system. This method uses nonlinear finite element (FE) analysis to predict LMS motions and stresses. Finite element results are interrogated to obtain damage and fatigue life predictions. The analytical results are compared to test data with excellent agreement thus verifying the methodology.
HYDROELASTIC
ANALYSIS OF A RECTANGULAR TANK, (Acrobat 271K) #2397, 26 pgs.
M.C. Kim and S.S. Lee--The Aerospace Corporation
ABSTRACT: A hydroelastic analysis of a rectangular tank is performed using MSC/NASTRAN. Natural frequencies of slosh modes and hydroelastic modes are evaluated, and are compared with results from other approaches as well as analytical values.
ABSTRACT:This paper will describe a consulting project that MSC France did for Snecma. This project was called time cycle reduction. We aimed at increasing the productivity of Snecma's Design Office by defining the most accurate methodology for meshing a compressor blade and disk using MSC/PATRAN.STRUCTURE SIMULATION AND BLADE DESIGN OF AN AIRCRAFT ENGINE(Acrobat 1.3MB) #1899, 12 pgs.Throughout this presentation the detailed process will be developed to explain how the time reduction was obtained.
According to what has already been done, both Snecma and MSC have great hope to enhance our first results by using MSC new tools.
ABSTRACT:Structural analysis have progressed at a level such that they are now increasingly used all days in activities of mechanical engineeringSince 25 years at SNECMA, analyses have for main objective to provide in both detail and overall a knowledge of the behaviour and damage of the part, they are an help with the decision in design conception via optimization.
We are currently in a period of utilization of more and more simulations , what allows to reduce significantly the number of tests. Researches allow to develop tools simulating the behavior increasingly precisely.
These simulations have become of necessary tools, to reduce costs, to reduce cycles, to design robust. Take into account very early manufacture constraints in simulations, improved the simultaneous engineering.
It is demonstrated here after that the large use of simulation during the period of life of the product, will allow to improve them, and to answer as quickly as possible to quality and reliability needs of the companies.
Finally, it is necessary to insist on the inter-operability of tools of simulation, centered on a numerical geometrical model. This inter-operability has to accompany the concept of extended enterprise and the world cooperation necessity. These are the keys of the success of industrial products design for the next century.
VALIDATION
AND UPDATING OF AN AERO ENGINE FINITE ELEMENT MODEL BASED ON STATIC STIFFNESS
TESTING(Acrobat 65 K) #1999, 8 pgs.
E. Dascotte --Dynamic Design Solutions
A. Schönrock--CargoLifter Development GmbH
ABSTRACT: Today's aerospace industry uses finite element analysis in a huge variety of applications in order to optimize structures and processes before hardware is procured. Efficiencies can be enhanced and margins are reduced because external loads and the structural properties are identified with higher confidence. The accuracy of finite element analysis predictions therefore becomes more and more important and directly influences the competitiveness of the product on the market.In particular, accurate shell element models are difficult to generate because of the inability to account for fillet radii and problems with coupling of the in-plane rotational stiffness. Another common uncertainty is the accuracy of modeling shell structure bolted flanges and especially their behaviour under large loads. These features are widely used for structural finite element modeling within the aeronautic industry.
Although modal testing has proved to provide valuable reference data for FE model validation and updating, static stiffness tests have the advantage to allow the application of large forces. In addition, static deformations are independent of the mass parameter.
To process static test data and MSC/NASTRAN analysis results and perform correlation analysis and FE model updating, appropriate methods were developed and implemented into the existing FEMtools software. This paper describes the approach and gives reference to a successful application.
ACRAT's software system design emphasis has been focused on standardized methods of electronic data modeling and exchange; a UNIX-less process management environment which insures geometric configuration management and material release control; integration of COTS and/or public domain software wherever possible to reduce the cost of development while maximizing system functionality and reducing future costs of ownership (upgrading/porting supportability); and a single user friendly graphical user interface (GUI) capable of supporting a wide range of perspective users (field technician or expert CAE/composites engineer).
Four (4) customized database schemas (M&P, Aircraft Design, Composite Repair, Component Test) were designed and sufficiently populated to evaluate each data model's ability to meet specific ACRAT system requirements. These prototype databases, coupled with the ACRAT Executive Control System (ECS) database, represent the foundation upon which the fully self contained ACRAT software system has been built.
The EMB-145 Nose Landing Gear Door is attached to the aircraft fuselage through three hinges which are driven by a hydraulic actuator attached to the central hinge. The EMB-145 N.L.G.D. structure, is made of two solid prepreg carbon/epoxy laminated skins, cold bonded and fastened. Carbon/epoxy tape is used in order to avoid panel buckling and to increase the required stiffness of the Aerodynamic Smoothness Requirements for EMB-145. The hinges are machined from aluminum alloy, attached to the structure by titanium alloy bolts.
The EMB-145 Nose Landing Gear Door is designed to resist the critical aerodynamical loading in normal condition and in case one of the hinges fails.
The EMB-145 Nose Landing
Gear Door structural analysis including finite element data, boundary
conditions and acting loading are presented in this report. The
present output results in MSC/NASTRAN allow one to obtain the most
critical condition among all subcases very quickly, when post-processed.
EVALUATION
OF AN ANALYTICAL DESIGN TOOL FOR BALLISTIC DYNAMICS SIMULATION
(Acrobat 672K) 1996, 13 pgs.
Ashish K. Sareen--Bell Helicopter Textron, Inc.
Michael R. Smith--Bell Helicopter Textron, Inc.
ABSTRACT: Usefulness of ballistic dynamics simulations as a design tool in assessing ballistic tolerance and as an aid in pretest guidance is studied. Accurate simulations of hydraulic ram, including failure mode prediction, can be useful in enhancing survivability and in guiding pretest specimen setup to ensure projectile strike and exit at critical locations, thereby minimizing the cost of expensive development tests. To understand the potential of ballistic simulation as a design tool, MSC/DYTRAN code has been evaluated at Bell Helicopter Textron, Inc. by conducting simulations using projectiles of different sizes to impact and penetrate a generic fluid-filled tank and a composite wing structure containing fuel cells. Projectile trajectory, fluid pressures in the fuel tank, and wing structural response from the analysis are compared with the measured data. The physics of the phenomenon appears to be accurately simulated, indicating that MSC/DYTRAN could be a useful design tool for enhancing ballistic tolerance.
ABSTRACT: MSC/DYTRAN, an explicit nonlinear finite element code, was used to determine the collapse characteristics of the Lynx helicopter main liftframe, for the vertical crash case. The liftframe was modelled by the Belytschko-Tsay four node shell elements. The analysis of the influence of the collapse velocity on the component structural failure modes and a sensitivity analysis of the material failure criteria were performed. The increase in crashing velocity from 4 to 8 m/s changed the mode of structural failure from torsional buckling, to bending/axial failure. The material failure criteria, however, did not significantly affect the structure collapse mechanism nor the force vs. displacement results. The MSC/DYTRAN simulation results showed good agreement with the full scale test data.
MSC/FLIGHT
LOADS AND DYNAMICS VERSION 1 (Acrobat 237K) #1198, 8 pgs.
Greg Sikes and Douglas J. Neill--The MacNeal-Schwendler Corporation
ABSTRACT: For the past year, the MacNeal-Schwendler Corporation (MSC) has been actively developing solutions to the challenges faced by our customers in the area of external loads and aerodynamic response. Through strategic partnerships with the world's leading civilian and military air vehicle manufactures, MSC has developed an in-depth understanding of our customers' needs. These efforts have lead to the development of an integrated, process-driven external loads and dynamics system called MSC/FlightLoads and Dynamics.
MSC/NASTRAN
FLUTTER ANALYSES OF T-TAILS INCLUDING HORIZONTAL STABILIZER STATIC LIFT
EFFECTS AND T-TAIL TRANSONIC DIP (Acrobat 768K) 1996, 10 pgs.
Emil Suciu--Gulfstream Aerospace Corporation
PARTICULARITIES
OF SINGLE SHEAR PIN JOINTS MODELING FOR MSC/NASTRAN (Acrobat 3.5MB)
#3898, 12 pgs.
Adrian Viisoreanu--Boeing Commercial Airplane Group
Kris Wadolkowski--Aerostructures, Inc.
ABSTRACT: Inspired from the analysis of aircraft engine mount fittings, this paper presents techniques applicable to the solid modeling of single shear pin joints in MSC/NASTRAN. A parametric study describes the influence of some joint geometry parameters on the stress and bearing load distribution along the pin length. The effect of the residual stress induced by the bushing interference fit is also considered.
POSTPROCESSOR
FOR AUTOMATIC MODE IDENTIFICATION FOR MSC/NASTRAN STRUCTURAL DYNAMIC SOLUTIONS
WITH EMPHASIS ON AIRCRAFT FLUTTER APPLICATIONS (Acrobat 33K) #1498,
4 pgs.
Emil Suciu--Raytheon Systems Company
Joseph Buck--DeHavilland Inc.,Ontario
ABSTRACT: A practical procedure and postprocessor FORTRAN program which sums strain energies for an aircraft structure, elastic element by elastic element for each component as outputted by MSC/NASTRAN Solution 103 or Solutions 145 and 146 is described and an example is provided showing an output table of strain energies for a hybrid finite element model of a twin turboprop aircraft and comparison with a few plotted mode shapes. The application of the procedure to the .f06 output of one of the structural dynamic solutions results in automatic naming of the analytical modes of vibration, a powerful aid for the flutter analyst.
PREDICTION
OF BREAK-OUT PATTERNS FOR AIRCRAFT CANOPIES FRAGILIZED MECHANICALLY OR
WITH DETONATING CORD (Acrobat 160K) 1996, 7 pgs.
Rocky Richard Arnold--Leapfrog Technologies, Incorporated
Patrick S. Collins--Leapfrog Technologies, Incorporated
SIMULATION
OF A HELICOPTER COCKPIT AIR BAG SYSTEM WITH MSC/DYTRAN (Acrobat
416K) 1996, 14 pgs.
David Furey--Simula Government Products, Inc
rjaan Buijk--MacNeal-Schwendler Corporation
Lindley W. Bark--Simula Government Products
THEORETICAL
VALIDATION AND DESIGN APPLICATION OF MSC/NASTRAN SNAP-THROUGH BUCKLING
CAPABILITY
(Acrobat 293K) #1598, 15 pgs.
Dr. M.M. Moharir--The Aerostructures Corporation
ABSTRACT: MSC/NASTRAN's Snap-Through Buckling capability is validated using a closed form solution based on the large displacement theory and the nonlinear eigenvalue extraction procedure for flat and "slightly" curved thin plates. Excellent correlation is observed for displacements, stresses, and buckling loads at Snap-Through. The capability is used to design and analyze the leading edge of a large commercial airplane.
THREE
DIMENSIONAL MODEL OF AN ARRAY OF PANEL BAYS INCORPORATING PRETENSIONED
FASTENERS, PRECOMPRESSED FASTENER SURROUNDINGS, SHELL-TO-SOLID AND BAY-TO-BAY
NASTRAN INTERFACE CONNECTORS (Acrobat 1MB), #3098, 21 pgs.
Steven Basic--Boeing Commercial Airplane Group
ABSTRACT: This paper extends applicability of the finite element method to the analysis of interaction between the main components of a panel bay (chords, webs and stiffeners) and an array of elastic fasteners on elastic plate-foundations.
The pre-tensioned fasteners and the pre-compressed fastener-surroundings of this model are three-dimensional fine-mesh-solid islands that are integrated into the rest of the plate-element structure using the new shell-to-solid Nastran Interface Connectors.
The outer cylinder mesh nodes of fasteners are connected to the fastener-bore mesh nodes with an array of substantially non-linear radial gap elements, whose radial stiffness may have two magnitudes.
The first run of the model will be made with the least possible radial stiffness of the gap elements. The main objective of this run is determination of the maximum stain gauge element stresses. The strain gauge elements are located at the outermost and innermost plate-to-hole edges.
The second run of the model will be made with a relatively high magnitude of the gap element radial stiffness generating a 'Filled Hole' mesh . The main objective of the 'Filled Hole' mesh is the reference stress determination at the hole edge strain gauge elements.
By definition, the maximum plate-to-hole edges to the reference stress ratios are the stress concentration factors 'Kt max' and 'Kt mm' at the outermost and innermost edges of the plates. This increase of the tensile and hoop stresses, relative to an inelastic fastener concept incorporating 'Kt mean' at the central lines of plates, is caused by an additional bearing stress component due to the fastener-to-fastened plate interference, in their elastically deformed configuration.
The Load Transfer Factor (LTF) will be calculated also in two stages. The first stage will be the same as that of the existing inelastic fastener methodology, i.e. the logarithmic magnitude of the LTF (that was substantiated with numerous tests) will be determined for a given ratio between bearing stress-flange thickness and the tensile stress -fastener diameter products.
Within the second stage a correction factor, to be applied to the LTF, will be established. This smaller than '1' correction factor will be found from increments of the the mean integral and the maximum 'Kt max' values of this model using the allowable stress for varying 'Kt', as obtainable from the Kinetic Theory of Solids and Reference [7].
ABSTRACT: With the common use of turbo-fluid machinery in the aerospace industry, rotor burst containment is an important design requirement. More demanding weight reduction goals are pushing containment structures to the brink of containment efficiency. Design engineers at Hamilton Standard have been reliant on design similarities and empirical data, to predict containability. However, limitations in the current methodology make detailed predictions difficult, especially if the geometry is not based on a previous design. In some cases, the limitations in the empirical method can lead to many costly tests. With the use of MSC/DYTRAN, and the help of the MacNeal-Schwendler Corp., Hamilton Standard has been developing an analytical method to predict rotor burst containment. Preliminary case studies have shown that MSC/DYTRAN can handle the physics involved with turbine rotor containment. Using the analytical methodology, structural damage and material response are characterized from the physics. Therefore, the prediction is independent of similar designs.
The immediate response analysis is determined with MSC/DYTRAN and the post explosion analysis is made by MSC/NASTRAN. A complete vulnerability map requires many failure scenarios and a large number of MSC/DYTRAN and MSC/NASTRAN analyses. Six points in the cargo hold were critically examined to demonstrate the concept.
ABSTRACT: In static analysis, the calculation of minimum margins of safety using yielding (Von Mises,...) or failure theories (instability for honeycomb structure,...) requires all stress components (3D case : sigma xx, sigma yy, sigma zz, tau xy, tau xz, tau yz ; both magnitude and sign) for a specific element. In frequency response analysis, the stress component magnitude and sign are functions of the reference phase angle and the phase angle of each of the various stress components. When the phase angle difference between the various stress components is almost equal to 0 or 180 degrees, the calculation of the minimum margin of safety is simple. However, in the general case, the minimum margin of safety will be dependent upon both the reference phase angle, as well as the phase angle of each of the various stress components. This paper describes a method used for the calculation of the exact minimum margin of safety for the general case. For the 2D and 1D elements, the exact minimum margin of safety is evaluated at the lower and upper fibers of the element where the flexural stress is maximum and the transverse shear stress contribution is equal to zero. The calculation of the exact minimum margin of safety is done by a general stress processor using the MSC/NASTRAN OUTPUT2 file.
ABSTRACT: This paper takes a look at the mesh density requirements when the geometry is a flat plate, has a circular hole, and is subjected to a uniform tension along two opposite edges. The program to be used is MSC/NASTRAN, Version 67, a finite element program from the MacNeal-Schwendler Corporation. The elements used are the 8 node parabolic shell, 8 node linear solid, and the 20 node parabolic solid. The objective is to determine the number of elements, in the radial and angular directions, to achieve an accuracy in deflection and in stress of less than 2% error. The mesh density to achieve the 2% error criteria will be checked on all nodes along 3 straight lines, at angles 0, 45, and 90 degrees, from the hole to the edge of the plate and also all nodes around the circumference of the hole.
ABSTRACT: The MacNeal-Schwendler Corporation has been researching parallel computational methods and evaluating their applicability to its products since 1985. Limited parallelism has been offered in various MSC/NASTRAN products, mainly on supercomputers, since 1987. Presently, there are 5 major computer platforms where shared memory parallel execution is supported.
The paper will discuss some of the technical details of the shared memory parallel methodology and explore the limitations of parallel speedup on the current parallel environments using MSC/NASTRAN. Results of the leading parallel applications will be shown on a moderate number of processors. Specifically, a 4 fold parallel speedup on 16 CPUs analyzing a large automobile industry job will be demonstrated.
The results of investigations on using a distributed memory methodology (applied in the massively parallel computers) will also be discussed. The main strategic aspect of Lagrange multiplier-based solution sequences and the topic of supermodules will be briefly addressed.
THE
COMBINATION OF MECHANICAL SYSTEM SIMULATION AND FINITE ELEMENT ANALYSIS
SOFTWARE TO MODEL STRUCTURAL FAILURE IN AN AIRCRAFT ACCIDENT INVESTIGATION(Acrobat
943 K) #2699, 15 pgs.
Greg Savoni--Boeing Long Beach
J. McConville-- Mechanical Dynamics
ABSTRACT: The MSC/NASTRAN finite element analysis (FEA) code is used in conjunction with the ADAMS mechanical system simulation (MSS) program to simulate the structural behavior of the airframe of a commercial aircraft maneuvered beyond its
design limits during a landing. FEA-generated linear elastic structures are subjected
to non-linear boundary conditions in the MSS analysis to simulate the initial
structural failure of the airframe. The analysis results are compared with crash site
evidence and subsequent, independent engineering analysis.
ABSTRACT: In fracture mechanics, the stress intensity factor is used to determine whether a crack will run, possibly causing catastrophic failure or arrest. Typically, this value can be computed from the stress or displacement fields around the crack tip, either by hand or by numerical methods, and then compared with empirical data.
MSC/PROBE-PLANAR has long had two methods of computing Mode l and II stress intensity factors which take advantage of the p-version, the contour integral and cutoff function methods, as well as the standard energy release rate. In Version 5, MSC/PROBE-SOLID has incorporated singularity elements to model exactly the displacement field for a closed crack, and the crack-opening displacement (COD) method to automatically compute Mode I, II, and III stress intensity factors. Combined with the automatic p-adaptivity, accurate and reliable factors may be computed for fully three-dimensional problems in an efficient manner.
ABSTRACT: A Coriolis mass flowmeter measures mass flow directly by vibrating a fluid-conveying pipe at resonance. Design of these meters was facilitated by solving the equations of motion via the finite element method. A complex eigenvalue analysis (SOL107) was necessary due to the presence of the Coriolis force terms in the damping matrix. Performance parameters of the meter can be predicted from the complex eigenvectors and were found to match experimentally determined values to within five percent.
THE
DEVELOPMENT AND USE OF A MATERIALS DATABASE FOR PRODUCT DESIGN AND COMPONENT
LIFING.(Acrobat 228K) #0199, 13 pgs.
Barry J Piearcey, Chris K Bullough, Martin Hughes and Steven J Moss--ALSTOM
Energy Technology Centre
This paper describes the development and structure of an MSC/MVISION materials database which is designed to store test and design data. Metadata has been defined to describe each material product and property precisely, standard methods of data analysis provide validated design data and each datum is allotted a quality value. Examples are included which illustrate how the data are used for statistical process control, thermal analysis, stress analysis and the prediction of component life using a continuum damage approach.
The similarity in the technologies used for these disparate activities is counterbalanced by the lack of material property data of sufficient quality. This situation is recognised world-wide as is the inability of any single company to justify adequate resource to correct it. It is concluded that the high cost of producing high quality material product data by independent testing calls for more facilities for the assessment, reporting and exchange of data within MSC/MVISION and highlights the need to agree an international schema and glossary of terms for data exchange.
ABSTRACT: Finite element
analysis is becoming an integral part of the design and manufacturing
process of heavy engineering machinery for the mining industry in Australia.
The Grinding Mill division of Australian National Industries (ANI) which
is the division of ANI responsible for design, manufacture and supply
of ore grinding mills to mines throughout Australia and overseas have
been using the MSC/NASTRAN finite element analysis code extensively
in all phases in the supply of their mills.
The finite element analyses of a 9600 mm diameter (5640 mm length) Autogenous
Grinding Mill is used to describe how today's available technology is
being used by one company to design and manufacture machinery for the
mining industry.
ABSTRACT: An overview is given of a recently completed finite element stress analysis of the Riser Column Chaintable and Chainhawse Structures for an offshore Floating Production Storage and Offloading (FPSO) oil and gas facility.
The project involved finite element modeling of a symmetric half model of the chaintable and analysis of the model under a series of Unit Load Cases and Load Combinations. The primary objective of the analysis was to quantify stress levels and stress combinations throughout the structure to enable strength and fatigue capacity of the chaintable and chainhawse structures to be confirmed.
The model involved approximately 60,000 DOF and analysis was carried out using a CRAY-YMP Supercomputer.
The paper will present a summary description of the problem and objectives of the analysis, finite element discretisation of the structure, analysis approach, and quality assurance checking procedures applied to verify the results.
ABSTRACT: An FEA study was conducted to examine the static and dynamic response of an SMC structure fabricated by adhesive joining method using MSC/NASTRAN. The appropriate modeling of the adhesive joining region is essential in precise FEA predictions of static and dynamic response of the SMC structure presented. An enhanced modeling technique for the adhesive joining region is presented in this paper. A composite mechanics approach was used to define the mechanical property of finite elements along adhesive joining region. Static and dynamic predictions of the enhanced modeling technique were compared with predictions of the conventional linkage modeling method in structure analysis.
In contrast with these findings, some of the present analytical models consider a "unit cell" as a repeat unit for the braided composite, and attempt to model the mechanical behavior of the composite from the properties of this unit cell. This unit cell is in the form of a parallelpiped with yarns connecting between the opposite corners along the body diagonals.
In this paper, a finite element based method is proposed for modeling the structure of the 3-D braided composite, and determining the elastic constants and coefficients of thermal expansion. MSC/NASTRAN is used in modeling the thermoelastic properties of the composite. Estimates of elastic constants and coefficients of thermal expansion are developed as a function of "interior braiding angle".
Among advantages of this technique are simplicity, and the ability to model and study the response of complex shapes subject to complex loads applied at the boundary.
MSC/FLIGHT
LOADS AND DYNAMICS-VERSION 1(Acrobat 358 K) #0299, 10 pgs.
Greg Sikes and Douglas J. Neill--The MacNeal-Schwendler Corporation
ABSTRACT: MSC has been actively developing solutions to the challenges faced by our customers inthe area of external loads and aerodynamic response. Through strategic partnerships with the world's leading civilian and military air vehicle manufactures, MSC has developed an in-depth understanding of our customers' needs. These efforts have lead to the development of an integrated, process-driven external loads and dynamics system called MSC/FlightLoads and Dynamics.
MSC/FlightLoads and Dynamics Version 1 supports static aeroelasticity (steady state external loads). This paper will present the current state of the technology within MSC/FlightLoads and Dynamics Version 1.
THE
NEW EXTERNAL SUPERELEMENTS IN MSC/NASTRAN AND A DMAP ALTER TO CREATE AND
USE OTM
(Acrobat 325 K) #2499, 17 pgs.
Ted Rose--The MacNeal-Schwendler Corporation
ABSTRACT: It often seems to be several years after the introduction of a new feature before it gains recognition among the user community. This paper is intended to provide an introduction to the new external superelement features introduced in V69 and also provide a DMAP alter which allows the creation and usage of OTM for them, allowing the creation and usage of "deliverable" models.
ABSTRACT: In analyzing the windshield of N-250, - Indonesian / IPTN's latest aircraft product - one major issue is how to model the windshield glass panel and the distribution of the load to its mounting structure. This paper concentrates on this issue.
ABSTRACT: Prior to Version 68, MSC/NASTRAN radiation exchange was restricted to ideal black/grey opaque surfaces exhibiting diffuse emission, absorption, and reflection characteristics. Most real surface behavior is considerably more complicated due to varying degrees of specular, spectral, and temperature dependent properties, as well as radiant transmission. Generalized numerical treatment of all of these phenomena simultaneously is beyond the scope of the current Version 68 effort, however, most materials in a practical engineering sense may be characterized by one or two dominant surface conditions. In particular, most solar collection device materials as well as high temperature metals can be satisfactorily described in terms of their spectral and temperature dependent surface properties. This problem class is addressed with a method known as the radiation energy-band approximation.
USING
MSC/MVISION TO COMPARE MSC/NASTRAN RESULTS WITH FLIGHT TEST DATA
(Acrobat 488K) #2599, 20 pgs.
Kirsten Husak--Raytheon Systems
ABSTRACT:At Raytheon Systems Company in Waco, Texas, a MSC/MVISION database has been developed which allows the comparison of flight test data with MSC/NASTRAN results output. A model can be opened in MSC/PATRAN, and strain gauge results generated during a test flight viewed directly on the model. The MSC/NASTRAN strain output can be applied to the model and contrasted with test flight strains in the MSC/PATRAN graphical user interface. If the results are reconciled within a predetermined degree of tolerance, it will then be assumed that the model is accurate. A model predicting the behavior of the aircraft after it has been modified can then be assumed to be accurate also. After the aircraft has been modified, more flight test data will be collected, which can then be compared with the post-modification
predictions to aid in support of FAA certification of the modified aircraft. MSC/MVISION will provide a user-transparent interface between MSC/PATRAN and the raw flight test data, allowing engineers to view the accuracy of their models with real-time strain measurements within the MSC/PATRAN graphical environment. Because Raytheon Waco specializes in aircraft modifications, the concentration in this project has been on the comparison of flight test data with airframe finite element models, but the application of this methodology for comparison of strains with models can be used in any industry which employs modeling and testing procedures.
VIRTUAL
MASS OF FLUID IN EGG-SHAPED DIGESTERS (Acrobat
316 K) #7793, 9 pgs.
Atis A. Liepins --
Simpson Gumpertz & Heger Inc.
Hamid Nazemi -- Simpson
Gumpertz & Heger Inc.
ADVANCED
MODE SHAPE IDENTIFICATION METHOD FOR AUTOMOTIVE APPLICATION VIA MODAL
KINETIC ENERGY PLOTS ASSISTED BY NUMBEROUS PRINTED OUTPUTS (Acrobat
488K) #1898, 17 pgs.
Manfred Wamsler-- Daimler-Benz AG
Ted Rose--The MacNeal-Schwendler Corporation
ABSTRACT: Design optimization procedures of full-vehicle simulation models - such a procedure as shown in this paper - require a very fast and reliable mode shape identification. Just because these simulation models necessarily contain a lot of large concentrated masses and mass moments of inertia, e.g., engine, gear, differential, car wheels, steering wheel, mufflers, airbags, and reduced masses from superelement processing, to name just a few, the kinetic energy method is especially destined to accomplish this task. In the present paper, a graphical Modal Kinetic Energy evaluation technique is described in detail. Moreover, the modal kinetic energy plots are a means to investigate the structure's eigenbevior in the low-frequency range, e.g., to see where dynamic vibration absorbers have to be attached and where bushings, and instrumentation for modal testing have to be placed. In summary, the presented graphs make even the most complicated subjects clear and provide the dynamicist with information he can use to achieve a better design quickly. The prints of significant values indicate the degree of coupling between energies in rotational and translational direction per mode and the energy portions of the physical residual chassis structure and the energy portions of appended body and subframe superelements. Representative applications for mode shape identification in automotive engineering, V70, are presented extensively in order to demonstrate the strength of the method. Surely, there are many other applications in the engineering structural analysis field where the advanced mode shape identification method will play key roles.
This technique is applied to an automobile suspension component. Results show excellent correlation of back calculated load with the actual load. Also a conventionally instrumented (with designed load cell) component is used for comparison. The proposed method consistently showed considerable improvement over the conventional method.
This paper attempts to present such a design and analysis method, using relatively simple beam model and fine meshed shell model. The analysis has been performed for center - center pendulum and barrier hits of a bumper system of XENOY™ 1102 newly developed by GEP (General Electric Plastics US) under the process of injection molding.
Finally, the results predicted from finite element method are compared with those of experimental tests to evaluate the analysis procedure.
In an effort to allocate more science to the problem of roll cage design it was proposed that nonlinear finite element analysis using MSC/NASTRAN would give a good indication of the true load carrying capacity and deflection under load of the roll cage/frame. The analysis carried out was verified by the test programmme on a full scale chassis. This analysis gave results within an accepatable 10% of the test results despite the simplifying assumptions.
This application of MSC/NASTRAN is new as most small automotive manufacturers rely on past experience for their development. This works well for evolutionary design but not for major structural modifications as were carried out. This report highlights the value of MSC/NASTRAN in this application.
DEVELOPMENT
OF A METHODOLOGY TO PREDICT THE ROAD NOISE PERFORMANCE CHARACTERISTICS
(Acrobat 329K) #0993,
8 pgs.
Mark P. Voutyras -- Chrysler Corporation
William F. Resh -- Chrysler Corporation
Kevin R. Thomson -- Chrysler Corporation
ABSTRACT: This paper describes the development of a methodology for predicting the road noise performance characteristics of an automotive vehicle system. An MSC/NASTRAN finite element model of a complete suspension system was constructed and analyzed for dynamic response. In addition, a customized system simulation software package, GRADAM, was developed for combining the FEA and experimental results in order to assess vehicle structural sensitivity to noise and also to study the effect of suspension design modifications on the interior noise levels. In the model development stage, the FEM modal and frequency response results for all the relevant suspension components were validated by comparing with the corresponding experimental measurements. The interior noise levels were then obtained through the system simulation software. This customized software combines the MSC/NASTRAN force output at suspension-to-body attachment points with the corresponding pressure/force (P/F) experimental data in order to predict the interior noise levels. The methodology developed herein permits the noise pressure levels to be determined for desired frequency domains. Furthermore, this methodology allows design engineers to answer "what if" questions in order to evaluate the effect of suspension design changes on the interior noise levels. It is anticipated that the methodology presented herein will be instrumental in optimizing the noise and vibration (NVH) characteristics of future car lines.
DEVELOPMENT
OF A NONLINEAR FREQUENCY RESPONSE PROGRAM FOR SIMULATING VEHICLE RIDE
COMFORT (Acrobat 491K) #3795, 9 pgs.
Keuchiro Tsutsui-- ESTECH Corporation
Ray Nogami--ESTECH Corporation
John L. Breti, Ph.D.-- Structural Dynamics Research Corp.
MSC/ABAQUS has been used to analyze and design airbag crash sensors. The analysis was geometrically nonlinear due to the large deflections of the springs and the contact between the ball and springs. Bezier 3-D rigid surface elements along with rigid surface interface (IRS) elements were used to model ball-to-spring contact. Slideline elements were used with parallel slideline interface (ISL) elements for spring-to-spring contact. Finite element analysis results for the force-displacement response of the sensor were in excellent agreement with experimental results.
FRICTION
INDUCED VIBRATION (Acrobat 732K) #3695, 18 pgs.
Wayne V Nack--General Motors Corporation
Arun M Joshi--General Motors Corporation
IMPROVED
IDENTIFICATION OF CONTRIBUTING MODES IN SUPERELEMENT MODAL FREQUENCY
RESPONSE ANALYSIS, V70 (Acrobat 325K) #2098, 15 pgs.
Manfred Wamsler-- Daimler-Benz AG
Ted Rose--The MacNeal-Schwendler Corporation
ABSTRACT: In parallel with experimental methods, modern-day cars are designed by advanced dynamic analyses using the Finite Element Method. These analyses help identify components sensitive to vibrations that could possibly lead to deterioration of ride comfort and safety. For correct simulation of the real dynamic behavior of a car all parts relevant to vibrations have to be taken into consideration when assembling a full-vehicle simulation model. Since this model contains many viscous dampers, such as shock absorbers, the steering damper, and several hydro-mounts for the engine/gear unit and the rear-axle support - when the modal transformation is applied for reduction purposes - the generalized damping matrix is not diagonal; that is, the modal equations remain coupled by the damping coefficients. Consequently, the dynamic response is composed of various contributions resulting from eigenvectors. Knowing the contributions from each mode shape is a very important requirement for taking suitable measures in order to decrease obnoxious vibration amplitudes, i.e., the modal contributors are a means of finding suitable locations for modifications aimed at improving the structure's dynamics. It is worthwhile to notice, that by the use of the presented procedure innovative redesigns may be found by the analyst which the automatic stuctural optimizers are never able to find. Guidelines on how to influence contributing modes in order to decrease high resonance peaks are given along with a V70 SOL 111 DMAP alter for the identification of contributing modes.
ABSTRACT: This paper describes the modal test and analysis carried out on the body of a 2 passenger cabriolet concept car designed by Pininfarina. It discusses the specific problems in a modal test on such a car body of extruded aluminium profiles. Next, the experimental modal model is correlated with an MSC/NASTRAN analytical model, and a diagnosis is made to improve the analytical model.
ABSTRACT: An efficient procedure for the analysis of brake squeal using MSC/NASTRAN models is described. A unique nonlinear method accounts for both superelement modes and surface friction data. The motions at the pad/rotor interface are described by small velocities and pressures relative to the steady-state condition. Both Transient Analysis and Complex Eigenvalues are provided analysis of brake systems.
ABSTRACT: This paper describes the methods and analyses used in the correlation of experimentally determined modal models to analytical solutions. The paper illustrates the significant benefits of Component Mode Synthesis and Design Sensitivity Analysis options available in MSC/NASTRAN in the correlation process. Neutral File Interface programs and remote orthogonality calculation methods that simplify the communication between the FEA solution and the laboratory results are also discussed. Three (3) specific experimental procedures formulated the basis for the paper. The first, a simple free-free beam case is presented. The second and third are examples of more complex automotive transmission assemblies with special boundary condition issues and internal component influences. Specific recommendations for improving correlation potential both in laboratory test methods and in the finite element modeling task have been provided.
ANALYSIS
AND EVALUATION OF MINIVAN BODY STRUCTURE FINITE ELEMENT METHODS
(NOT
PRESENTED) (Acrobat 1.3MB) #4099, 15 pgs.
Jin ya-min--Harbin Hafei Motor Co., Ltd., China
ABSTRACT: The paper describes the application of MSC product in Harbin Hafei Motor Co., Ltd and then describes how the finite element methods can be used for analysis and evaluation of minivan body structure. Including static, dynamic, fatigue, crashworthiness analysis, optimization and sensitivity and so on. In this paper, Author use MSC-NASTRAN calculate the strength and stiffness in both bending and torsion loadcase. Summarized the strength and stiffness evaluation standards for minivan. And then done the normal model analysis in order to consider the influence of tyre unbalance and engine idle excite. The calculations and analysis were verified by test.
APPLICATION
OF FEM ANALYSIS IN ENGINE DEVELOPMENT (Acrobat 780K) #3299, 13 pgs.
Naohisa Mamiya--Nissan Motor Co. Ltd. Japan
ABSTRACT: To address environmental issues and at the same time supply products that are attractive and a high quality to the market, Nissan is adopting predictive development based on the latest computer-aided engineering (CAE) technology in engine development.To achieve efficiency in the development from an early stage of engine development to the making of a highly complete prototype and finally to the mass production stage, a tool for advance evaluation of engine performance, function, and reliability is needed. The use of computer simulation technology has become indispensable for that purpose.
Here, we briefly introduce the incorporation of CAE technology into actual engine design work and the current state of affairs, presenting some specific examples that focus on finite element method (FEM) analysis.
APPLICATION
OF FEM-TOOLS IN THE ENGINE DEVELOPMENT PROCESS (Acrobat 18MB) #2399,
10 pgs.
H. Petrin and B. Wiesler--AVL List GmbH, Austria
ABSTRACT: The requirements for the development of a new engine are the considerable reduction of development time and costs as well as the reduction of production costs, considering a higher number of product variants and higher product quality, are boundary conditions for the actual engine development. To achieve this goal the automotive industry worldwide tries to organize their development activities more efficiently in "Development Processes" and searches for optimization potential.AVL is working together with a various number of automotive companies all over the world trying to adjust its services (e.g. FEM-calculations) for best fitting into the "Engine Development Process" of each of the customers. AVL also takes over to some extend working parts of the customer's processes and is even asked to optimize the processes.
The paper discusses the effective use of FEM-tools in engine development processes, as derived in co-operation with many automotive companies and in-house engine development, under special consideration of latest tools for mesh generation and calculation performance.
The optimized correlation between the different calculation tasks and the development process, the right starting time and extend (time frame) for the use of the simulation and the application of fast and validated simulation software assures reliable results in time.
The proper application of the FEM-tools in the design phase and the best support during the testing phase reduces the risk and the testing effort in the prototype and pre-production phase and is the essential basis for the reduction of development time and costs.
AUTOMATIC
SHAPE OPTIMIZATIONS OF ELASTOMERIC PRODUCTS (Acrobat 1.5MB) #2199,
15 pgs.
M. Friedrich and J. Baltes--Freudenberg Forschungsdienste KG
M. Schütz and H. Gärtner--Freudenberg Dichtungs- und Schwingungstechnik
KG
ABSTRACT: In increasing international competition, technologically oriented companies can only survive, if they can also provide cost efficient products as well as a high technological innovation strength. Therefore, in modern development philosophies, like "Simultaneous Engineering" the calculations engineer is more and more consulted in the conceptional phase of product development. Consequently, it is compellingly necessary in an effective procedure that all tools and data be placed at everyone's disposal. This way, everyone is better able to assist the conceptional design of new products as well as to make detailed improvements on already existing designs. Therefore, efficiently implemented optimisation algorithms complement the proven discrete calculation procedures (FEM, BEM) of mechanically loaded structures .In structural mechanics, there are three levels of optimisation:
Topology
Shape
SizingTopology optimisation, like that from Bendsoe and Kikuchi , has the capability to support the design level. Presently, for the industrial application of topology optimisation only a small number of commercial codes is available. The shape optimisation has been used for industrial applications for some time, but it is used to handle almost exclusively linear problem sets. The sizing optimisation is offered from almost every large FEM-package. It is industrially applied mainly for complex beam and shell structures.
While not as complex as the topology optimisation is, shape optimisation will be strengthened and widely applied in industry in the near future. This results from the necessity to apply a detail shape optimisation to already topology optimized components, too. In this paper the special case of shape optimisation for handling models with hyperelastic materials is focussed.
BONDING
AREA OPTIMIZATION FOR REDUCING WAVEFRONT ERROR IN OPTICAL ELEMENTS
(Acrobat 683K) #1299, 15 pgs.
Yair Soffair--Electro-Optics Industries Ltd., Israel
ABSTRACT: The objective of this analysis is to recommend an optimal bonding configuration for a large Dove prism for minimal wavefront error, maintaining bond strength while subjected to severe environmental conditions.
DRIVING
YOUR DESIGNS WITH MSC.SOFTWARE'S AUTOMOTIVE SOLUTIONS (Acrobat 455K)
#0199, 5 pgs.
Ken Blakely--MSC.Software Corporation
ABSTRACT: The automotive industry accounts for nearly 30% of MSC.Software's business. It is truly global in nature for us, with our business being spread equally around each of the world regions (Americas, Europe, and Asia-Pacific). "Automotive" includes cars, trucks, SUVs, buses, motorcycles, tires, engines, and components, from OEMs to third-tier suppliers.This paper briefly describes MSC.Software's automotive solutions. These are comprised of our core software, our automotive-specific software, and our automotive services. This paper provides a glimpse of things you will learn about in more detail during the Conference.
A
FINITE ELEMENT VEHICLE ANALYSIS LIBRARY FOR COMMERCIAL VEHICLES (Acrobat
130K) #2799, 9 pgs.
Ir. J. Maasdam--DAF Trucks N.V.
ABSTRACT: MSC/NASTRAN is one of the general purpose finite element programs used at DAF Trucks N.V. Performing a finite element analysis of a commercial vehicle may be time consuming for two reasons. Firstly, many variations in vehicle specification exist, due to customer request. Secondly, the investigation of the static and dynamic behaviour of commercial vehicles often requires a full vehicle model. The resulting large numerical model has typically several hundred thousand degrees of freedom.
In order to perform the requested static and dynamic analysis on time, DAF Trucks N.V. applies component mode synthesis and automatically assembles a full vehicle model from a vehicle analysis library.
This paper addresses some aspects of the vehicle analysis library and shows examples of a full vehicle model used for static and dynamic analysis. The dynamic analysis example shows how frequency response functions, calculated with MSC/NASTRAN, are post-processed with the aid of a toolbox. This toolbox enables fast evaluation of e.g. ride comfort and load spectra for a variety of operating conditions. Furthermore, online sensitivity or optimisation studies are possible.
HIGH
PERFORMANCE, PROCESS ORIENTED, WELD SPOT APPROACH (Acrobat 325K) #2599,
14 pgs.
Daniel Heiserer and Juergen Siela--BMW AG Muenchen
Mladen Chargin--CDH GmbH
ABSTRACT: Simulation of automotive vehicles has become a more important step in car development in the last few years. Rapid prototyping, which offers a close-to-market product, with less hardware, requires a fast and accurate computer simulation to guarantee a quality product.Generation of body-in-white nite element models for full vehicle simulation of Linear Statics, Normal Modes, NVH, and Crash is one of the most critical items. This is due to the need to connect various body-in-white components which requires:
a signicant amount of manpower because of difficult automation possibilities
a "physically correct" representation of part-connectors such as weld spots, screws, etc., which cannot be easily automated and requires more manpower resulting in delays and a potentially large source of errorIn the past, a number of methods were developed for joining these parts together, such as homogenous models and various other weld spot approaches. In the generation of FE-models, each part depended on its connected parts, which made it difficult to shorten the modeling process. Benefits of faster hardware, and some improvements in preprocessors, were diminished by the need for bigger models.
Despite the above improvements, a signi.cant amount of time was still required to generate FE models. CDH and BMW developed a spot welding approach, linchweld, which simultane- ously reduced the modeling time, invested manpower, and increased the quality of simulation (compared to test).
The program containing the linchweld approach is called CDH/SPOT.
INTEGRATION
OF CFD AND THERMAL STRESS ANALYSIS FOR TURBOCHARGERS
(Acrobat 650K) #3499, 7 pgs.
Mikio Obi, Nobuo Takei and Natsuko Matsuura--Ishikawajima-Harima Heavy
Industries Co., Ltd., Japan
ABSTRACT: In the manufacturing industries, there is a trend lately to employ a new manufacturing method using 3D-CADs in the manufacturing process. The purpose of employing the new method is to cut the lead time of a new product and achieve the timely introduction of the product into the market when it meets customers' needs by solving manufacturing problems with 3D-CADS in the design phase. The real effects of introducing 3D-CADs can be realized by not only examining designs in three dimensions in the design phase, but also by converting entire development processes to be based on digital data by reflecting design model data in such production data as those for various analyses and mold production. We also have been changing development processes from drawing-based conventional processes to those based on digital data.
Our company develops such rotating machinery as turbochargers and turbo-compressors. Because they are fluid machinery with complex geometry consisting of many free form surfaces, many good results can be expected by employing 3D-based development. Further, because we produce products by partially altering the design of our standard specification products for general-purpose applications according to the customer's requirements, we can expect to improve design speed by establishing the new development processes mentioned about and by re-using existing data effectively. Generally, rotating machinery consists of many machine elements and some of them are put into such severe conditions as high-speed rotation under high temperature. Therefore, analysis is very important in the developing processes and it is fundamental to implement analysis procedures smoothly in the development processes. We analyzed the thermal stress of a turbine housing of turbocharger by transferring the results of temperature distribution analysis, which is based on the results of thermofluids analysis, to structural analysis. By comparing the flow of the analysis with the conventional analysis procedures, we will describe the effects and problems of the new procedures, which we encounter when applying them to design procedures.
INTEGRATION
OF INNOVATIVE CAE METHODS IN CHASSIS ENGINEERING AT PORSCHE
(Acrobat 163K) #1899, 11 pgs.
Harald Bähr--Porschestraße
ABSTRACT: The consistent application of CAE methods in Porsche's Chassis Engineering helps to clearly lower development times and costs while improving both quality and reliability.This presentation describes the CAE-assisted development procedures used by Porsche in chassis engineering. It outlines the results obtained and the development activities planned for the future.
The CAE process chain is presented and software packages for various tasks such as linear and non-linear statics, dynamics, optimization, misuse and life are explained.
Further new subjects such as process simulation (casting, forming) are discussed.
Due to the rapid development in the field of CAD-integrated calculation tools, standard calculations are increasingly done in the design departments themselves. This trend will further intensify in future, since the scope and complexity of the calculation tasks to be accomplished by the calculation engineers keeps increasing.
Some examples of current chassis developments are given.
METALLIC
GASKET MODELING USING MSC/PATRAN ADVANCED FEA (Acrobat 98K) #3399,
8 pgs.
Michael de Jesus Fernandes--Sabó Indústria e Comércio Ltda,
Brazil
ABSTRACT: This work presents the modeling methodology for multi-layer and single-layer-steel gaskets, MLS and SLS. Among the approached themes discussed are some concepts regarding metallic gaskets, the design methodology itself, main considerations and assumptions, as well as the most common problems in regards to the input data acquisition, and in the convergence process. The entire approach is carried out considering a fictitious problem example.
MSC.ACUMEN
EXPERT SYSTEM ACCELERATES TRUCK STRUCTURE DESIGN (Acrobat 664K) #3199,
21 pgs.
Les Grundman--Navistar International Transportation Corp.
David Bremmer, Sue Rice, and Geetha Bharatram--MSC.Software Corporation
Tom Phillips--Thermal Engineering Services, Inc.
ABSTRACT: Navistar Technical Engineering Center has teamed with MSC to exploit a new technology with the goal of significantly enhancing the impact of concurrent simulation on the truck structure design process. MSC.Acumen was used to build an expert system of designer tools. Design Engineers use these tools to perform up-front concurrent simulation, yielding the same quality of results that the dedicated simulation experts produce. The specific best practices and methods for simulating particular design categories were captured from the experts at the NTEC structural analysis group and cast into customized and automated applications.By using this system, component structural performance takes place on the same day that the design form is first rendered in CAD, as opposed to waiting in a queue for 4-to-6 weeks. If fact, design iteration for changes of material dimension, shape, or structural reinforcements is now supported by high quality simulation on the same day.
The custom MSC.Acumen applications are unique because they drive a Navistar specific process. They serve the collaboration and review process through automatic output of supporting data and simulation results in the form of web page HTML reports.
Navistar has selected two "work flow categories" for the first application set. They consist of eleven different "simulation templates" for structural brackets. These categories were chosen as very common and frequently designed structural components. The "simulation templates" will therefore see a high usage rate and yield the maximum impact to the design process. An additional benefit is that the structural analysis group experts are freed to pursue more complex and challenging tasks.
OPTIMIZATION
OF CAR COMPONENTS USING MSC/CONSTRUCT (Acrobat 1.9MB) #2099, 15 pgs.
Dr. F. Dirschmid--IABG
ABSTRACT: New CAE tools are necessary to fulfill the increasing demands for new car components. Typical demands are lightweightness, costs and developing time. Efficient tools and methods have to be used in the very early stage of development to achieve these goals. As soon as the design space, the boundary conditions and the loads are fixed, the topology optimization is an appropriate method to define a first design of the component. The topology optimization is a method that change the density and stiffness distributions in an iterative process to achieve a homogeneous stress distribution. This design proposal must be transferred in a real component by taking into account manufacturing and design points of view. The industrial application of this optimization method using MSC/CONSTRUCT is demonstrated in this paper for different car components.
STRUCTURAL
OPTIMIZATION IN VEHICLE DEVELOPMENT
(Acrobat 878K) #0899,
10 pgs.
Leo W. Dunne--CDH GmbH
ABSTRACT: This paper presents an overview of structural optimization and some closely related subjects in the automobile industry. An historical review of the development of structural optimization is given. Some of the fundamental steps which were taken and the nature of the problems that had to be overcome will be highlighted. The current state of technical affairs relating to the optimizer algorithms, analysis and pre/post processing is reviewed, considering theoretical as well as application oriented aspects. Finally, the application of structural optimization during the development process of an automobile is discussed, including identification of its major benefits. Examples and case studies will demonstrate the applicability and limitations of structural optimization in daily engineering practice. The paper ends with a review of future trends in structural optimization applications and their implications.
This paper presents the uses of MSC/NASTRAN and advantages of using this software for non-linear analyses of RC members. Brief discussion on modeling procedures and discussion of results of three RC shallow beams are also presented to illustrate the degree of accuracy in results which could be achieved from non-linear post-yielding analyses of R.C. members by using MSC/NASTRAN.
PVC
SEWER SYSTEM SEISMIC ANALYSIS MADE PRACTICAL (Acrobat 520K)
#0298, 14 pgs.
Hirokazu Nishiura--Sekisui Chemical Co., Ltd.
Eiichi Satoh--SC-Japan
David Bremmer--The MacNeal-Schwendler Corporation
ABSTRACT: MSC is announcing a new business offering based upon a breakthrough technology. MSC has developed a means by which design engineers or occasional CAE software users can reliably perform complex engineering analysis with the same resultant quality as do the dedicated analysis experts. This breakthrough technology captures the expert's engineering knowledge and specific process solution methodologies to enable and guide the novice. Now CAE can readily enhance the design processes where it was previously unavailable. Most importantly, large productivity gains are realized in the design process. The first practical test case for this technology was to solve the problem that prevented Sekisui Chemical Company from deploying their analysis methods for creating earthquake resistant designs.
Sekisui Chemical Co. has developed new earthquake resistant PVC pipeline components. To support this new materials technology, complex nonlinear FEA models for evaluating system performance under earthquake loading were developed. The challenge now is to integrate for practical use, the performance analysis methods into the design process for system layout.Sekisui wishes to provide earthquake resistance checks for all new drainpipe system designs.
Modeling of one sewer system layout, including selected earthquake loads and nonlinear soil behavior has required an average of 40-days for expert analysts. A radical departure from the traditional FEA modeling tool set is required to enable non-FEA-expert design engineers to use the developed sewer system analysis methodology.
A sewer system modeling application was written in the form of extended HTML drive pages similar to web pages. Automation functions were produced by capturing MSC/PATRAN session files from the manual analysis process as performed by an expert. The special application written for Sekisui will reduce the effort of producing sewer system analysis models from 40-days, to a matter of hours. Furthermore, it will allow design engineers who are not FEA, earthquake engineering, or soil engineering experts to perform the job with expert quality results.
COMPOSITE
DESIGN EXPERIENCE USING MSC NASTRAN FOR THE HYDRODYNAMIC FAIRINGS OF
A NEW SUBMERSIBLE (Acrobat 1.2 MB) #1698, 22 pgs.
Dr. E. Thomas Moyer Jr., Dr. Richard Cobb and Mr. Kim Grubbs--Analysis
and Technology Inc.
Dr. William Gordon--Northrop-Grumman Corporation, Oceanic Systems
ABSTRACT: This paper details our recent experiences designing the fairings for a new submersible vehicle being constructed. A unique composite material design approach was chosen to meet challenging structural requirements while minimizing weight. Analysis examples include material selection decisions, laminate design tradeoff studies, modeling of bolted joints, establishment of material allowables and global/local analysis approaches.
DESIGNING
OPTIMUM FIBRE LAYOUT FOR COMPOSITE SANDWICH PANELS (Acrobat 32K)1996,
6 pgs.
W Boruszewski--Instituto Nacional de Pesquisas Espaciais
M Kataoka-Filho--Instituto Nacional de Pesquisas Espaciais
ABSTRACT: The design of composite sandwich panels in terms of face sheet fibre orientation layout is examined searching for a maximum stiffness with total mass constant. Two basic layouts are considered: the first using constant fibre orientation and the second having a different fibre angle for each panel quarter. Specimens are tested showing good agreement with the first natural frequencies calculated for their finite element models. Taking fibre angles as design variables both layouts are maximized for the first eigenvalue. Two subsequent partitions are modeled with important stiffness increases achieved.
ABSTRACT: In the most of the studies, if not all, the composite stress analysis is made considering the unidirectional graphite/epoxy prepreg (tape). However, in the practical design, in many situations it is interesting to use the woven graphite/epoxy prepreg (cloth). Therefore, this report outlines the preliminary results in through-width delamination specimens made of graphite/epoxy prepreg tape with graphite/epoxy prepreg cloth.
Initially, a simple model based on the results presented in ref. [ 1 ] was made, analyzed and compared with MSC/NASTRAN, ref. [ 2 ]. This model considered a two-dimensional geometrically nonlinear finite element. The results obtained by MSC/NASTRAN in finite element model with 153 nodes and 128 four-node isoparametric elements were in very good accordance when compared to classical theory, presented in ref. [ 1 ]. The model contained four sub-structures with a total of 813 nodes and 740 four-node isoparametric elements.
The next step was to analyse through-width delaminations in specimen made of graphite/epoxy tape with graphite/epoxy cloth. This specimen not only contains two types of graphite/epoxy, tape and cloth, but also presents a non-symmetrical laminated. The results obtained by MSC/NASTRAN were compared with the classical theory and were found to be in very good accordance. This report shows how these results were obtained.