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Company:

Guardian Europe S.A.

Products:

Marc

Industries:

Automotive
Machinery

Guardian Automotive - Simulation of Automotive Glass Components

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

 
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Company:

Invernizzi Presse

Products:

Marc
Patran

Industries:

Aerospace
Machinery

Invernizzi Presse - Simulation Drives Manufacturing Press Inovation

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

 
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Company:

Draper Labaratory

Products:

Easy5

Industries:

Aerospace

Draper Labs

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

 
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Company:

Automotive Systems Laboratory, Inc. (ASL)

Products:

Dytran

Industries:

Automotive

Automotive Systems Laboratory (ASL) - Vehicle Occupant Restraint Systems

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

 
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Company:

Autoliv, Inc.

Products:

Dytran

Industries:

Automotive

Autoliv - Side-curtain Airbag Simulation

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

 
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Company:

The Boeing Company

Products:

Adams

Industries:

Aerospace

The Boeing Company

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

 
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Company:

Moeller GmbH

Products:

Adams

Industries:

Electronics

Moeller GmbH

Overview:
Moeller GmbH, a major innovator in switchgear and safety solutions for a wide range of industries, used MSC ADAMS for studies and calculations in new switchgear development, and to analyze improvements in existing products. Moeller engineers performed various tests on the same virtual model, inlcuding forces and load calculations, resulting in fewer physical prototypes and high-speed recordings. Thanks to MSC ADAMS, Moeller reduced the development time of new and modified products and improved the quality of existing products.
Challenge:
In order to effectively protect machines and engines, the circuit breakers must operate as predicted and therefore must be tested beforehand. Experimental hardware tests of circuit breakers require the building of a realistic prototype including all essential sub-assemblies and all necessary materials, making these tests laborious, time-consuming and expensive. Before using computer-aided engineering (CAE) software, the AE engineers performed motion analyses of their switches using high-speed video recordings of the physical prototype. Static calculations were done manually with functions and loads - a demanding and tedious method, and a major handicap in the field of advanced engineering.
Solution:
Since computer-aided design (CAD) software was already in use at Moeller for switch development, it was a logical step to implement CAE software for functional analysis of the switchgear. Among several software packages, MSC ADAMS was chosen to be the most suitable for multibody simulation because it enables the engineers to perform a complete analysis of the assembly as well as dynamic calculation of the loads.
Benefits:
  • Higher overall quality of the product could be improved
  • Results are more accurate and faster
  • The MSC ADAMS post-processor offers significant plots and animations, which quickly reveal the right development direction.
  • With precise results, management can come to their decisions more quickly and with more confidence
  • The number of hardware prototypes can be significantly reduced

 
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Company:

SAAB Automotive

Products:

MSC Nastran

Industries:

Automotive

SAAB Automotive - Put the Top Down and Drive

Overview:
Saab Automobile AB used MSC Nastran as their primary tool for structural dynamic analysis and structure-borne acoustic calculations to the development process of a new convertible. Design studies early in the development cycle and easily shared data improved interdisciplinary collaboration between the NVH and the chassis departments, enabling Saab to realize a vehicle balanced between weight, safety, and NVH performance.
Challenge:
Reduce product development costs
Benefits:
Able to perform analysis across disciplines and exchange common data models

 
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Company:

Products:

Patran

Industries:

Aerospace

Sikorsky Aircraft - Nonlinear Analysis to Reduce Design Bottlenecks

Overview:
Sikorsky, a world leader in the design and manufacture of advanced helicopters, reduces design bottlenecks by using implicit nonlinear for contact analysis. The integrated solutions from MSC Software allow Sikorsky to perform contact analysis and get an accurate estimate of the true buckling strength of their structures with minimal software training.

 
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Company:

Armor

Products:

Adams
Easy5

Industries:

Machinery

Armor Increases Machine Productivity by 20% with MSC Software’s Adams and Easy5 Simulations

Overview:
With sales of 137 million Euros in 2011, Armor is one of the leaders in producing inked ribbon used in thermal transfer printing for product identification and other applications. Ribbon is produced by applying ink to polyethylene terephthalate (PET) film in a web coating process in which the speed, tension and position of the web and other variables must be closely controlled in order to ensure the highest possible quality while maximizing throughput.
Benefits:
  • Increased machine productivity by 20%
  • Achieved optimal coating conditions
  • Increased quality

 
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Company:

Beacon Power

Products:

Dytran

Industries:

Energy

Beacon Power's Flywheel Energy Storage System reduces Material Costs By 50%

Overview:
Physical testing of prototypes is mainly used as a last check before a new design is approved, providing correlation between simulation and the actual results. Because of the success that Beacon Power has achieved by utilizing simulation early in the design process, most of the companies engineers are being trained in simulation, using MSC Patran and MSC Nastran, which results in a stronger technical organization, directly impacting both the product and processes, lowering costs and improving the final product.
Challenge:
With a 150 lb. rotor spinning at an angular speed in the mid 20 KRPM range, stress, vibration, safety containment and thermal issues all must be addressed when designing a flywheel energy storage system. However, developing prototypes for physical testing is time and cost prohibitive.
Solution:
To improve design efficiency, MSC Patran, MSC Nastran, MSC Dytran, were deployed to simulate problems before incurring the expense of prototypes and physical testing. As a side benefit, Beacon Power improved its designs, while reducing material costs 50%.

 

Company:

Talfourd-Jones Inc.

Products:

Dytran

Industries:

Automotive

MSC Software Professional Services Team Enables Development of Patented, Energy Absorbing Bus Bumper System

Overview:
The high up-front cost of product development was hindering the development of an innovative energy absorbing bus bumper system conceived by Talfourd-Jones Inc., parts makers for leading original equipment manufacturers. By retaining the simulation services of MSC.Software Professional Services, Talfourd-Jones Inc. was able to test and prove the concept for the bumper system before investing in the tooling required to produce the technology.

Challenge:
The bumper must protect the bus from any damage as a result of 6.5-mph direct impact into a rigid barrier and a corner impact from a common carriage. In addition, the bumper must return to pre-impact shape within 10 minutes of the impact.
Solution:
The primary system for meeting the impact requirements is through energy absorbing bumpers mounted on the front and rear. To meet this requirement, the Reflex bumper was designed to progressively collapse, cushioning the vehicle from a collision. Following impact, the bumpers return to their original shape without permanent damage or degradation in strength.
Benefits:
  • Easy to adapt for a modular design, minimizing tool costs and allowing easy installation for the bus service departments.
  • Easily modified, so the design can be tailored to other energy absorbing requirements by modifying cell wall thickness.
  • Easy interface with support beam, by incorporating a simple tongue for insertion into beam groove.
  • Provides a strong vertical support for front bumper step requirements.

 

Company:

Naval Surface Warfare Center

Products:

Dytran

Industries:

Shipbuilding

Navy use Adams Simulations to Validate Designs for Ships' Hull and Deck Machinery

Overview:
Engineers at the Naval Surface Warfare Center use ADAMS simulations to conceptualize and validate their designs for ships' hull and deck machinery. This has helped them slash equipment design cycles by 50% and more.

 

Company:

Products:

Dytran

Industries:

Shipbuilding

Low Velocity Impact Analysis of a Composite Mini Unmanned Air Vehicle During Belly Landing

Overview:
In this study belly landing of an unmanned mini air vehicle with low velocity impact on the soil and rigid ground has been investigated by explicit finite element analysis using MSC Dytran.
 
 

Company:

Pratt & Miller

Products:

Adams
Adams Car

Industries:

Automotive
Motorsports

Motorsports to Mission Critical - Pratt & Miller

Overview:
Pratt & Miller engineers used Adams and Adams/Car to design the front and rear suspension during the first few weeks of the project, long before there was a complete CAD model of the vehicle. One Adams analyst and two to three designers worked full-time on the front suspension while a similar team focused on the rear suspension. Adams simulations were used to evaluate and tune the suspension according to the specifications and also to supply loads to the designers for use in their FEA analyses.
Challenge:
Development of a Fully Engineered Military Showcase Vehicle in Only 12 Weeks
Benefits:
  • Quickly build and test functional virtual prototypes of complete vehicles and vehicle subsystems
  • Tests are performed in a fraction of the time

 
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