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Company:

Integrative Simulation and Engineering of Materials and Processes

Products:

Digimat
Marc

Industries:

Aerospace

ISEMP - Curing of Carbon Fiber Reinforced Plastics (CFRP)

Overview:
“Digimat enables the engineers at ISEMP to perform in-depth studies of complex and realistic microstructures. As they continue to invest into the future they now base their simulation approach on the Digimat software, improving their own research method as well as the education of a new generation of simulation engineers."
Challenge:
  • Processing of CFRP results in residual stresses in the material
  • Residual stresses lead to micro-­-damage & failure of CFRP
  • Goal is to simulate residual stresses of a carbon fiber composite material at the micro scale with realistic topology
Solution:
  • Generation of RVE with continuous fibers and layered microstructure
  • Realistic RVE with stochastically distributed fibers
  • CAD geometry of RVE to be used with external solvers
Results Validation:
"DIGIMAT enables us to perform in depth studies of complex and realistic microstructures. As an invest into the future we base our simulation approach on the DIGIMAT software, both for our research and the education of a new generation of simulation engineers who will be experts in the modeling of materials." Prof. Vasily Ploshikhin, Airbus endowed chair for Integrative Simulation and Engineering of Materials and Processes
Benefits:
  • The FE-­Simulation of laminate layers with inhomogeneous properties enables a detailed analysis of stress distribution and possible origins for different types of micro defect formation
  • Highest stresses can be found at the fiber matrix interface
  • Matrix areas between very close fibers are under higher load
  • Fiber matrix interface between differently oriented laminate layers shows higher stresses

 
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Company:

CADF

Products:

Digimat

Industries:

Energy

CADFEM - Continuous Fiber Reinforcement in Wind Turbine Rotor Blades

Overview:
Digimat assisted the engineers at CADFEM to develop a more efficient wind turbine by closing the gap between advanced modeling of heterogeneous anisotropic and nonlinear materials. The possibility of taking into account the micromchanical properties of fiber reinforced plastics in wind turbines is another area Digimat can aid in the production process of green energy.
Challenge:
  • Design of bigger turbine blades with low weight & high rotational inertia
  • Optimal use of expensive high-­-end composite materials
  • Flexible & realistic simulation approach to investigate design concepts
Solution:
  • Multi-scale analysis based on ANSYS Composite PrepPost™ model
  • Describe GFRP and CFRP composites via a unique material modeling approach using the mean field homogenization on the microscopic scale in DIGIMAT
  • Fiber description taking into account isotropic or transversely isotropic properties
  • Systematic analysis of failure directly in the Epoxy and the fiber phases
Results Validation:
"DIGIMAT enhances our product portfolio and closes the gap towards advanced modeling of heterogeneous anisotropic and nonlinear materials. We see a large potential for taking into account the micromechanical properties of fiber reinforced plastics." Martin Kracht, Product Manager DIGIMAT at CADFEM GmbH - ANSYS Competence Center FEM in Germany
Benefits:
  • Failure indicators are in general much lower for carbon fiber than for glass fiber reinforcement Carbon fiber reinforced blade fails on different ply level compared to the glass fiber design
  • The usage of a transversely isotropic description for the carbon fibers is critically important for a realistic simulation approach

 
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Company:

SOLVAY Speciality Polymers

Products:

Digimat

Industries:

Consumer Products

Solvay - Fatigue Failure of Injection Molded Bow Limbs

Overview:
By using DIGIMAT the engineers at Solvay could clearly demonstrate the tight link between geometry, flow of material, fiber orientation and mechanical behavior. They successfully used the approach to evaluate the endurance of a number of different bow limb designs.
Challenge:
  • A manufacturer injection-molded plastic bows set the goal to produce the best bows for recreational archery on the market based on SOLVAY material
  • A new and apparently improved design of the bow limbs showed a reduced fatigue lifetime as compared to an existing geometry
  • The question arose whether the premature failure of the new design is directly connected to the change in the processing of the bow limbs
Solution:
  • Reverse engineering of an elasto-plastic DIGIMAT material model
  • Computation of 1st principles stresses for preload and load cases based on fiber orientation data coming from Moldflow
  • Life time prediction using a Haigh diagram
  • Comparison between the two different designs for the bow limbs
Results Validation:
"By using DIGIMAT we could clearly demonstrate the tight link between geometry, flow of material, fiber orientation and mechanical behavior. We successfully used the approach to evaluate the endurance of a number of different bow limb designs." Laurent Hazard, CAE Senior Specialist, SOLVAY
Benefits:
  • The lifetime in fatigue of the original design should be slightly longer than the new design
  • The higher stress level for the new design could be connected to a higher local stiffness in the critical region in the bow limb
  • The higher local stiffness could be explained by a “better” fiber orientation due to a change in the melt flow in the processing step (combination of two “converging” flows)

 
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Company:

Optimec Consultants

Products:

SimXpert

Industries:

Machinery

Optimec Consultants

Overview:
Based in the Greater Montreal area in Quebec, Canada, Optimec Consultants is an advanced engineering consulting firm offering Computer Assisted Engineering (CAE) services and complete Finite Element Analysis (FEA) solutions, and is a certified reseller of the MSC Software product line. For the past year, major efforts have been directed towards maximizing the potential uses of templates for building and analyzing FEA models. Templates are powerful macros that allow automation and improve productivity. Template building is a very promising capability within the MSC SimXpert multidisciplinary simulation environment. The goal of developing templates is to use them internally and to offer personalized simulation solutions to existing clients and new industries looking to implement the Finite Element Method in their design process. This case study presents four key templates that have been developed specifically for the large machinery industry and for work in future developments.
Challenge:
Automating the modeling and analysis of large FEA models.
Solution:
The SimXpert template building capability permits the creation of templates aimed at automating repetitive processes. Building templates can be done using actions library or via macro recording. Specific scripts can also be coded using Python programming language. SimXpert’s main advantage over its competitors is its ease of use and straightforward interface.
Benefits:
  • Quick verification of results
  • Shorter analysis time
  • Ease of use

     
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    Company:

    Patrick Air Force Base

    Products:

    Adams

    Industries:

    Aerospace
    Defense

    Patrick AFB

    Overview:
    Ejection seats must work perfectly every time they are used in an enormously wide range of altitudes, aircraft motion profiles, wind conditions and pilot weights while at the same time taking manufacturing variation into account. Physical testing of course plays a pivotal role in ejection seat design but time, cost and safety limit the number of situations that can be tested to far fewer than the number of potential ejection scenarios. Analysts at the Naval Surface Warfare Center (NSWC) at Indian Head, Maryland, and the 45th Space Wing at Patrick Air Force Base, Florida, have developed a model of an ejection seat using MSC Adams rigid body simulation software. During the model’s initial 5-year joint-force development process, Adams was the first professional dynamics software used to completely model the complex physics involved in the deployment of an ejection seat.
    Challenge:
    Improve ejection performance and safety.
    Solution:
    Adams was used to model the complex physics involved in the deployment of an ejection seat.
    Benefits:
    • Accurate Simulation
    • Reliable Analysis
    • Improved Design Process

     
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    Company:

    Setforge Engineering

    Products:

    Patran

    Industries:

    Aerospace
    Automotive
    Heavy Equipment

    Setforge - Simulating the Electro-upsetting Process During Metal Forging

    Overview:
    When Setforge joined the group, Farinia took the opportunity to review its simulation resources. Nicolas Behr, Chief Project Engineer at Setforge Engineering explains: “We realized the limits of the tools we were using and that their maintenance cost was too high relative to their capacities. What’s more, because of some of the methods used by the group – especially electro-upsetting – we had to model and simulate the nonlinear multiphysics phenomena that characterize these technologies.”
    Challenge:
    Simulate the electro-upsetting process used to make very long sectional parts
    Solution:
    • Patran to develop simulation model.
    • Marc to simulate the nonlinear multiphysics phenomena that characterize electro-upsetting technologies.
    Benefits:
    • Achieve Best Cost/Performance Ratio
    • Process Optimization

     
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    Company:

    Achates Power

    Products:

    Adams
    Patran

    Industries:

    Automotive

    Achates Power

    Overview:
    Achates Power, Inc. is developing a lightweight, low-emissions and low fuel consumption two-stroke, opposed-piston diesel engine designed as a modular and scalable mechanism termed A40. Achates Power places heavy emphasis on modeling and simulation through state-of-the-art analytical tools and methods. Within the structural dynamic analysis arena, the focus is on overall dynamics, such as torsional and bending vibrations, including torsional vibration damper (TVD) and flywheel layouts, as well as (hydrodynamic) bearing analysis. The emphasis is on identifying areas of conceptual, structural and dynamic improvement with regard to overall dimensions and weight. A hybrid approach is utilized, thus combining the advantages of multi- body simulation (MBS) and finite element analysis (FEA).
    Challenge:
    Develop a light-weight, low-emissions, and low fuel-consumption diesel engine
    Solution:
    MSC Adams with FEV Virtual Engine powered by Adams
    Benefits:
    • Confirmed structural integrity
    • Optimized components
    • Weight reduction

     
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    Company:

    Kosme

    Products:

    Adams
    MSC Nastran

    Industries:

    Machinery
    Packaging

    Kosme - Design and optimization of packaging machines

    Overview:
    Kosme produces a full range of turnkey filling, labeling, capping, packaging and conveying solutions for beverage products including soft drinks, water, beer, wine, and spirits, as well as personal care products.
    Challenge:
    In developing custom solutions for customers, Kosme is frequently asked to develop machines that will operate faster and more reliably than their predecessors. Increasing the speed of machines raises inertial loads, creating the potential for vibration and resonances that could substantially reduce the life of the machines and cause breakdowns. In the past, Kosme engineers used hand calculations to estimate the performance of components and built physical prototypes to evaluate system performance. Problems were frequently discovered during the prototype stage. These problems often required many iterations of revisiting the design and modifying and re-testing the prototype.
    Solution:
    MSC Nastran and Adams simulation software made it possible for Kosme to design, optimize and visualize packaging machines prior to the prototype stage. The result is that the company is able to engineer substantial performance improvements while getting the design right the first time.
    Benefits:
    Simulation makes it possible for Kosme to design, optimize and visualize packaging machines prior to the prototype stage. The result is that the company is able to engineer substantial performance improvements while getting the design right the first time.
    • Increase the processing speed of bottling machines by 50%
    • Reduction of vibration levels
    • Reduction of mass of critical moving components by 20% to 30% while reducing stress levels.

       
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      Company:

      Sikorsky Aircraft Corporation

      Products:

      Dytran

      Industries:

      Aerospace

      Sikorsky Aircraft Corporation - Certifying Helicopter Components

      Overview:
      Sikorsky, a world leader in the design and manufacture of advanced helicopters, reduces design bottlenecks with MSC Nastran Advanced Nonlinear.
      Challenge:
      Sporadic use of advanced finite element (FEA) software, such as nonlinear analysis by design engineers, can result in either excessive refresher training time or a bottleneck while in the queue for an analyst. The cause is a result of different types of solvers requiring different models. Commercially available translators can help, but still require significant amounts of cleanup.
      Benefits:
      • Accurate FE Model Reproduction
      • Reliable Analysis
      • Improved Design Process

       
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      Company:

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

      Products:

      Adams

      Industries:

      Automotive
      Motorsports

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

      Overview:
      Joel Ortiz is a Concept Engineer at Transmisiones y Equipos Mecánicos S.A. de C.V. (TREMEC) in Querétaro, Mexico. TREMEC is a leading producer of rear wheel drive light duty manual transmissions. Ortiz and other TREMEC engineers are responsible for ensuring that the performance of TREMEC transmissions matches up to demanding customer expectations. In the past, the only method available to resolve performance issues in prototypes was to go through the time-consuming and expensive process of making modifications to the prototype and hoping for the best.
      Challenge:
      In testing an early prototype of a six-speed manual transmission, jumps were seen in the force applied to the shifter lever and felt by the driver of the vehicle. These jumps in shifting effort, called nibble by transmission manufacturers, do not affect the performance or durability of the transmission, but they are important because the reaction force against the gear shift helps define the shift quality of the transmission for the driver.
      Solution:
      Ortiz created a virtual prototype of synchronization mechanism in Adams with 17 parts including the shift rail, fork, roller detent, gear synchronizer cone, inner synchronizer ring, blocker ring, strut, sleeve, intermediate ring, clutches and gears. The geometries of these parts were based on the measurements of the prototype transmission.
      Benefits:
      Ortiz used a virtual prototype to reduce nibble by 93% from the early prototype to the production model, contributing to rave reviews from automotive journalists.

       
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      Company:

      PROTON

      Products:

      Adams
      FEA, AFEA and TFEA
      MSC Nastran
      Patran

      Industries:

      Automotive

      PROTON - Driving Engineering Innovation

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

       
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      Company:

      Triple Eight Race Engineering Ltd.

      Products:

      MSC Nastran
      Patran

      Industries:

      Automotive
      Motorsports

      Triple Eight Race Engineering Ltd. - Racing to Win

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

       
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      Company:

      Products:

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

      Industries:

      Defense

      Agency for Defense Development - Improving the Survivability of Airframes

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

       
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      Company:

      Diagnostic Simulations, Inc.

      Products:

      Marc
      Patran

      Industries:

      Medical Devices

      Diagnostic Simulations, Inc. - Designing Palatal Implants

      Overview:
      Dr. Paul Buscemi was the VP of Research and Development at Restore Medical Inc. in Medina MN, now a part of Medtronic. Paul and his team were responsible for conceptualization and realization of a new tongue implant to treat sleep apnea.
      Challenge:
      Restore Medical’s challenge was to build a simple, innovative, minimally invasive, palatal implant. The R&D group needed to get insights beyond airway closure to study the effect of the implant on critical tongue functions such as speech and swallowing.
      Solution:
      Using MSC.Software’s CAE products Paul and his team were able to perform a complete analysis of a new human tongue implant design.
      Benefits:
      Using MSC.Software technology, Paul’s R&D team created an accurate model of tongue musculature and motion. The model was used to design and test a virtual prototype for a new tongue implant and its effects.

       
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      Company:

      Cleveland Golf

      Products:

      Dytran
      MSC Nastran
      Patran

      Industries:

      Consumer Products

      Cleveland Golf - Virtual Prototype for Golf Clubs

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

       
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