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Company:

Alson E. Hatheway Inc (AEH)

Products:

MSC Nastran

Industries:

Aerospace

Mechanical Design of Optical Systems using MSC Nastran

Overview:

A common mechanical failure in optical systems is inadequate stiffness in the supporting structure. Stiffness is crucial for maintaining the alignment of the optical elements and achieving adequate optical performance. It is the responsibility of the mechanical engineer to provide adequate stiffness in the mechanical design.

Solution:

In the first days the mechanical engineer analyzed the optical performance of the proposal’s mechanical design, identified and implemented needed refinements and validated that the resulting conceptual design could be developed into a detailed design that would meet the project’s optical requirements. Further, by working in simple, early structural models (lumped mass, beam and shell elements) as well as the large models of a more mature design (meshed and CAD joined tetrahedral solids), AEH/Ivory provides the project a continuous and traceable record of the adequacy of the structural stiffness supporting the optical system.

Benefits:
  • Saved months of schedule time on projects
  • Hundreds of thousands of dollars saved
  • Assurance from the very beginning of the mechanical engineering effort that the structure is designed correctly

 
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Company:

Meritor

Products:

Adams

Industries:

Automotive

Adams Used to Simulate New Control Strategy that Reduces Truck Stopping Distance by over 30%

Overview:

Regulators are continually increasing the performance standards required of automobile manufacturers. An example is FMVSS 105 and 121 which define the performance of braking systems and are intended to ensure safe braking performance under normal and emergency conditions for heavy trucks and trailers. A typical change in these regulations is to reduce the distance required to stop the truck under emergency conditions. This can be achieved by designing bigger, heavier, more expensive brakes. Ragnar Ledesma, Principal Engineer for Meritor, took a different approach by addressing the algorithms used to control anti-lock braking systems used in nearly all medium- and heavy-duty trucks.

Results Validation:

The simulation showed the proposed control system brings the vehicle to a complete stop in less than 4 seconds in a stopping distance of 177 feet (54 meters), demonstrating a way to meet the requirements of a tougher regulation without major changes to braking hardware. The results show a nearly constant deceleration response at the driver seat as opposed to the cyclical response with conventional ABS braking. The explanation for the improved performance is explained by the simulation results. The wheel angular velocities and tire slip ratios do not fluctuate from their desired values, hence the new ABS control system can sustain maximum braking forces almost over the entire braking cycle.

Benefits:
  • Leveraged Adams-Controls Integration to provide virtual testing of the new braking algorithms used in the ABS system
  • Achieved a reduction in truck stopping distance by over 30% using current disc braking systems
  • Evaluated the truck braking performance without many expensive prototypes iterations

 
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Company:

Comat Aerospace

Products:

Adams
SimXpert

Industries:

Aerospace

Developing the 3POD Antenna Pointing System

Overview:

Comat Aerospace is in the process of developing the 3POD Antenna Pointing System (APS) in collaboration with the Centre National d’Etudes Spatiales (CNES), the French national space agency. The role of the 3POD APS is to keep the antenna pointed at ground stations regardless of the satellite’s orientation while maintaining low mechanical jitter to ensure line of sight stability. For its first projected deployment on the OTOS satellite, the 3POD ATS will be required to provide a 74° pointing domain with a worst case pointing precision of +/- 1° at a pointing speed of about 5° per second.

Results Validation:

Comat engineers originally used Adams to perform kinematic simulation of the motion and piloting functions of the robot and to complete a parametric study on the various design parameters and their impact on the overall performance. But incorporating flexibility into the Adams model required a long design loop between the CATIA model, Adams model and Nastran/Patran model. By the time this design loop could be completed, the design had often been changed so the results were outdated. Going further in the process, Comat engineers built a prototype of the robot that highlighted the importance of the flexibility of the elements on its overall rigidity in certain positions.

Benefits:
  • Study various design parameters
  • Accelerate the design cycle
  • Modify the design and validate the performance in about 4 hours

 
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Company:

Dynetics Technical Services Inc.

Products:

MSC Apex

Industries:

Aerospace

MSC Apex Used to Reduce Geometry Cleanup of Fuel Pump Components from Two Days to One Hour

Overview:

The National Aeronautics and Space Administration’s (NASA’s) Space Launch System (SLS) will be the most powerful rocket in history, launching crews of up to four astronauts in the Orion spacecraft to explore multiple, deep space destinations. The SLS is designed around an evolvable architecture that will support versions ranging from 77-metric-ton (77 ton) to 130 metric ton (143 tons) lift capability. The SLS core stage, more than 200 feet tall with a diameter of 27.6 feet, will store cryogenic liquid hydrogen and oxygen that will feed four RS-25 engines. The RS-25 served as the Space Shuttle main engines and operated with 100% mission success during 135 missions. The RS-25 is being modified to serve on the SLS by increasing its power from 491,000 to 512,000 pounds of vacuum thrust among many other improvements.

Benefits:
  • Identify and remove all undesirable boundary edges in a single step
  • Create new surface boundaries by sketching lines in place
  • Create a global solid element mesh while maintaining curvature based refinement and topological congruency

 
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Company:

University of California, Irvine

Products:

MSC Nastran

Industries:

Consumer Products

MSC Nastran Helps Perfect New Nondestructive Testing Method for Adhesive Bonded Composites

Overview:

Compared to other joining methods, bonding composite structures with adhesives distributes the load over a larger bond area, reduces weight, joins dissimilar materials and provides higher stiffness and toughness. Bonding also generally reduces manufacturing costs. However, when using adhesive bonding for composites it can be very difficult to determine if the bonded joint meets structural requirements without destroying the part.

Solution:

UCI researchers used MSC Nastran and Patran to simulate the operation of quantitative percussion testing to reduce the need for physical testing and eliminate the potential for manufacturing errors.

Benefits:
  • Reduce the need for physical testing
  • Eliminate the potential for manufacturing errors
  • Perfect the use of percussive testing in a wide range of applications.
  • Evaluate the ability of the test to clearly distinguish between well bonded and kiss bonded panels.

 
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Company:

Italian Institute of Technology

Products:

Adams

Industries:

Machinery

Accurately Simulating a Four-Legged Walking Robot with Adams

Overview:

Search and rescue is extremely hazardous work and there are some areas which cannot be reached by humans because the danger is too great. A new generation of robots is being designed to address these challenges. While there are a number of different potential search and rescue robot designs, one of the most interesting is a four legged robot being designed by the Dynamic Legged Systems Lab led by Dr. Claudio Semini (Italian Institute of Technology) to perform dynamic tasks such as walking in rugged terrain, carrying heavy loads, climbing hills and even jumping and running.

Solution:

Advanced Industrial Automation Lab engineers instead used Adams and MSC Nastran to simulate the performance of the robot in a fraction of the time that would have been required for the analytical approach. Each robot leg contains about 450 parts. IIT engineers merged these components into just a few rigid bodies, one for each moving part of the structure

Benefits:
  • Up to 90% correlation between physical tests and simulations on both robot displacements and contact forces
  • Researchers are now able to evaluate different folding methods and new package designs with the simulation model
  • Including flexibility into Adams model further increases the accuracy of predicting complex robotic behavior

 
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Company:

Italian Institute of Technology

Products:

Adams

Industries:

Machinery
Packaging

Adams Used to Simulate Complex Package Folding Machinery

Overview:

Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami. Most of these packages are not secured by glue, but rather with complicated tuck-in operations, requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation. Complex packages are traditionally built by human operators, because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed.

Results Validation:

“The physical finger displacements correlate very well with the actual robot displacements,” said Ferdinando Cannella, Head of IIT’s Advanced Industrial Automation Lab of Advanced Robotic Department. “The carton folding sequence of the folding model also matched up perfectly to the actual robot.

Benefits:
  • Up to 80% time savings using Adams and MSC Nastran compared to the traditional analytical approach
  • The model built with realistic flexibility correlates well with the physical measurements for slider displacement, knee force and hip force
  • Accurate modeling of the robot’s leg enables the engineers to investigate the performance of the complete robot in tasks such as walking or running over different types of terrain as a next step

 
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Company:

TLG Aerospace, LLC

Products:

MSC Apex

Industries:

Aerospace

MSC Apex Helps Reduce Time Required to Clean Up and Mesh Geometry by 75%

Overview:

Wings USA, Inc., a flight services company based in Janesville, Wisconsin, contracted with TLG Aerospace, LLC to analyze a proposed modification to light aircraft. The twin-engine aircraft is to be modified to include a large circular cutout in the floor adjacent to the aircraft door. TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness. TLG engineers generated the pre- and post-modification geometry in CATIA V5. To accommodate the cutout, a section of the longitudinal beam at the center of the floor of the fuselage was removed in addition to a section of skin at the lower outer mold line (OML).

Benefits:
  • Create mid-planes on the fly
  • Quickly simplify geometry for meshing purposes
  • Achieve a high quality mesh in significantly less time than traditional meshing applications

 
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Company:

University of Technology of Compiègne

Products:

Adams

Industries:

Medical Devices

Adams Helps Unravel the Complexities of Hand Motion for Manipulation of Virtual Objects

Overview:

The manipulation of objects is fundamental to virtual reality applications. Better methods are needed to grab and manipulate virtual objects by moving one’s hands in 3D space. But the anatomical complexity of the human hand makes it very difficult to accurately track manual motions. Haptic technology, which recreates the sense of touch by applying forces, vibrations, or motions to the user, provides cues in object manipulation. Haptic interfaces are essential in order to generate sensations relating to touch and effort. Active hand mounted devices make it possible to accurately track the hand and feel virtual objects with the fingers but they are complex and costly.

Benefits:
  • Develop a highly accurate muscularskeletal model of the hand and forearm from real kinematic data
  • Simulate the operation of the musculoskeletal system during motion
  • Unravel the complexities of hand motion

 
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Company:

BAY-LOGI

Products:

Marc

Industries:

Energy

Marc Simulates Welding of Nuclear Pressure Vessel Reactor Nozzles

Overview:

The reactor pressure vessels make up the heart of a nuclear power plant, containing the core, core shroud and coolant. In water-cooled water-moderated energy reactors type power plants, nozzles on the ferritic steel pressure vessel are welded to primary coolant pipes made of austenitic steel. These nuclear power plants were built and started operating 20 to 30 years ago. The company operating one of these power plants needed to know how these welds can be expected to perform after a long period of service. It’s not practical to perform measurements on the reactor itself because of the complex geometry and the presence of radiation. Building and testing a duplicate structure would be expensive and it would also be very hard to replicate the effects of 20-plus years of operation. So the operator of the power plant agreed with the Department of Structural Integrity at Bay Zoltan Institute for Logistics and Production Engineering (BAY-LOGI) to simulate the manufacturing process to better understand the characteristics of the welded joint.

Benefits:
  • Model coupled thermomechanical effects of multi-pass welding process
  • Gain insight into residual stress distributions
  • Save on costly physical testing

 
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Company:

Litens Automotive Group

Products:

Adams
Marc

Industries:

Automotive

Adams-Marc Co-simulation Makes System Analysis 15 Times Faster than Pure Nonlinear FEA Analysis

Overview:

Litens Automotive Group’s patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional vibrations. The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia. Because the spring stiffness is softer than traditional rubber isolators, vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt. This results in isolation of all components in the accessory drive, and any accessory drive resonance has very small peak amplitudes, since there is very little excitation.

Results Validation:

The Marc simulations have previously been found to be very close to physical measurements. The co-simulation results for key values, such as the inner drive angle as a function of input torque, were found to vary by less than the 10% from the Marc simulation over two revolutions of the input shaft.

Benefits:
  • Adams-Marc Co-simulation Makes System Analysis 15 Times Faster than Pure Nonlinear FEA Analysis
  • The solution maintains high accuracy of the simulation
  • Enables engineers to run many design iterations in a short period of time to optimize in a practical fashion

 
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Company:

Infosys

Products:

MSC Nastran
Patran

Industries:

Medical Devices

MSC Nastran Provides More Accurate Solution to Assess Bone Fracture Risk

Overview:

Humans lose bone mass with age because their bones lose calcium and other minerals and become lighter, less dense and more porous. As this process continues, our bones become weaker, increasing the risk of bone fracture. A patient is said to have osteoporosis when bone mineral density (BMD), the concentration of minerals in a unit volume of bone, falls below a threshold value.

Results Validation:

This innovative solution to osteoporosis developed by Infosys uses computer-assisted design and FEA for the evaluation of fracture risk of the vertebrae quantitatively. Stresses computed through the simulation provide more accurate assessment than traditional BMD measurements in the determination of fracture risk. It applies best practices in mechanical engineering to understand the biomechanics of vertebrae.

Benefits:
  • Using MSC Nastran to study the mechanics of vertebrae while taking into account various factors such as the shape, density distribution of cortical/cancellous bone and other material properties of bone tissue and porosity.
  • The solution helps practitioners to study bones in a detailed and non-invasive manner, and quantitatively analyze the fracture risk of vertebrae
  • Stresses computed through the simulation provide more accurate assessment than traditional BMD measurements in the determination of fracture risk

 
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Company:

Ford Motor Company

Products:

Adams

Industries:

Automotive

Ford Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Overview:

Noise/vibration/harshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process.

Challenge:

When developing a new vehicle model, engineers are responsible for meeting a wide variety of often conflicting performance targets. Fuel economy and NVH are two of the most important categories of targets.

Benefits:
  • This case study successfully demonstrates the FMI integration approach for vehicle lugging NVH assessment
  • Effectively coupled AMESim Converter Controller model with Adams Driveline and Vehicle model
  • An Optimum Torque Converter slip speed was determined meeting lugging target requirement while balancing with fuel economy
  • Simulation results showed drivetrain torsional vibration along with vehicle vibration (steering wheel & seat track) were effectively reduced with converter slip

 
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Company:

Deggendorf University

Products:

Adams
Adams Car
MSC Nastran

Industries:

Automotive

Quick as Lightning - MSC Software supports 'Team Fast Forest' from Deggendorf

Overview:

Young university students make use of Adams multi-body simulation software to construct a vehicle for entry in the Formula Student competition. ‘Team Fast Forest’ from Deggendorf is using the software to study tires and chassis. Breaking conventional car design, the team will focus on electric vehicles.


 
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Company:

Mahindra Two Wheelers

Products:

Adams

Industries:

Automotive

Adams Multibody Dynamics Simulations Help Bring Two Wheelers to Market 7-21 Weeks Faster

Overview:

In the past, the design of new two wheeler models at Mahindra was based on building prototypes and driving them on a test track. The limitations of this approach were that prototypes took an average of five weeks to build and had to be run for about two weeks to evaluate component durability. A major improvement came when test rigs were introduced and used to recreate the conditions of the test track using automated equipment that eliminated the need for a driver and could be operated 24X7. This approach saved time, however, a complete vehicle prototype iteration was still required for each major design change.

Solution:

Mahindra selected MSC Software’s Adams, the most widely used MBD software for over three decades. MSC Software is the world leader in both MBD and FEA software. Speaking the language of both domains gives MSC the capability to develop the rich data transfer required to fully integrate them. Mahindra has evolved a new virtual testing design process that uses Adams to simulate the performance of new designs and accurately predict their performance prior to the prototype phase.

Results Validation:

Basing the design process on simulation rather than testing provides substantial time and cost savings. The largest savings come from being able to evaluate alternative designs without having to build a prototype. The number of prototypes required to bring a new two wheeler to market has been reduced from 4 or 5 in the past to 2 or 3 now. The time to build and test a new prototype is about 7 weeks so the company has been able to bring new two wheels to market at least 7 to 21 weeks faster than was possible in the past.

Benefits:
  • Simulation provides much more diagnostic information than can be obtained from physical testing
  • Engineers perform parametric analyses to investigate the influence of design variables such as the location of hard points on accelerations
  • Excellent correlation between simulation and measurements on suspension systems
  • The number of prototypes required to bring a new two wheeler to market has been reduced from 4 or 5 in the past to 2 or 3 now
  • Adams bring new two wheels to market at least 7 to 21 weeks faster than was possible in the past

 
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