Company:

European Space Research and Technology Center

Products:

Digimat

Industries:

Luft- & Raumfahrt

ESA/ESTEC - Thermo-mechanical Design of an Ultra-light Satellite Antenna

Overview:
Digimat offered the engineers at the European Space Research and Technology Center the tools they needed to bridge the gap between the Micro world and the Macro world. Using Multi scale modeling of advanced woven composite material Digimat can support a virtual design of an ultra light satellite antenna.
Challenge:
  • Satellite antennas have to be designed in a sturdy and reliable manner
  • There is no easy way to repair a satellite once it breaks down
  • The extreme sensitivity of the structure towards thermal loads has to be investigated under environmental conditions
Solution:
  • Multi-scale modeling of advanced woven composite material on 3 scales
  • Carbon/epoxy composite: homogenization of yarn properties
  • Triaxial woven fabrics (TWF): detailed analysis of a representative cell
  • Satellite antenna: simulation of the full structure based on an equivalent multi-layer shell model representative for TWF
Results Validation:
“DIGIMAT is able to bridge the micro to the Macro world. A great example of high-­-quality european know-­-how” Dr Julian Santiago Prowald, TEC-­-MSS Structures Section ESA/ ESTEC
Benefits:
  • Mean-field homogenization gives high quality prediction of yarn properties (stiffness & CTE)
  • Yarn properties used to compute accurate results for stiffness & CTE for TWF
  • Good prediction of displacement behaviour of the satellite antenna due to thermal loading

 
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Company:

L&L Products

Products:

Digimat

Industries:

Fahrzeugtechnik

L&L Products - Impact on a Stiffener for Lower B-Pillar

Overview:
Digimat provides L&L Products with state of the art simulation methods which aid engineers in product development. The key advantage provided by Digimat coupled to Radioss and other CAE software is a drastic predictability improvement for glass filled polyamide materials. With an improved predictability, optimal and robust lightweight design is possible in the future.
Challenge:
  • To move towards greener technology by replacing classical metal design by composite structures
  • To use the outstanding performance of composite materials whilst tackling all additional difficulties arising from the injection molding process
  • High quality prediction of impact on a short fiber reinforced stiffener beam
Solution:
  • Strain rate dependent micromechanical material model for AKULON K224 HG7 supplied by DSM
  • Mapping of MOLDFLOW fiber orientations onto the structural mesh
  • Solution of a nonlinear multi-scale analysis with DIGIMAT coupled to RADIOSS
Results Validation:
"The key advantage provided by DIGIMAT coupled to Radioss and other CAE software is a drastic predictivity improvement for glass filled polyamide materials. With an improved predictivity, optimal and robust lightweight design is possible in the future." F. Braymand, Simulation Manager at L&L Products
Benefits:
  • Excellent correlation on the force-­-displacement curve with experiment
  • Excellent correlation on the failure location compared to experiment
  • Drastic improvement of predictivity enables robust and lightweight design focusing on cost efficiency based on advanced DIGIMAT CAE technology

 
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Company:

Integrative Simulation and Engineering of Materials and Processes

Products:

Digimat
Marc

Industries:

Luft- & Raumfahrt

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:

Energie

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:

Konsumgüter

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:

Industries:

Maschinenbau

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:

    Luft- & Raumfahrt
    Rüstung

    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:

    Luft- & Raumfahrt
    Fahrzeugtechnik
    Schwermaschinen

    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:

    Sikorsky Aircraft Corporation

    Products:

    Dytran

    Industries:

    Luft- & Raumfahrt

    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:

    Meritor

    Products:

    MSCOne

    Industries:

    MSC One helps Meritor virtually test a new braking algorithm

    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 mediumand 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
    • On-demand access to the Adams Controls module via the MSC One token licensing system

     
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    Company:

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

    Products:

    Adams

    Industries:

    Fahrzeugtechnik
    Motorsport

    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:

    Diagnostic Simulations, Inc.

    Products:

    Marc
    Patran

    Industries:

    Medizintechnik

    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:

    Products:

    Dytran

    Industries:

    Rüstung

    Agency for Defense Development - Airframe Survivability Research

     
     
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    Company:

    TI Automotive

    Products:

    SimManager

    Industries:

    TI Automotive - Focus on design simulation

    Overview:
    When leadership at TI Automotive—a global supplier of fuel storage and delivery systems for cars and trucks— evaluated the company’s product development process, it discovered repeated design and test cycles. MSC gave the engineers at TI Automotive the essential tools they need to save time and money, by reducing prototyping.
    Challenge:
    The problem that TI faced was that simulation was disconnected from the design process. Compounding the situation was that in going from CAD geometry to simulation models, many data translations or fixes were necessary. TI really only had one simulation expert in the company, which kept analysis from being scaled across the enterprise.
    Solution:
    Using design simulation to support its product development process would enabled TI to account for complexities of manufacturing upfront, and, additionally, would move simulation from the desktop of one expert engineer to that of many engineers.
    Benefits:
    Since TI implemented an engineering simulation solution from MSC Software, the supplier of enterprise simulation solutions. The benefits have been significant.
    • TI Automotive now is able to run virtual tests without having to rely on the one in-house expert, which eliminates the previous bottleneck.
    • TI reduced physical prototyping, and analysis time went from two weeks to four days per design. With less than a half hour of user effort, engineers are able to create a new design, run all of the simulations, and receive results.
    • The new simulation capabilities have driven notable enterprise savings.
    • The use of simulation has aslo brought gains to the top line, by demonstrating significant engineering expertise and competitiveness to end customers early in the sales cycle.

     
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    Company:

    BMW Group

    Products:

    Industries:

    BMW Group - High Performance Computing

    Overview:
    In early 2007 the computer assisted engineering process chain at BMW was reviewed in order to identify possible bottlenecks in the future caused by the increasing size of simulation models. Under the name “Model of The Day After Tomorrow” the group of functional design body and fitting developed the largest known FEM model for a system-benchmark.
    Challenge:
    Identify the theoretical limits and bottlenecks of today's computing rsoruces

     
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