Company:

Airbus

Products:

Actran TM

Industries:

Aerospace

Simulation Helps Airbus Optimize Acoustic Liners and Reduce Noise

Overview:

Noise is becoming a major obstacle to growth in air transport as increasing numbers of airports place restrictions on the amount of noise that can be generated by an aircraft during various phases of flight. Airbus is working hard to reduce aircraft noise such as by improving the nacelle acoustic liners used to minimize the fan noise radiated from the engine. The company has dramatically reduced the time required to design and evaluate optimized acoustic liners by moving to a simulation-based process using Actran acoustic simulation software developed by Free Field Technologies (FFT), MSC Software Company.

Challenge:

The acoustic liners that are built into the engine nacelle are fundamental in controlling fan noise. Acoustic liners present a major design challenge because they must address a large number of conflicting design requirements. Liners must provide high levels of noise reduction over a wide range of engine operating conditions and frequencies. Liners must also meet tight space restrictions and need to be as light as possible in order to limit fuel consumption. The liner is typically designed at a point when aspects of the airframe and engine are not completely defined so the liner design must be flexible enough to adapt to changes. The liner must be able to survive exposure to heat, cold, water, oil, and maintenance operations. Finally, the liner must be durable enough to deliver decades of service in the highly demanding aircraft engine environment.

Solution:

Liners are typically manufactured in two or three curved segments that are assembled with longitudinal splices. Simulation with Actran and other numerical tools helped to reveal the substantial impact of splices on forward fan noise and these simulations were confirmed with physical testing. These simulations made it possible to compute the radiated noise fields under all relevant engine operating conditions and predict the noise reduction in certification conditions. The design of the zero-splice concept, through numerical simulation, made it possible to significantly reduce the fan noise and the acoustic discomfort.

Results Validation:

Airbus developed an integrated numerical chain for Actran in order to streamline its use by acoustics engineers who are not numerical experts. The chain, called Automated Liner Optimization Chain for Nacelles Air Inlets and Exhausts (ANaNax), automates the simulation process from engine geometry to Actran results including prompting the user for all required information and performing validation checks on the data entered by users. “A typical optimization loop for the nacelle liner requires evaluation of 80 liner iterations and three flight conditions at a frequency range from 125 Hz to 5650 Hz which means we need to simulate several thousand different cases,” Suratteau said. “Robustness and accuracy of the simulations is critical so realistic 3D shapes, flows and boundary conditions are a must. ANaNax greatly reduces the time required for non- analytical experts to perform simulations and to check their work to be sure inputs are realistic. Computation time has also been drastically decreased by the implementation of a high performance computing (HPC) platform based on Westmere X5670 Infiniband technology with 5312 cores combined with the high scalability of Actran.

Benefits:
  • Reduce product development costs by avoiding expensive post-design changes.
  • Reduce test/analysis iterations
  • Improve performance predictions

 
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Company:

IDEA International

Products:

Dytran
MSC Nastran
Patran

Industries:

Shipbuilding

IDEA International - Explicit Analysis of Tsunami Survival Capsule

Overview:
In order to ensure that the capsule can withstand the harsh environment of a tsunami, IDEA engineers are using MSC’s simulation technology. “The use of MSC Nastran and Patran allows us to understand the performance of the capsule and reduce the test program substantially,” said Scott Hill, IDEA Engineering Director of IDEA, Inc. “Also, the analytical simulation results that MSC Nastran and Patran provides, allows us to greatly understand the structure and predict eventualities which may cause issues during a Tsunami event. As a result we can remove these issues during the design phase.”

Benefits:
  • Greater understanding of structural damage due to a variety of large impact events.
  • Less physical testing and prototypes due to accuracy of simulation.
  • Increased safety of vessel.
For more information please watch the Tsunami Survival Capsule Video.

 

Company:

Scania

Products:

Adams

Industries:

Automotive

Scania - Improving Heavy Truck Designs

Overview:
Scania uses simulation to evaluate a much greater number of vehicle configurations than was possible in the past. “We selected MSC Adams/Car because Adams provides the premier solver technology and has become the de fact standard in the automotive industry..MSC Adams/Car supports Scania’s modular vehicle configuration strategy by enabling us to model and simulate different vehicle configurations in a small fraction of time that would be required to build and test them.”
Benefits:
  • Significantly improve the handling, comfort and fatigue life of vehicles
  • Reduced stress levels in many parts, resulting in improvements in component life
  • Identify potential problems early in the design process and make corrections on the virtual model

 
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Company:

Knud E. Hansen

Products:

Adams

Industries:

Shipbuilding

Knud E. Hansen A/S - Safe Marine Operations in Wind Energy

Overview:
The Anholt Offshore Wind Farm is a Danish wind farm currently under construction, located in Kattegat, between Djursland and Anholt Island. Knud E. Hansen was contracted by MT Højgaard A/S to assess the Drill Rig’s waves induced motion while transported by HLV SVANEN, and to calculate the maximum tensions on the lashing cables for a maximum operational wave height.

“Adams Software helped us to understand the motion and forces involved by capturing the full gamut of real world complexities including rigid bodies, flexible bodies, springs, dampers, joints and all others mechanical components. The software never placed any limits on what I wanted simulated, yet it made it possible to assemble the complex model very quickly. ”

Mirco Zoia, Navel Architect & Offshore Eng., Knud E. Hansen A/S

Challenge:
Accurate assessment of complex mechanical systems that require a dynamic analysis
Solution:
Initially, the 3D Multi-body Dynamic model of the system composed by HLV SVANEN, the Drill Rig and its crane lifting components (Lifting Spreaders, Lifting and Lashing Equipment), was created in a CAD software and then imported to Adams. Densities and other material properties were given to the parts of the 3D Model. All the parts in motion were joined together with translation, revolving, spherical and cylindrical joints to simulate as close as possible the real behaviour of the system. The steel and fibre ropes of the system were defined as flexible dynamic bodies with the same material properties (density, young’s modulus, poisson’s ratio, and damping coefficient) as the actual ropes. The winch pretensions were defined using preloaded spring-dampers. Motions, constraints, wind forces and winch pretension loads were then applied to HLV SVANEN. The motion analysis was based on the HLV SVANEN maximum response motion previously assessed.

The dynamic analysis was carried out to assess the maximum displacement of the Drill Rig, and the minimum required winch pulling force to fulfill the requirements of the client and to safely carry out the necessary marine operations.
Benefits:
  • Ensure the safety of the marine operations
  • Reduce risks and costs of the wind turbines installation
  • Anholt offshore windfarm to become the biggest offshore windfarm in Denmark

 
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Company:

BioSimulations, LLC

Products:

Marc

Industries:

Medical Devices

BioSimulations, LLC - Simulation of a Molded Elastomeric Helical Anchor Nerve Clamp

Overview:
The ability to control, modify or block the signals from the receptors to the brain may be accomplished through selective electrical stimulation of a specific nerve path. MSC Software’s Marc nonlinear simulation solution was selected to generate the model, perform the analysis and post-process the results.
Challenge:
To evaluate a proposed design concept for an electro-mechanical device
Benefits:
  • Successfully check the model components and generate a final assembly of the model.
  • Performed model pull-off loading using incrementally applied large displacements.
  • Make results plotting easy using Marc post-processing features.

 
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Company:

Fokker Aerostructures

Products:

MSC Nastran
SimXpert

Industries:

Aerospace

In Summa Innovation & Fokker Aerostructures - New Methods for Simulation Automation

Overview:
In May 2011, MSC Software, In Summa Innovation, and Fokker Aerostructures entered into a close partnership. In the so-called “Fokker Virtual Lab” the three companies started to do serious research with MSC Software products SimXpert and MSC Nastran.

The goal of this first project was twofold:

1) Familiarization and testing of MSC Nastran

2) Familiarization with SimXpert to create a prototype for a process to automate the creation of a QA-sheet, the quality assurance of FEM models.
Challenge:
Investigate new simulation technologies for future use.
Benefits:
  • Created a prototype for a process to automate the creation of a QA-Sheet.
  • Researched new technologies in a joint effort between suppliers and users.
  • Developed the process of how to use SimXpert & MSC Nastran in the complete design process outside the production environment.
  • 50% reduction in report generation
  • Identification and reduction of errors

 
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Company:

Schindler

Products:

MSC Nastran
SimXpert

Industries:

Machinery

Schindler - The Ups and Downs of Finite Elements

Overview:
Schindler is a concern with business activities in all five continents and a market leader in the lift and escalator sector. Schindler’s offering ranges from passenger lifts suitable for small blocks of flats to sophisticated transport solutions for skyscrapers. Service lifts ensure the stress-free movement of goods and people in shopping centres, office buildings and railway stations. Bed lifts provide for the smooth and vibration-free movement of patients and equipment in hospitals. In industrial buildings, many of the hoists and small goods lifts in use are supplied by Schindler, while glass cabin lifts in tall buildings offer both a novel experience and a feeling of safety.
Challenge:
Find reliable & energy efficent solutions which make the optimum use of materials for complete lift systems
Benefits:
  • Simulate wall fixings of lifts and determine whether deformations and loadings remain within the permissable range
  • Model and evaluate a greater number of design variants using automated processes
  • Carry out static (strength) calculations, dynamic and vibration analyses with the aid of FE methods.
  • Construct consistent model

 
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Company:

TLG Aerospace, LLC

Products:

MSC Nastran
MSC Nastran Desktop
Patran

Industries:

Aerospace

TLG - Making Better Aircraft Everyday

Overview:
TLG Aerospace, LLC (TLG) is an aerospace engineering services company founded in 2008 in Seattle, Washington. TLG, ‘The Loads Group’ specializes in full vehicle analysis and optimization including static and dynamic loads, flutter, stability and control, aerodynamic design, Computational Fluid Dynamics (CFD) analysis, FAA certification and aircraft performance and handling qualities. TLG provides design, analysis and certification for new and modified aircraft and related aerospace products.

TLG’s primary customers are OEMs, thirdparty modifiers, and other companies who design, analyze, build and sell aircraft, aircraft modifications, and related products. TLG’s focus is on helping these customers get those products to the marketplace and in service as efficiently as possible. TLG routinely works with hardware-related groups such as manufacturing and test organizations. TLG engineers specify flight test instrumentation requirements and test conditions, act as engineering test crew for test flights, and prepare flight test reports within their disciplines.TLG also provides overflow capability for OEMs needing extra capacity, and helps new aircraft companies develop and validate their own loads and dynamics capabilities. TLG engineers have analytical and hands-on experience with over 100 aircraft models from more than 40 different manufacturers.
Challenge:
Determine design loads by involving a full aircraft analysis of the air pressure and inertia forces during prescribed maneuvers, either in the air or on the ground.
Benefits:
  • Faster design iterations
  • Efficient use of capabilities for aeroelastic analysis is used in all parts of the design process
  • More efficient aircraft design & analysis

 
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Company:

DEMA

Products:

MSC Nastran

Industries:

Aerospace

DEMA - Stamping Out Waste

Overview:

Design Manufacturing SpA (DEMA) is a major tier-one aerospace supplier to Bombardier, Alenia Aermacchi, AgustaWestland and other leading aerospace original equipment manufacturers. The company recently faced a challenge with an aluminum acoustic barrier which is part of a jet engine nacelle. DEMA performed finite element analysis (FEA) with the MSC Nastran implicit nonlinear solver which identified two problems in the initial design. These included a stress concentration around a radius and excess material beyond the dimensions of the finished part which would have required an expensive secondary operation.

Challenge:
  • Maintaining allowable stress concentrations during metal stamping procedure
  • Reducing expensive secondary operations
Benefits:
  • Reduced prototyping and manufacturing costs
  • Substantial reductions in design time

 
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Company:

University of Cassino

Products:

Dytran

Industries:

Medical Devices

Understanding Eye Injuries as a result of Blunt Impact Trauma

Overview:
The detachment or tearing of the retina in the human eye as a result of a collision is a phenomenon that occurs very often. The project was aimed at understanding the actual processes of dynamic deformation taking place in the human eye when subjected to blunt impact. For this project an FEA model was developed in MSC’s Dytran software starting from 3D measurements of real human eyes. The results of the model were then compared to measurements with respect to the deformation at different times and to the residual velocity of the projectile during the rebound phase.

Challenge:
  • Over 60% of all eye injuries are caused by blunt impact, i.e. impacts with objects of various kinds that do not cause a perforation of the globe.
  • Based on evidence of a patient who, despite having undergone the removal of the vitreous, had a clear macular hole resulting from a blunt impact, it was decided to investigate this phenomenon in more detail in order to validate the various hypotheses of damaging mechanism with the help of a MSC Dytran simulation.
Solution:
  • The computational model of the ocular globe was generated starting from an average size human eye represented with the help of the code MSC Dytran.
  • The preliminary results of the project indicate that the laceration of the retina mainly occurs due to the tension resulting from the reflection of compression waves in the moments immediately following the impact, and not necessarily due to the deformation of the whole eye.
Benefits:
  • The availability of a reliable and validated model for the simulation enabled the research team to understand in detail the pathogenesis of the blunt impact phenomenon, which is particularly difficult to reproduce in a controlled and instrumented manner through physical tests in the laboratory.
  • Practical applications of this study are to be found especially in the military industry, for example in the design of advanced security systems for personnel and for helicopter pilots in the event of a crash landing.

 
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Company:

NASA/JPL-Caltech

Products:

Adams

Industries:

Aerospace

Only One Chance to Get it Right - NASA/JPL-Caltech

Overview:
NASA Jet Propulsion Laboratory (JPL) engineers simulated this final sky crane landing sequence of the Curiosity Mars Rover using MSC Software’s Adams multibody dynamics software. The simulation identified problems with the initial concept design and guided engineers as they resolved these issues and made the design more robust. The simulation was also used to validate the landing sequence and determine loads on subassemblies and components. The controls software code that guides the mission through the sky crane landing sequence was integrated into the Adams environment to validate and tune its performance. The accuracy of these simulations was proven by the success of the mission.

Challenge:
Validate the landing sequence and determine loads on subassemblies and components on the Curiosity Rover during its historic landing sequence on Mars.
Solution:
The engineers at JPL were not able to test most of the critical mission events on Earth so they had to rely upon MSC Software simulation technology to design most of the hardware and control sequences for this mission.
Benefits:
  • Optimize the design of every component to ensure their ability to withstand loads and successfully perform their mission.
  • Determine the bounding limit design loads that could be expected on every component.
  • Ensure that there was no possibility of contact between the flight hardware.

 
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Company:

General Dynamics Land Systems

Products:

Adams

Industries:

Defense

General Dynamics Land Systems

Overview:
The gun turret drive on a combat vehicle presents a very complex design challenge. When the vehicle travels over rough terrain, the gun turret drive compensates for the vehicle’s motion and keeps the gun pointed precisely at its target with 99.5% accuracy. In the past, General Dynamics Land Systems (GDLS) engineers used separate simulations to evaluate different aspects of the gun turret drive design, such as the rigid body structures, flexible bodies and control system. But engineers were not able to evaluate the performance of the gun turret drive as a complete system until they built and tested prototypes.
In the last few years, GDLS engineers have begun using a multidisciplinary-based co- simulation process to model the operation of the gun turret drive system while taking into account all of the key physics involved in its operation. The centerpiece of this simulation effort is the use of Adams dynamics software to model the rigid bodies, nonlinear joints and contacts in the gun turret drive.
Challenge:
Create the multidiscipline model for the gun turret drive. Early prediction of the jamming condition in the gun turret drive.
Solution:
In this highly complex weapons system, the ability to account for nonlinearities is critical to accurate simulation. The key advantage of Adams is that it accounts for the nonlinearities in this system through its ability to model nonlinear on/off contacts, large displacements associated with part deformations and nonlinear materials.
Benefits:
  • Quick verification of results
  • Shorter product development cycle
  • Cost saving

 
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Company:

BL Advanced Ground Support Systems

Products:

Adams
FEA, AFEA and TFEA
MSC Nastran
MSC Nastran Desktop
SimXpert

Industries:

Defense

BL Advanced Ground Support Systems

Overview:
BL Advanced Ground Support Systems specializes in developing vehicles used by air and ground forces. In the past, when the company relied on outside consultants for simulation support, it found that considerable time was wasted in communications and waiting for simulation results. Building the internal capability to do multibody dynamics and multidiscipline simulations with MSC Software’s Adams and SimXpert has been key to developing the capacity to design vehicles to its own specifications that can later be configured to meet a range of specific customer requirements.
Challenge:
Develop a robotic vehicle platform that will handle a wide range of military missions without requiring a human driver.
Solution:
Support provided by MSC Software was crucial to BL’s success. With the help of SimXpert, the engeneers at BL were able to sped less time translating and fixing CAD data, and more time devoted to developing new vehicle concepts and bringing them to the market faster.
Benefits:
  • Cost & time savings
  • Design optimization
  • Greater understanding of design behaviors

 
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Company:

ITW Delfast group

Products:

SimXpert

Industries:

Automotive

ITW Delfast group

Overview:
The ITW Delfast group designs and produces engineered plastic and metal fasteners for the automotive industry. The plastic fasteners typically are secured by a clip snapping into contact with a serrated shaft. These fasteners present a difficult design challenge because of the complexity involved in multiple contacting bodies undergoing large deformations with sliding contact.
Challenge:
  • Bringing non-linear finite element analysis to the designers
  • Automation of CAE processes including model setup, analysis and report generation
Solution:
Ostergren and MSC worked together to develop a template that provides a high level of automation while enabling users to interact with the analysis in order to ensure that it accurately represents the current design. The template fully automates the process of defining and naming parts and properties, generating symmetry constraints, defining contact bodies, load set generation, analysis setup, job submission and report generation.
Benefits:
  • Automated simulations and report generation make engineers more efficient
  • Substantial reductions in analysis time
  • Improved design performance
  • Reduced prototyping and manufacturing costs

 
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Company:

Polestar Racing/Volvo

Products:

Adams

Industries:

Automotive
Motorsports

Polestar Racing/Volvo - Racing to Win

Overview:
Polestar engineers spend months over the winter offseason struggling to squeeze a few extra tenths of a second per lap out of their cars. One of their most valuable tools is MSC Software’s Adams/Car which they use to evaluate different vehicle designs in critical areas of the track such as the corners.

Before we used Adams/Car we found that only 40% to 50% of what we tried at the test track turned out to be effective. Since we began using Adams/Car, 80% to 90% of the ideas that we try on the track succeed.”

Per Blomberg, Manager Chassis Development, Polestar Racing
Challenge:
In the past Polestar used hand calculations and spreadsheets to perform some very rough estimates of vehicle performance to attempt to select the best designs for testing. “These tools provide some value in sharing knowledge but contribute little towards predicting the performance of a prospective design,” Blomberg said. “We have long used simulation at the component level to, for example, evaluate stress and deformation in suspension components, but we were not aware of the possibility of predicting the performance of the complete vehicle until the MSC representative introduced us to Adams/Car.
Solution:
Engineers create a model of the vehicle in Adams/Car to match a configuration that they are interested in evaluating. One of the key aspects of the vehicle is the pickup points in the suspension, the points where the suspension link arms attach to the chassis. The front end of Polestar’s current vehicle has a Macpherson strut with a damper that attaches to the body under the hood and a lower link arm that attaches to the hub. The rear end uses a multilink suspension. The locations of the pickup points are limited by the rules of the racing series. Polestar sometimes simulates vehicles outside these limits in order to get a better understanding of the sensitivity of the vehicle performance with respect to certain design parameters. Other parameters whose impact is evaluated during simulation include the spring thickness, anti-roll bar thickness, camber angles, tire properties and weight distribution in the vehicle
Benefits:
  • Quickly Build & Test Virtual Prototypes
  • Analyze Events
  • Evaluate Small-Scale Improvement

 
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