Company:

Tesat-Spacecom

Products:

MSC Apex Generative Design

Industries:

Aerospace

Satellite technology: Lightweight construction for weightless conditions

Overview:

The enormous efforts needed to send technical equipment into space require a particularly high degree of lightweight construction. Generative design allows these complex optimisation processes to be significantly simplified and automated. The potential offered by this approach is demonstrated by a case study from German satellite specialist Tesat-Spacecom.


 
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Company:

Vellore Institute of Technology

Products:

Adams

Industries:

Automotive

Virtual prototyping of Magneto-Rheological (MR) damper by comparing realistic motion behavior using Adams

Overview:

In automotive design, the seat plays an important an important role in ensuring passenger comfort, especially in the case of long-distance drives. Most OEMs today focus on static comfort of seats, while paying limited attention towards dynamic comfort. This project by the students of VIT helped shed some more light on importance of dynamic comfort.

Using simulation tools from Adams, the students designed a model to scrutinize the performance of a semi-active seat suspension system using a PID controller and a newly designed magneto-rheological fluid damper. The software helped the students to test their model seamlessly and cost effectively on real time basis, using virtual prototyping and virtual testing, before physical prototyping and testing.


 
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Company:

SABIC

Products:

Digimat

Industries:

Medical Devices

Anisotropic explicit simulation, considering manufacturing effects and nonlinearity

Overview:

For short fiber reinforced composites, SABIC uses Digimat to define nonlinear strain rate dependent material model for accurate prediction of part performance under impact loads


 
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Company:

SABIC

Products:

Digimat

Industries:

Medical Devices

Accurate prediction of part performance in response to static loads for short fiber reinforced composites

Overview:

SABIC uses Digimat for high-fidelity anisotropic simulation, considering manufacturing effects and non-linear material behavior


 
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Company:

Thai Steel Cable

Products:

Adams
MSC Nastran

Industries:

Automotive

Designing a plastic robotic arm using Adams & MSC Nastran

Overview:

MSC Software helps Thai Steel Cable apply Multibody Dynamics & Finite Element simulations to design the structure of a Robotic Arm with Polyamide


 
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Company:

The FormulaStudent Team from Paderborn University

Products:

MSC Apex Generative Design
Simufact Additive

Industries:

Motorsports

Race sports: Catch the highest performance with lightweight design

Overview:

From load simulation via generative design to manufacturing and verification – optimisation of a wheel carrier for FormulaStudent with MSC Software


 
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Company:

Avio

Products:

Actran Acoustics
MSC Nastran

Industries:

Aerospace

MSC Software helps Avio ensure the VEGA launcher's structural integrity

Overview:

Using MSC Nastran and Actran – engineers at Avio were able to accurately predict the effect of noise vibrations on the structural integrity of its launchers.


 
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Company:

Northrop Grumman Mission Systems

Products:

MSC Apex

Industries:

Aerospace

MSC Apex makes hexahedral meshes practical and cuts the entire workflow time in half

Overview:

Lacking a productive tool for taking advantage of hex mesh in product development missions, engineers reviewed and benchmarked MSC Apex versus their legacy workflow and tools, and found quite a few benefits from using the new workflow.


 
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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 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:

Aerospace Industry

Products:

MSC Apex Generative Design

Industries:

Aerospace

Enabling reliable aircraft structures with generative design

Overview:

The aerospace industry is one of the most demanding industries in terms of quality and reliability. There is an enormous potential for the use of additive manufacturing as this technology gives the opportunity to create function-oriented part designs for a highly purpose-oriented geometry.

In a research project of the Direct Manufacturing Research Center in combination with an industrial partner, such a function-oriented component optimisation was developed using MSC Apex Generative Design. A fixture has been identified and selected for redesign which is installed less than 100 times per year. The previous design consists of a two-part assembly in which the individual components are milled from a solid aluminum block and then connected to each other by several rivets. This produces a correspondingly high amount of waste in the production process.


 
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Company:

Tyvak Nano-Satellite Systems, Inc.

Products:

MSC Apex

Industries:

Aerospace

Tyvak engineers use MSC Apex to reduce satellite mass by 5 to 10 percent

Overview:

Tyvak considered and evaluated MSC Apex because of its “smart” nature, ease of use, and seamless compatibility with MSC Nastran. When utilizing MSC Apex for pre-/post-processing an FE model, engineers conveniently achieved firstrun- success in simulations.


 
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Company:

Inteva

Products:

Digimat

Industries:

Electronics

Influence of fibre orientation in the design of a collector box ground cable retention feature

Overview:

The collector box ground cable retention feature was improved over the earlier design further for better performance. An economical and reliable feature was to be redesigned to meet the requirements of the intended retention force which ensures that the feature is always under pre-stressed condition. In the process of design modification of this existing feature, several parameters like length of the arm, width and thickness at the root, etc. were considered. The retention forces were estimated through a structural simulation using non-linear isotropic material properties (glass-filled Polybutylene Terephthalate material). The extracted retention force for this redesigned feature was found to be exceeding the intended force value which in turn caused the failure of the feature. However, the physical test results showed that the features were safe, and the retention forces measured were also in the acceptable range. Hence to understand the influence of fibre orientation in such glass-filled components; extended FEA studies were carried out using Digimat software.


 
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Company:

Scania Bus

Products:

Actran Acoustics
MSC Nastran

Industries:

Automotive

Increase Commuters' Comfort Thanks to New Actran NVH Capabilities

Overview:

Numerous cities around the world are facing changes in the way urban transportation is considered. The need for lower particle emissions and for a safer and quieter environment are key concepts shaping the future of mobility. Among sustainable transport system enablers, recent technological progresses in electric and autonomous vehicles are accelerating user adoption.

Designing electric and autonomous vehicles is a challenge for the NVH design and engineering teams that need to cope with increasing acoustic comfort expectations while dealing with new noise sources and structural designs.

For Scania, a world-leading provider of transport solutions, the acoustic comfort of drivers and passengers has always been of great importance in the design engineering process. Not only is a pleasant drive critical for buyers or commuters, but it also impacts health and productivity. Scania is focused on getting their vehicles up to speed with today’s acoustic expectations by addressing the level and quality of vehicle interior noise. The development of increasingly optimized NVH properties is supported by extensive testing and by the introduction of new methods based on vibroacoustic simulations. In this endeavor, the calculation team at Scania Bus decided to use the new capabilities of Actran Virtual SEA approach to assess the vibro-acoustic performances of their design at mid- and high frequencies.


 
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Company:

MBFZ toolcraft GmbH

Products:

Simufact Additive

Industries:

Machinery

Flexibility through additive manufacturing: How simulation supports 3D prototyping

Challenge:

Transfer prototyping into serial manufacturing. Using the example of a filigree blade geometry we consider the challenges of traditional manufacturing.

Solution:

Generate variant diversity with the help of additive manufacturing. This technique helps you save time and money. Reach the first-time-right approach through simulation.


 
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Company:

EDAG, voestalpine, and Simufact

Products:

Simufact
Simufact Additive

Industries:

Automotive

LightHinge+: Additively manufactured hood hinge

Overview:

In a common innovation project called LightHinge+, EDAG Engineering, voestalpine Additive Manufacturing Center and Simufact Engineering jointly developed a new hood hinge. The project team used the extended possibilities of additive production in order to re-think the component, to re-construct it and subsequently to manufacture it additively. As a result, the new hinge was built with 50% weight reduction compared to the original part, and with the additional advantage to have nearly the entire pedestrian protection functionality integrated within one part. It takes fewer component parts and less assembly steps to build the new hood hinge.

The design was done supported by topology optimization, which finally led to a bionic-like extremely filigree and lightweight structure. Such parts can only be reasonably produced by utilization of AM technology.


 
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