Company:

GE Tidal Turbines

Products:

Adams
Adams Machinery
MSC Nastran

Industries:

能源

Adams Simulation Helps Reduce Need for Physical Testing of Tidal Turbines

Overview:

There are many coastal areas where local geography constrains the movement of ocean tides, resulting in very strong currents. Water is 800 times denser than air so these currents could potentially generate a lot of electricity. GE tidal turbine technology brings proven concepts and industry-leading knowledge to tap into this reliable and predictable energy source. The Oceade* tidal turbine features a buoyant nacelle that enables the turbine to be easily towed to and from the operating site. This eliminates the need for specialist vessels, reducing the cost of installation and maintenance. GE has proven its Oceade* turbine operating at a full 1 Megawatt, injecting over 1.2 GWh of electricity to the grid. This test program has enabled GE to validate the installation and retrieval processes, autonomous running, and the performance and power curve of the new turbine.

Results Validation:

The simulation results provided the information to evaluate the dynamic response of the proposed design prior to investing in a physical prototype and testing. Based on the results, GE design assumptions and margins were verified and opportunities for optimization identified. The company is now moving forward to the testing phase confident that the design has been “de-risked” from a dynamic as well as a kinematic standpoint. “This project was a great working experience that allowed the GE team and MSC consultants to share knowledge and gain experience from their own respective expertise,” concluded Valentin Radigois, Lead Engineer, Mechanical- Components, GE Renewable Energy.

Benefits:
  • Predict the dynamic behavior of the turbine including multiple flexible components
  • Integrate real bearing and gear effect including 3D contacts
  • Simulate various dynamic loads to evaluate complex behaviors and coupling effects
  • Performed modal analysis of the full structure

 
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Company:

Products:

Simufact

Industries:

能源

成形仿真技术简化大型锻件制造工艺

Overview:
用于集装箱船的大型柴油发动机曲轴通常以中小批量方式锻造。由于每个曲轴都有其具体特征,因此这些曲轴的制造与设计是一项挑战。而这正是成型仿真技术大显身手之处。Wildauer Schmiedewerke GmbH 是欧洲少数几家能够制造此类“卡钳”的公司之一。Wildauer 的旗舰型压机是一款 630 kJ 锻锤,能够锻造重达 3500 kg 的模锻部件。Wildauer Schmiedewerke 的客户几乎囊括所有为造船、柴油机车及发电机制造大型柴油发动机的厂家。 过去六年里,Schmiedag 一直使用 Simufact.forming 进行成型仿真。自那时起,该公司对锻模中的材料流、飞边形成以及不同锻模及工件形状的变形进行了虚拟分析和优化。以前是先制作模具,然后根据熟练工人所掌握的知识进行锻件试验。这种方法需要三到四个改型。如今借助仿真,最多只需要两个改型就可以得到满意的结果。

 
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Company:

Products:

Simufact

Industries:

能源

通过成型仿真技术实现工艺优化

Overview:
1996 年,Uponor公司决定开始自行生产以前一直从外部厂商处购买的金属配件。原因在于这样可以更好、更灵活地应对此类零部件的需求。首先,在开姆尼茨的弗劳恩霍夫研究所(IWU)的支持下完成了开发成型工艺所需的仿真。然后由 Uponor 对零部件进行测试和生产。 经过一段相对较短的时间后,可以很明显地看出,Uponor公司自己直接进行仿真更为有利。公司内部进行仿真在灵活性和时间方面能为工艺开发带来许多优势。此外,还可以大幅降低长期的工艺成本。如今,在从事锻造业务 12 年之后,Uponor 采用了预先对锻造工艺进行仿真和优化的方法,事实证明这种方法不仅可靠,而且效率极高。Uponor 将 Simufact.forming 用于成型过程的仿真,该仿真环境由位于汉堡的 Simufact Engineering GmbH 提供,专门针对金属成型行业的实际应用而开发。借助这一软件,可在进行首次试制之前即完成对成型工艺和模具进行评估和优化。

 
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Company:

Tower International

Products:

Marc

Industries:

汽车

Automotive Supplier Uses Marc to Improve Design of Stamping Tools

Overview:

Stamping operations used to form metallic automotive components can generate forces of thousands of tons. The tools (die components) that form these products must be able to withstand this cyclic loading environment for the life of the vehicle program. At the same time, it is important to optimize the tool design in order to be competitive. The evolution of higher strength materials also adds to the challenge. The large loads involved in forming these components increase the challenge of designing robust tools. Both linear and non-linear analysis must be used to support the tool design process.

Results Validation:

“In order to get reliable predictions, we prefer to use the nonlinear software Marc to solve these types of problems because it accounts for the inherent nonlinearities of materials experiencing plastic strain,” said Yueming Cheng, Computer Aided Engineering Engineer at Tower International. “In years of using Marc and Mentat, I have found it to be capable of accurately simulating a wide range of nonlinear product behavior under static, dynamic and multi-physics loading scenarios. Marc is also one of the commercial solutions in markets I am aware of that has robust manufacturing simulation capabilities, with the ability to predict general damage, failure and crack propagation.”

Benefits:
  • Accurate simulations help reduce risk of downtime and lost revenues, by predicting regions of potential failure
  • Get the design right the first time with computer models and deliver reliable performance

 
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Company:

比利时建筑研究所

Products:

Actran Acoustics
Actran AeroAcoustics
Actran DGM
Actran for Trimmed Body
Actran SNGR
Actran TM
Actran VI
Actran VibroAcoustics

Industries:

汽车

Actran 帮助改善对房间之间振动传递的预测能力

Overview:
比利时的住宅标准((NBN-S01-400-1(2008))采取了严格的声学要求,这给建筑师们带来了严峻的挑战。此标准尤其针对各个房间之间的整体隔音性能制定了苛刻的要求,该性能主要是由直接传声和侧墙传声决定的。侧墙传声是指在其中一个房间所产生的声波会激励墙壁结构生成结构波,并经由该结构传播结构波。随后墙壁会向隔壁房间辐射声音。两个相邻房间之间有四个接合部,每个接合部有三种侧墙传声路径,总共 12 个路径。当声波穿过接合部时,其能量会衰减,衰减程度由振动衰减指数 Kij 确定。

 
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Company:

LuK USA LLC、Schaeffler Group Automotive

Products:

Simufact

Industries:

汽车

LuK 采用 Simufact 成型仿真技术实现制造工艺创新

Overview:
在汽车行业,创新的产品设计与制造解决方案是保持竞争力的根本所在。所加工的零部件和子系统不仅要达到最高质量标准,还要具有价格竞争力。由于这些零部件通常为量产,因此只要有一个零部件失效,就可导致非常昂贵的召回,甚至会有损于厂商的声誉。因此要求设计及仿真解决方案所提供的环境能够提供一种成熟而可靠的方式,既能储备更多有关最佳设计及制造工艺的知识,又能够让工程师找到创新的解决方案。

 
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Company:

上海交通大学

Products:

Adams
Adams Machinery

Industries:

机械

上海交通大学为核电站救援行动开发有腿机器人

Overview:
上海交通大学的研究人员,其中包括上海交通大学机械系统与振动国家实验室主任高峰博士以及上海交通大学博士后研究员潘阳博士,设计了章鱼 III 六腿机器人,可用于在核辐射、火灾及水下等极端环境中进行移动、搜索、探测、修理及救援。六腿章鱼 III 机器人可利用有腿机器人的非常规能力,例如横动崎岖地形、克服障碍、进行垂直爬升以及翻倒后自动站立等。

 
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Company:

Demshe Forge Inc.

Products:

Simufact

Industries:

机械

Simufact.forming 帮助 Demshe Forge 首次试制即获得正确的锻造工艺设计方案

Challenge:
加工制造过程中,锻件出现了折皱,零件报废
Solution:
锻造工艺仿真及重新设计
Results Validation:
采用 Simufact.forming 仿真环境对这一工艺重新进行设计及优化。Demshe Forge 的工程经理 Ramachandran 是设计和仿真方面的专家,他建立仿真成型工艺过程,并且优化工艺参数,避免在关键区域出现折叠,零件最终达到了理想的形状。

 
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Company:

Products:

Simufact

Industries:

机械

全球领先的高尔夫球用具制造商--Cleveland Golf应用MSC软件将设计效率提高3000%

Overview:
Cleveland Golf 的目标是成为全球首屈一指的高尔夫球用具制造商。公司需要对大量的设计可行性进行彻底、快速的评估,以便为各种技能水平的高尔夫球手生产顶级的球杆。为此,公司需要Cleveland Golf 性能研究工程师及其团队每月都能创作、制作并测试众多样品,以便快速优化高尔夫球杆的设计。考虑到制作样品所需的前期时间和成本,传统的“制造与试验”设计方法已无法满足这一要求。通过使用MSC Nastran、Patran、Dytran等有限元分析软件,如今,Jeff 的性能研究团队在一天内就可以完成一种新式或者改进后的高尔夫球杆的建模和虚拟测试——设计效率提高了3000%!

 
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Company:

Shanghai Jiao Tong University

Products:

Adams

Industries:

机械

Chinese University Develops Legged Robot for Rescue Operations in Nuclear Plants

Overview:

Shanghai Jiao Tong University researchers including Dr. Gao Feng, Director of the Chinese National Laboratory of Mechanical System and Vibration at SJTU and Dr. Yang Pan, Postdoctoral Research Fellow at SJTU, have designed the Octopus III six-legged robot for moving, searching, detecting, repairing and rescuing in extreme environments such as nuclear radiation, fires, and underwater. The six-legged Octopus III robot takes advantage of the unusual capabilities of legged robots such as traversing uneven terrain, overcoming obstacles, performing vertical climbs, and righting themselves after turning over.

Legged robots are substantially more difficult to design than wheeled robots because they require complex mechanics and control strategies to maintain their equilibrium, orientation, efficiency and speed. The Octopus III’s six legs each have an identical drive mechanism consisting a parallel mechanism with three limbs. Each leg has one UP limb with a universal joint and a prismatic joint connected in series and two UPS limbs with a universal joint, a prismatic joint and spherical joint connected in series.

The robot is controlled by an onboard computer running the Linux operating system that communicates wirelessly with a remote computer running the Windows operating system. Orders such as move forward or turn left can be issued to the robot through a human machine interface (HMI) on the Windows computer. The onboard computer contains optimized kinematics and dynamic models of the robot and controls the robot’s 180 servo motors. The robot weighs about 270 kg, can climb a 20 degree slope and walks at 1.08 km/hr.

Results Validation:

The SJTU researchers tested the prototype under a wide range of conditions such as turning valves and switches and carrying loads of up to 500 kilograms in order to evaluate its fitness for proposed missions. The physical experiments showed that the performance of the prototype closely matched the Adams predictions. “If we had not used Adams to optimize the design prior to building the prototype, we would probably have needed five additional prototypes at a cost of $100,000 each to get the design right,” Pan said. “With Adams, the first prototype worked exactly as intended so we did not have to make a single change.”

Benefits:
  • The Adams/View command language works well for parametric modeling of robots
  • The performance of the prototype closely matched the Adams predictions
  • Applying Adams simulation early in their robot design saved five additional prototypes at a cost of $100,000 each

 
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Company:

Auburn University

Products:

Adams

Industries:

消费品

Sample of Auburn University Projects Utilizing MSC Adams

Overview:

Auburn University fielded a senior design team working to compete in the 2016 AFRL University Design Challenge. The senior design team designed and constructed the TRIAD (Tactical Rope Insertion Assist Device) to assist soldiers in a rapid decent. During the design process, Adams was utilized to model the flexible rope and the TRIAD and simulate how the device would perform. The flexible rope was modelled using beam elements with material properties that replicated the behavior of the actual Nylon rope used in practice. An image of one of these simulations is provided in Figure 1. The weight of the person using the device is represented by the addition of the weight highlighted in green. Scripts were developed in the form of command files that would enable an Adams user to enter a variety of parameters for the rope for quick model building and further simulations. These simulations revealed some problems in the preliminary designs that were also seen in testing, and these problems were subsequently addressed for the final design and competition prototype.

Auburn University worked in developing user written subroutines and an Adams plugin that would predict the wear rates of objects rattling inside of an enclosure. An example of this includes a projectile with attached shoe (Figure 2), that can slide out from the enclosure upon release. During transport the projectile could rattle causing wear of the enclosure. An experimental wear study was performed to determine wear coefficients, which were employed in an Adams simulation to determine contact forces, contact area, wear rate and total wear over time.

We have worked with them on undergraduate capstone design projects and graduate student research projects, where we design and build a physical prototype, run experiments and performance studies on those, and virtual prototype in Adams.
David Beale, Professor, ME

 
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Company:

Interseals

Products:

Marc

Industries:

汽车

Gasket Manufacturer Delivers Product 16 Weeks Earlier by Reducing Prototype Iterations with Marc FEA Simulations

Overview:

The traditional approach for suppliers to the automobile industry has been to build parts according to drawings provided by original equipment manufacturers (OEMs). Today, OEMs are delegating much more of the design responsibility to suppliers. This trend significantly changes the role of suppliers who, instead of competing primarily on quality, price and delivery time, are now often judged based on their ability to develop an innovative design that can meet the OEM’s requirements and be produced at a high level of quality and a low cost.

As a leading supplier of gaskets to the automotive industry and other markets, Interseals responded to these trends by increasing the size and capabilities of its engineering team. Yet, in the past, the company still faced difficulties in meeting its customers’ requests for innovative and economical designs. Gaskets are difficult to design because rubber components can undergo large deformations under load, sustaining strains of up to 500% in engineering applications. The load-extension behavior of rubber is extremely nonlinear and time and temperature dependent. Previously, when Interseals engineers based their initial designs on experience and handbook formulas, they usually found that the initial prototype did not meet the customer’s requirements. Typically, it took two more iterations to get the design right. Each design iteration cost an average of 5,000 Euros in tooling expenses and took between six and eight weeks.

Results Validation:

Interseals engineers shared the simulation results with the customer and the customer gave the go-ahead to build the mold. When the mold was completed, Interseals made a number of prototypes and provided them to the customer. “The customer tested the prototypes and said that they met every requirement,” Izzo said. “Getting the design right the first time saved an estimated 10,000 Euros in additional tooling costs and made it possible to deliver the gaskets 16 weeks earlier than if 2 additional prototype iterations had been required as was normal with our previous design methods.”

Benefits:
  • Marc has been capable of predicting the complex nonlinear behavior, while taking into account time and temperature effects and calculate compressible and incompressible material models based on test data.
  • Using simulation allowed the customer to save an estimated 10,000 Euros in additional tooling costs and made it possible to deliver the gaskets 16 weeks earlier than with the previous design methods

 
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Company:

Tenneco Inc.

Products:

Actran Acoustics

Industries:

汽车

Exhaust Active Noise Cancellation

Overview:

An automobile’s exhaust system is becoming more and more critical to its success in the marketplace. Most important, the sound produced by the vehicle serves to a considerable degree as the signature of the brand. For example, an auto enthusiast can recognize the approach of a Bentley or Ferrari with his or her eyes closed. Purchasers of lower-priced vehicles may not be quite so finicky but they still expect to hear a certain sound when they start up the engine. Meanwhile, automotive original equipment manufacturers (OEM) are being forced by government regulations to reduce the levels of noise emitted from the tailpipe. Automakers are also hoping to reduce the back pressure of exhaust systems in order to achieve improvements in fuel economy.

It’s becoming increasingly difficult to meet these often conflicting goals using conventional passive exhaust system technology which relies upon the use of perforated tubes and chambers to filter out acoustic waves. Automotive original equipment manufacturers (OEMs) are looking at active exhaust systems as a way to address these issues. Active exhaust systems use a loudspeaker driven by a microprocessor to cancel out unwanted sound generated by the engine as well as to produce more desirable sounds. A key advantage of active exhaust systems is that they can be controlled by software to adjust the output of the loudspeaker to deliver just the right sound under a wide range of different operating conditions.

Results Validation:

“Actran has enabled Tenneco to develop a process for electroacoustic simulation of an active exhaust system including the loudspeaker and housing that correlates very well with physical experiments,” said Nicolas Driot, Senior Core Science Engineer for Tenneco. “We are now using simulation to develop our next generation active exhaust system. Simulation will make it possible to evaluate the performance of many alternative design concepts in a minimal amount of time without the expense of building physical prototypes. This should make it possible to improve the performance of the exhaust system beyond what can be achieved with the traditional process where only a few different design alternatives can normally be evaluated. Simulation will also make it possible to bring new products to market faster.”

Benefits:
  • Actran results match very closely with physical test measurements both when modeling the loudspeaker alone and then when simulating the loudspeaker integrated it in a complete exhaust system.
  • Simulation allows evaluating the performance of many alternative design concepts for active noise cancellation in a minimal amount of time without the expense of building physical prototypes.

 
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Company:

Leyland Trucks, Ltd.

Products:

Adams
Adams Car

Industries:

重型装备

Building Better Trucks - Simulation at Leyland Trucks Expands Analysis, Cuts Design Time, and Reduces Physical Prototypes

Overview:

As one of the UK’s leading manufacturing companies, Leyland Trucks Ltd. is PACCAR’s established center for light and medium-truck design, development, and manufacture. Leyland used MSC ADAMS to access ride behavior of trucks earlier in the design cycle. In addition to studies of detailed procedures such as cab tilt, lane-change maneuvers, and ride comfort, MSC ADAMS simulation allowed Leyland to rapidly assess the effect of minute changes in suspension, wheelbase, tires, or payload position. For Leyland, the use of VPD tools led to significant benefits in terms of final design quality and considerable time savings.

Challenge:

As design technology has improved, the details of the truck have evolved almost beyond recognition. For instance, new materials have been introduced in recent years, leading to global initiatives to reduce weight through the use of these advanced high-strength steels. Other design details are changing – trucks are now using disc brakes rather than drums – and Leyland engineers must balance incorporating these details while improving quality and still keeping costs under control.

Solution:
  • A full MSC ADAMS truck model contains a flexible body and chassis, springs, roll bars, axles, cab and engine suspension, the steering mechanism, and any frequency dependent rubber mounts. Extra detail, such as brakes, propeller shafts, and out-of-balance engine forces can be included on an ‘as needed’ basis.
  • Simulation also allows several aspects of the operation of crane-bodied vehicles to be better understood, such as vehicle stability on slopes and uneven surfaces, the need for stabilizing legs, and the effects of loading and unloading.
Benefits:
  • Significant benefit in terms of final design quality,
  • considerable time savings
  • A recent project named LF was completed two years faster than the previous equivalent one – in a four-year design cycle rather than six.

 
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Company:

Standard Profil and Bias Engineering

Products:

Adams
Marc

Industries:

汽车

Co-Simulation Helps Win Order to Supply Seals for a New Model Vehicle

Overview:

The amount of effort required to close the doors of an automobile is critical to the consumer’s perception of its quality. If too high a closing velocity is required, the customer may have a negative impression of the car and the potential also exists for an unpleasant noise to be created by closing the door. The goal for most automobile manufacturers is to require a relatively low effort to close the door while at the same time meeting weather sealing and acoustic insulation requirements.

Results Validation:

“The results of the cosimulation were provided to our customer and helped win the order to supply seals for a new model vehicle,” said Dr. H. Tuncay Yüksel, Design Director for Standard Profil. “Now that the simulation process has been developed it will be possible to simulate new seal designs in much less time and at a lower cost than physical prototyping. This will make it possible to evaluate more design alternatives to improve door closing performance as well as reduce the time and cost of the product development process.”

Benefits:
  • Adams-Marc cosimulation helps the engineers accurately evaluate the amount of effort required to close the doors, which is critical to the consumer’s perception of its quality
  • Co-simulation helps MSC customer to win order to supply seals for a new model vehicle
  • Users can now simulate new seal designs in much less time and at a lower cost than physical prototyping.

 
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