Company:

Products:

Adams

Industries:

Adams 有助于缩短疲劳试验的时间并降低成本

Challenge:
阿纳多卢五十铃的工程师们面临的挑战是对悬架进行优化设计,以便改进巴士的舒适性、操控性和安全性,同时确保悬架、底盘及车身零部件的疲劳性能。过去设计悬架时,需要组装样机,并且样机要完成单移线试验等标准试验。通过安装仪表的车辆来采集道路荷载数据,然后将这些数据作为四柱试验台上加速试验的输入值来评估单个零部件,从而对零部件的耐用性进行评估。四柱试验台由四个液压执行机构组成,每个执行机构连接在车辆的一个车轮上。通过执行机构的移动来仿真道路施加在车轮上的加速度。这种传统方法带来的问题是,组装样机并进行实物试验不仅极其耗时且成本高昂。

 
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Company:

Products:

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

Industries:

早期设计中的悬架零件评估

Overview:
MSC公司最近开发了Adams-Marc联合仿真技术,这种技术在首次让几何非线性和材料非线性的结构特性在多体动力学仿真中得到实现。任何Adams和Marc的模型的都能在联合仿真中使用,而后处理又是相对独立的。Adams得到的结果在Adams中,Marc得到的结果在Marc的后处理中,或者ComputationalEngineering International 公司 EnSight 的后处理中能同时导入Adams和Marc的结果。

 
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Company:

Products:

MSC Apex
MSC Apex Modeler
MSC Apex Structures

Industries:

航空

NASA 工程师使用MSC Apex 将几何体清理所需时间从两天缩短至一小时

Overview:
美国国家航空航天局(NASA)太空发射系统(SLS)将成为史上最强大的火箭,可通过猎户座飞船运载多达四人的航天员乘组探测多个深空目标。SLS 以一种可发展的架构为核心进行设计,支持从77 公吨(77 吨)到130 公吨(143 吨)的各种推力型号。SLS 的芯级高200 英尺,直径27.6 英尺,将储存供四台RS-25 发动机使用的液氢和液氧。RS-25 曾用作航天飞机的主发动机,在135 次发射任务中成功率达100%。为能在SLS 上使用,对RS-25 进行了修改,通过大量改进措施将其功率从491,000 真空推力磅提升至512,000 真空推力磅。

 
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Company:

Products:

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

Industries:

重型装备
机械

从一年到三个月:Actran帮助轮式装载机缩短满足更严格噪声标准的周期

Overview:
一个主要拉美国家的噪声规定被修订到更低的水平,这促使CNH公司和其他的建筑设备制造商降低其产品的噪声排放。新规范使用一个公式基于机器的功率来确定其允许的声压级。在这种情况下,新的标准要求噪声相对于现有的设计降低大概6分贝。噪声测量基于ISO6393标准:六个麦克风分布于设备周围半球形的特定位置,在设备高怠速条件运行时测定声压级。CNH工程师进行了物理实验,以努力更好地了解噪声贡献源。工程师做了众多尝试,如开启和关闭风扇,开启和关闭液压泵,或掩盖排气来噪声以更好地了解噪声贡献源的相对重要性。这一系列分析表明风扇是头号噪声贡献源。

 
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Company:

Kiekert

Products:

Adams

Industries:

汽车

CAE 助力Kiekert设计汽车儿童座椅锁

Overview:

Kiekert公司拥有 150 多年的设计、开发及制造定制化锁系统的历史,在车门锁制造方面经验丰富。该公司的产品既有侧门锁、锁模块、后舱及发动机罩盖锁,也有用于侧门、平移门、行李箱盖的各种作动器及专业解决方案,其中最重要的是嵌入到后车门中的儿童安全座椅锁。以前,儿童安全锁啮合时,只能从外部打开后门。但在新车型上,可利用侧门锁内的小电机通过开关来电子激活或停用这种安全锁,开关通常位于司机侧的门锁开关附近。

Challenge:
侧门锁是一个复杂的系统,包括电缆、凸轮、杠杆机构、联轴节、作动器、齿轮、棘爪及锁闩。侧门锁通过激活棘爪和锁闩来锁住车门,使其绕着锁扣夹紧。锁扣为 U 形部件,固定在 C 柱上。而儿童安全锁是必须通过侧门锁实现的众多功能中的一个,它不仅能延长车辆寿命、在较大的温度范围内工作、符合噪声和振动要求,而且在出现碰撞时能够保持车锁的完整性。 过去,Kiekert的工程师采用运动学分析和工程手册公式等手工方法来进行侧门锁机构的初步设计。由于未能考虑到机构的动态特性,并且手册公式无法处理机构的具体几何结构,运动学分析的作用有限。因此,初期的机构设计操作通常无法满足设计要求。工程师完成初步设计并进行试验,然后根据试验结果进行反复设计,并制作出新样机。每一轮样机制作的高昂费用和冗长的研制周期都会增加设计新锁的时间和成本。采用这种设计及试验方法,设计一个锁机构需要 6 到 18个月。
Solution:
在 Adams 里可以定义机构的各种参数,以齿轮为例,可选择齿轮类型、位置、传动比、材料及连接方式。为加速锁的研发过程,Kiekert最近应用了虚拟样机技术,其关键特征是这种虚拟验证过程可以准确地仿真机构的性能,其中包括运动学和动态特性,同时还能考虑到机构的整体几何结构。Kiekert公司的仿真工程师 Darius Schendzielorz 首先将Catia中的原始设计模型导入到 Adams 中进行仿真,并通过输入参数定义儿童锁中的齿轮、轴承及电机。例如,他通过选择齿轮类型、位置、传动比、材料、连接方式及其它参数对机构中的齿轮进行了定义。对塑料杆的性能进行准确建模是至关重要的。借助最新的Adams功能,Darius Schendzielorz 在 Adams View 中通过实体创建柔性体,为前面提及的杆创建了模态中性文件(MNF)。模态中性文件包含惯性矩阵、模态振型及模态频率等信息。 然后,仿真与有限元分析项目工程师 Stelian Borlodan 在整个设计条件范围内对儿童安全锁机构的性能进行了仿真。对不同温度下的性能、假设碰撞中的载荷以及制造偏差对机构性能的可能影响进行了全面的评估。通过仿真来确定用于驱动儿童安全锁机构的电机规格,利用动画来帮助诊断与机构有关的问题,帮助工程师通过重新设计找到满足全部要求的设计。
Results Validation:
通过采用多体动力学仿真技术,Kiekert将设计儿童安全锁机构所需的时间大幅缩短到3星期左右,这意味着新型锁在 18 个月内就可以面市。

 
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Company:

TLG Aerospace, LLC

Products:

MSC Apex

Industries:

航空

MSC Apex 可将几何清理与网格划分所需时间缩短75%


 
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Company:

TürkTraktör/Bias Engineering

Products:

Adams Machinery

Industries:

汽车

Adams Machinery 只需两周就可得出传动系试验的预测结果


 
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Company:

Omni-Lite Industries

Products:

Simufact
Simufact Forming

Industries:

机械

Simufact Reduces Development Costs and Time in Cold Forming Tool Design

Overview:

Omni-Lite Industries is an advanced materials company. They recently designed a new part that was exhibiting a unique material flow. The part was cold formed out of 1100 aluminum material. The manufacturing process for this new part utilized a three-die progression, and was produced on a Nakashimada TH3-6A cold forming machine.

Results Validation:

Omni-Lite found that there is a very accurate correlation between the software prediction of material flow and the real-world results from the heading tooling. The results prove that simulation is a very necessary tool to use for cold forming tool design in order to reduce development cost and product development lead time.

Benefits:
  • Reduce product development costs
  • Reduce time to market by eliminating need for repetitive physical testing
  • Very close correlation between physical test results and Simufact simulation results

 
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Company:

Omni-Lite Industries

Products:

Simufact
Simufact Forming

Industries:

机械

Omni-Lite Optimizes Manufacturing Process of Automotive Rivet using Simulation Software

Overview:

Omni-Lite is a rapidly growing advanced materials company that develops and manufactures precision components utilized by several Fortune 500 companies including Boeing, Airbus, Alcoa, Ford, Caterpillar, Borg Warner, Chrysler, and the US Military, Nike, and Adidas. To aid in its aggressive product development process, the engineering team began using the sophisticated finite element forging simulation software package Simufact.forming, from MSC Software.

Results Validation:

It was found that Simufact.forming provides invaluable information at a critical time in the design process. The software provides the opportunity to see how design variations will work out prior to purchasing any tooling. It allows Omni-Lite to shorten its process development time considerably, and respond faster to customer requirements and design new products faster.

Benefits:
  • Optimize manufacturing process to reduce development time
  • Ability to respond more quickly to changing customer requirements
  • Accelerated innovation due to faster design process

 
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Company:

DEMA SpA

Products:

MSC Apex

Industries:

航空

MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60%

Overview:

DEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787, Airbus A380 and A321, ATR 42-72, Augusta Westland AW139, and Bombardier CS100. DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet. DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints. DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin. These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready.

Results Validation:

“Editing the geometry for one scenario took only 4 hours, a 75% reduction from the traditional method,” said Antonio Miraglia, Stress Lead for DEMA. “Prepping the model took four hours, the same as the traditional method. A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios, a 60% reduction from the time required in the past.”

Benefits:
  • Process of constructing 4 damage scenarios reduced from 80 hours to 32 hours
  • Time to modify geometry reduced by 75%
  • Solver validation further reduces the process from 80 hours to 26 hours

 
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Company:

TECHDYN Engineering

Products:

Marc

Industries:

消费品
能源

Marc Accurately Predicts Results of Dynamic Tensile Extrusion Test

Overview:

In a wide range of industrial and defense applications, materials are required to perform at extreme operating conditions involving large plastic deformation, high strain rates, elevated temperatures and severe dynamic pressure. For example, materials used in armor and antiarmor technology experience deformations of 500% and higher, strain rates up to 106 per second, temperatures above the material’s melting point and pressure of several gigapascals (GPa). Likewise, in industrial applications such as forging, hot rolling, extrusion, wire drawing and sheet metal forming, workpieces undergo plastic deformations ranging up to 100%, temperatures from 500oC to 800oC, strain rates up to 100 per second and pressures up to several hundred Megapascals (MPa). Other examples of applications where high deformations, temperatures, strain rates and pressures are experienced include perforating guns in the oil and gas industry, debris impact in aerospace engineering and ship collisions in naval engineering.

Results Validation:

Now that TECHDYN has validated their material model and ability to simulate extreme conditions, the company is preparing to offer engineering consulting services using Marc with the new material model to provide accurate simulations of extreme conditions. “The ability to accurately simulate extreme conditions will help improve product performance by making it practical to evaluate many more design alternatives than would be practical using the build and test method while at the same time reducing product development cost and leadtime,” Bonora said.

Benefits:
  • Reduce physical tests
  • Improve accuracy of material behavior prediction
  • Improve product performance

 
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Company:

Boiler Structure

Products:

MSC Apex
MSC Nastran

Industries:

能源

Static Simulation of Boiler Structure in Power Plant Using MSC Apex and MSC Nastran

Overview:

Power plant sites consists of numerous built up structures, each of which must be designed for positive margins of safety. Finite Element Analysis (FEA) is a common numerical method used for determining and improving the strength and dynamic performance of such structures. With an increasing need to find optimal power plant structural designs, the most efficient FEA workflows are critical. This case study discusses methods to expedite the FEA process, namely: rapid construction of Finite Element meshes from geometry and leveraging FEA technology to quickly connect hundreds of structural members.

Challenge:

Most industrial structures consists of hundreds of structural members, many of which have the common trait of being thin-walled. This boiler structure, part of a large power plant, is an example that is characterized by thin-walled members. Finite Element Analysis (FEA) is a common method used for strength analysis, but the large size of this structure presents a number of challenges that can delay FEA. The first challenge involves constructing the finite element model, and traditionally requires hours of work. The second challenge is adjoining numerous structural members together, but the process should be both rapid and without error. The use of MSC Apex for mesh construction and the use of MSC Nastran for analysis is demonstrated.

Benefits:
  • MSC Apex accelerates the creation of midsurface geometry and FEM model
  • MSC Nastran Glue Technology is leveraged to perform strength analysis on highly an interconnected structure

 
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Company:

TürkTraktör/Bias Engineering

Products:

Adams

Industries:

重型装备
机械

Adams Machinery Predicts Results of Driveline Testing in Only Two Weeks

Overview:

With annual production of 50,000 tractors, TürkTraktör is the largest producer of tractors in Turkey. The powertrains of the company’s tractors contain many gear pairs and gear groups that transmit torque through the system. For example, the transmission group includes spur and helical gear pairs. Next the torque is transmitted to the differential via a hypoid gear pair. After the differential, a planetary gear group reduces the torque. The torque is transmitted through shafts between gear pairs and most of the shafts are fastened with multiple bearings to the chassis.

Results Validation:

With the simulation model validated, TürkTraktör engineers will begin using it as part of the design process. “We are planning to use simulation in future development projects to minimize lead time and cost,” Akce said. “We have concluded that we can accurately predict the results of a testing campaign that takes several months with only two weeks of simulation. The faster speed and lower cost of simulation will also give us the ability to evaluate more design alternatives than was possible in the past. This will make it possible to reduce the weight and cost of some parts and to increase the durability of others. Of course, the design will be subjected to durability testing as a final validation step.”

Benefits:
  • Accurately predict the results of a testing campaign that takes several months with only two weeks of simulation
  • Faster speed and lower cost of simulation will also give them the ability to evaluate more design alternatives than was possible in the past
  • Adams Machinery Gear module was leveraged to quickly and easily model the gear pairs in the driveline system
  • Bearing was conveniently generated using the Adams Machinery bearing library by referencing the product code

 
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Company:

Anadolu Isuzu

Products:

Adams

Industries:

汽车

Adams Helps Reduce Time and Cost of the Fatigue Test

Overview:

Andolu Isuzu’s new 12 meter long bus, called the Citiport, is equipped with a ZF 6-speed full automatic transmission and a 6 cylinder common rail turbo diesel Cummins engine that produces 283 horsepower at 2100 rpm. The bus can be configured to hold up to 103 people. A wheelchair ramp and kneeling system simplify entry and exit for passengers with disabilities. The bus uses an independent air suspension powered by an electric or engine-driven air pump or compressor. This compressor pumps the air into a flexible bellows made from textilereinforced rubber. The air pressure inflates the bellows, and raises the chassis from the axle. There are two air suspensions in the front of the bus and four in the rear.

Results Validation:

With the aid of simulation results, Anadolu Isuzu engineers were able to dramatically improve the initial design concept. For example, the optimized suspension design parameters developed in the simulation reduced the rollover risk by 8.37%. The fatigue life predictions highlighted excessive stress in several body components. These components were redesigned to meet design specifications. “The use of simulation reduced the cost of the product development process because fewer physical prototypes and less physical testing were required,” Sert said. “Simulation also reduced the time required to bring the new product to market. The product was introduced about one year ago and has become a major success in the export market.”

Benefits:
  • The optimized suspension design parameters developed in the simulation reduced the rollover risk by 8.37%
  • Simulation also reduced the time required to bring the new product to market, which is a major success
  • The predictions of the simulation model closely matched the results of actual measurements

 
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Company:

Framework Construction

Products:

MSC Apex
MSC Nastran

Industries:

能源

Static Simulation for Framework Construction in Power Plant Using MSC Apex

Overview:

Many structures in plant engineering are characterized as thinwalled. The Finite Element Method (FEM) is a common method used to assess the performance of such thin structures. Creating a FEM model of a thin structure involves midsurfacing models and meshing with shell elements. However, the process for creating FEM models is time consuming often requiring hours and days. The use of MSC Apex can help produce midsurface models significantly faster than with other traditional CAE pre/post processors. In addition to FEM creation, MSC Apex can be used to perform strength analysis.

Benefits:
  • Geometry is easily edited to construct FEM models rapidly
  • FEM models are validated for materials, properties, mesh congruency, connections and boundary conditions
  • FEM models may be exported from MSC Apex and used in a separate pre/post processor

 
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