Engineering case study

Skills and Experience
Simulation – CAE:
Modell building, meshing
Structural analysis (linear, non-linear)
Creep analysis
Dynamic and kinematic simulations
Thermal analyses
Electromagnetic simulations
Transient simulations
Endurance calculations
Seismic analyses
Analysis of composite structures (CRP, GRP, …)
Explicit simulations (crash, drop, airbag)
Multi-body simulations
Optimizations
Programming for CAE applications
Design – CAD:
Special equipment
Robots
Welding and riveting machines
Assembly lines
Employees by experience
CAE: 20 Employees
7 – ANSYS Classic/Workbench
2 – ANSYS/CFX, Fluent
4 – ANSYS/LS-DYNA,
4 – LS-DYNA, PAM-Crash, RADIOSS
2 – ANSYS/ACP
2 – ANSYS/Optislang
4 – ABAQUS/Standard
2 – ABAQUS/Explicit
4 – NASTRAN, Patran
2 – FEMFAT, nCode
8 – HyperWorks
3 – Optistruct
10 – ANSA
1 – MAXWELL
2 – Medina
3 – Moldex3D
2 – MoldFlow
1 – ADAMS, Simpack
3 – LMS AMESim
Designers: 15 Employees
8 – SolidWorks
8 – CATIA
4 – ProEngineer
http://www.econengineering.com 2
2http://www.econengineering.com

Composite capabilities
Calculations for Automotive, Railway and Aircraft

CAE Experience in Composites
• FE modeling – HyperWorks, ANSA, ANSYS Composite PrePost
• Shell models
• Mixed models – Shells and Solids
• Solid models
• Sub-modeling
• Material property definitions
• Solvers – ANSYS, NASTRAN, ABAQUS
• Static calculations
• Thermal and coupled thermal-structural analyses
• Dynamic calculations
• Optimization – Finding an optimal layup, based on predefined loads and boundary conditions
• Minimize deflection
• Weight reduction
• Topology and Topography optimizations
• Assessment based on failure criteria
• Calculations based on some major criteria: maximum stress, maximum strain, Tsai-Hill, Tsai-Wu, Hashin, Puck, LaRC
4
http://www.econengineering.com

Composite Camera Console
5
High frequency dynamic analysis
The model combines shell, solid and beam elements. An Orthotropic
Material model was used. The effect of the impact is a 90G load
applied in two directions
Problem:
A test bench for crash experiments was equipped with high-speed
cameras. The cameras are to be fixed onto composite levers.
Shaking of the cameras due to the impact is critical
Optimization
The outer shape of the arm is fixed. Design variables are the layup
and the reinforcing ribs. The goal is to keep peak deformation under
5mm in both loadcases.
Reinforcing ribs
Mesh closeup Interior structure
Displacement
Acceleration affecting the camera Model overview
Test video

Modular Sandwich Composite Autobus Development
Composite structures• Complete vehicle models
• Shell or hybrid Solid/Shell models
• Modelling and optimization of layups
• Multiple failure criteria for strength analysis
• Material model setup based on in-house and/or external measurement
results

ULTRA LIGHT aircraft
• Ultra Light category:
• max. 450kg total weight
• Geometry is based on a previous model with upper
wing configuration
• lower wing aircraft
• Non structural simulations
• Preliminary design prozess & CFD simulations
• Structural calculations
• Simulating different in-flight and landing
positions - over 10 different loadcases
• Static calculations, based on aviation standards
• Loads readily include all desired safety and
overload factors
• Composite structure is modelled using layered
shells
• Using Tsai-Wu failure criterion to assess
composite strength

ULTRA LIGHT aircraft
Ply size optimization – free-size optimization result
• Ply thickness is determined by either
• Removing the ply altogether
• Placing one …
• … or more layers into the layup
• to achieve an optimal thickness
of a given orientation
• Objective:
• Minimum Weight
• no material failure
• Utilization of most utilized layer
• Improved strength
29% improvement

Optimization in
Automotive
Calculations for Automotive

Topology optimization
• Development for
DAIMLER
• Part
Side Support
• Material
MakroBlend KU
(Polycarbonate + PBT)
• Preprocessing:
ANSA, Hypermesh
Shell model
• Solver:
OptiStruct
Static loadcases
• Postprocessing:
HyperView

Case Study #1
Original Design Space Optimization result Engineering interpretation Wall thickness optimization

Case Study #2

Case Study #3
02. 12. 2013.http://www.econengineering.com 13

Optimization Results
Part Performance
Property Case Study 1 Case Study 2 Case Study 3
Mass reduction 0% -7% -7%
Stiffness in X direction increased +14% +22% 0%
Stiffness in Y direction increased +42% +14% +20%
Stiffness in Z direction sustained +36% 0% +12%
Mode 1 frequency increased +15% +16% +22%
Mode 2 frequency increased +11% +17% +5%
02. 12. 2013.http://www.econengineering.com 14

Organic design – Engine Bearer Optimization
• Part
Engine Bearer
• Material
Aluminum
• Preprocessing:
ANSA, Hypermesh
Solid model
• Solver:
OptiStruct
Static loadcases
• Multi level optimization:
Minimum mass w/ stress constraint
Maximum stiffness w/ same mass
• Postprocessing:
HyperView

Optimization for a
Composite bumper
concept

Original version
Version Mass Deformation
Original (1) 1.7kg 8mm
Uniform wall thickness (2) 0.98kg 4mm
Optimized wall thickness (3) 0.67kg 4mm
1
2
3
Topology Optimization
Part performance

Optimization for a
plastic-hybrid
door concept – study

Smart Tür A451
Projektkonzept, Aussenhaut aus faserverstärkten Materialen
Aus faserverstärkten Mateialen als eine
Platte.
In diesen Platte wird die neue Verstärkung
einsetzen/zusammenmontieren, dann
werden die Rippen eingespritzt.
Die neue Verstärkung, aus einen Teil
Kontur des Bauraums

Smart Tür A451
Lastfälle
Nondesignable steel structure
Wandicke (alle Rohre und
Blech): 1.5 [mm]
Designable skin – z.B. Organoblech
Designable solid – PA

Smart Tür A451
KONZEPT #3 - Ergebnisse

Low speed impact &
pedestrian safety

Pendulum speed = 2.6km/h – 4.25km/h
Pendulum mass = 2048 kg
Low Speed Pendulum Impact
• Part
Complete car front
• Preprocessing:
ANSA
Shell model (with some solids)
• Solver:
LS-Dyna
Full transient explicit
• Postprocessing:
HyperView

Pedestrian Safety Calculations

Strength
calculations for
automotive industry
Coupled thermal – structural analysis

Strength and CFD Calculations of Turbochargers
Structural Simulations
• Preprocessing: ANSA, Solid model
• Solver: Abaqus
Coupled thermal and structural
analysis
• Postprocessing: HyperView
• Extensive strength evaluation of the
housing using numerous loadcases
CFD Simulations
• Frozen rotor model
• SST Turbulence model
• Steady state with physical timescale

Calculations for
the Railway industry
Other Industries

Railway Calculations
• Preprocessing:
ANSA, Hypermesh
Shell model
• Solver:
NASTRAN
Static loadcases
• Postprocessing:
HyperView
• Standardized loadcase
combinations for fatigue
evaluation and strength
assessment

Tram Calculations
• Preprocessing:
ANSA, Hypermesh
Shell model
• Solver:
ANSYS
Static loadcases
• Postprocessing:
ANSYS, HyperView
assessment

Strength Calculation of Motor Bogie
• Preprocessing:
ANSA, Hypermesh
Shell model
• Solver:
Nastran
Static loadcases
• Postprocessing:
HyperView
assessment
• Fatigue evaluation

Calculations for
the Autobus industry
Other Industries

Static calculations
• Complete vehicle model – Chassis, body & suspensions
• Vehicle mass modelled at full load
• Static loadcases – accelerations, suspension forces and towing
• Stress evaluation in structure and in welds

Dynamic calculations
• Transient simulation of durability field testing
• Estimating results for Altoona durability test
• Transient stress signals in welds
• Complete vehicle FE model is used

Durability & Fatigue
• Varying stress in weld lines is analyzed
• Static loadcases are used to represent min/max stress states
• Transient loadcases are used to generate a transient stress signal for
rain flow analysis and damage accumulation
• Fatigue in welds is based on
• SN curves from standards
• Modified SN curves for improved reliability

Rollover simulations
• ECE-66/01-02, standard test for inter-urban buses
• Complete structure rollover or single module “static” testing
• Very strong correlation with physical test results
• Precise evaluation of Survival Space
• Prediction of local failure – break and buckling of tubes can be estimated

CFD
Calculations
Other Industries

Simulation with Moving Domains
• Target
Determination of minimum and average static
pressure in chambers at given boundary
conditions.
• Method
Transient simulation with mesh deformation
Rotation of whole domain is considered
Average static
pressure in
chambers

Centrifugal Pump
• Target
Determination of moment on
turbine wheel, and efficacy.
• Method
Frozen rotor model

Cabin Heat Exhanger Device
• Model
All solid parts included
Air around the heater
Interfaces between solid-solid
and solid-fluid domains
• Solver
ANSYS CFX
• Method
Steady state simulations with
heat transfer
SST Turbulence model
• Postprocessing
comparison with experimental
results
heating performance

System simulation
Other Industries

System Simulation
• LMS AMESim system simulation
software
• Experience in modeling
Mechanical
Electromechanical
Hydromechanical systems
• Valves on design level
• Calibration by CFD
• Parameter studies
• Stability analyses

Plastic injection
molding simulation
Other Industries

• Goals
Reduce production losses
• Reason
Inhomogen filling
• Solution
Modify runner system
Modify cooling parameter
• Results
More even filling
Reduced shear stress in problematic region
Cable tie sumilations
43
2014 eCon Engineering Kft. - http://www.econengineering.com - info@econengineering.com – phone: +36 1 279 0320 - fax: +36 1 279 0321Material - PA66 Vydyne

Inhaler holder
44
• Goal
Show and eliminate the vacuum void
• Reason
Thick area in the part
Thin gate diameter
• Tasks – simulations versions
Oblique gate
Thicker gate diameter 0.60.9 mm
Increase Mold temperature 1550°C
Increase Mold temperature and gate diameter
• Results
None of the examined changes solved the problem
Conclusion: The void is only an aesthetic problem, it won’t break to the surface
Material – Marlex (HPDE) Increased Mold temperature and Gate
diameter
Increased Mold temperature

ANSYS Workbench – Moldex3D
45
• Model desctruption
Fixed support on bolt
10 [Nm] moment on shaft.
bolt & shaft from Structural Steel
Clutch PA66: Ultramid A3EG6
Isotrop material properties Fiber orientation directly from Moldex3D
Injection molding simulation  anisotrop
material properties

Rapid prototyping
capabilities

RPT capabilities – with cooperation partner
47
Sand casting
Printex wax pressure tool
Special gearbox parts –
gravity casting

Engineering case study

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Engineering case study