Engineering case study
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1) The document describes the engineering consulting and simulation skills of Econ Engineering, including CAE modeling, meshing, structural analysis, thermal analysis, and design capabilities using various CAD software. 2) Econ Engineering employs over 100 engineers with expertise in various simulation tools like ANSYS, LS-DYNA, ABAQUS, and CAD tools like SolidWorks, CATIA. 3) The company provides composite material analysis and design services for industries including automotive, railway, and aerospace, with experience in shell modeling, failure criteria assessment, and optimization of composite layups.
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Engineering case study
- 2. 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
- 3. Composite capabilities Calculations for Automotive, Railway and Aircraft http://www.econengineering.com 3
- 4. 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
- 5. 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 http://www.econengineering.com
- 6. 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 http://www.econengineering.com 6
- 7. ULTRA LIGHT aircraft 7http://www.econengineering.com • 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
- 8. ULTRA LIGHT aircraft Ply size optimization – free-size optimization result 8http://www.econengineering.com • 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
- 9. Optimization in Automotive Calculations for Automotive http://www.econengineering.com 9
- 10. Topology optimization • Development for DAIMLER • Part Side Support • Material MakroBlend KU (Polycarbonate + PBT) • Preprocessing: ANSA, Hypermesh Shell model • Solver: OptiStruct Static loadcases • Postprocessing: HyperView http://www.econengineering.com 10
- 11. Case Study #1 Original Design Space Optimization result Engineering interpretation Wall thickness optimization http://www.econengineering.com 11
- 12. Case Study #2 Original Design Space Optimization result Engineering interpretation Wall thickness optimization http://www.econengineering.com 12
- 13. Case Study #3 Original Design Space Optimization result Engineering interpretation Wall thickness optimization 02. 12. 2013.http://www.econengineering.com 13
- 14. 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
- 15. Organic design – Engine Bearer Optimization 15http://www.econengineering.com • 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
- 16. Optimization for a Composite bumper concept Calculations for Automotive http://www.econengineering.com 16
- 17. 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 http://www.econengineering.com 17
- 18. Optimization for a plastic-hybrid door concept – study Calculations for Automotive http://www.econengineering.com 18
- 19. 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 http://www.econengineering.com
- 20. Smart Tür A451 Projektkonzept, Aussenhaut aus faserverstärkten Materialen Lastfälle http://www.econengineering.com Nondesignable steel structure Wandicke (alle Rohre und Blech): 1.5 [mm] Designable skin – z.B. Organoblech Designable solid – PA
- 21. Smart Tür A451 Projektkonzept, Aussenhaut aus faserverstärkten Materialen KONZEPT #3 - Ergebnisse http://www.econengineering.com
- 22. Low speed impact & pedestrian safety Calculations for Automotive http://www.econengineering.com 22
- 23. 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 23http://www.econengineering.com
- 25. Strength calculations for automotive industry Coupled thermal – structural analysis http://www.econengineering.com 25
- 26. 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 http://www.econengineering.com 26
- 27. Calculations for the Railway industry Other Industries http://www.econengineering.com 27
- 28. Railway Calculations • Preprocessing: ANSA, Hypermesh Shell model • Solver: NASTRAN Static loadcases • Postprocessing: HyperView • Standardized loadcase combinations for fatigue evaluation and strength assessment http://www.econengineering.com 28
- 29. Tram Calculations • Preprocessing: ANSA, Hypermesh Shell model • Solver: ANSYS Static loadcases • Postprocessing: ANSYS, HyperView • Standardized loadcase combinations for fatigue evaluation and strength assessment http://www.econengineering.com 29
- 30. Strength Calculation of Motor Bogie 30http://www.econengineering.com • Preprocessing: ANSA, Hypermesh Shell model • Solver: Nastran Static loadcases • Postprocessing: HyperView • Standardized loadcase combinations for fatigue evaluation and strength assessment • Fatigue evaluation
- 31. Calculations for the Autobus industry Other Industries http://www.econengineering.com 31
- 32. 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 http://www.econengineering.com 32
- 33. 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 http://www.econengineering.com 33
- 34. 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 http://www.econengineering.com 34
- 35. 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 http://www.econengineering.com 35
- 37. 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 http://www.econengineering.com 37
- 38. Centrifugal Pump • Target Determination of moment on turbine wheel, and efficacy. • Method Frozen rotor model http://www.econengineering.com 38
- 39. Cabin Heat Exhanger Device http://www.econengineering.com 39 • 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
- 41. System Simulation 41http://www.econengineering.com • LMS AMESim system simulation software • Experience in modeling Mechanical Electromechanical Hydromechanical systems • Valves on design level • Calibration by CFD • Parameter studies • Stability analyses
- 42. Plastic injection molding simulation Other Industries http://www.econengineering.com 42
- 43. • 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 http://www.econengineering.com
- 44. 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 0.60.9 mm Increase Mold temperature 1550°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 http://www.econengineering.com
- 45. 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 http://www.econengineering.com
- 47. RPT capabilities – with cooperation partner 47 Sand casting Printex wax pressure tool Special gearbox parts – gravity casting