FEA Structural Analysis @ Zeus Numerix

1Build-to-Specifications | Product Approval | Engineering Services | Software Development
Structural Analysis @ Zeus
Numerix
Structural and FEM Capabilities at Zeus Numerix for the
strategic and industrial sector along with coupled
problems
V3
Abhishek Jain

2
©ZeusNumerixPvtLtd:ConfidentialDocument
Presentation Overview
16 June 2019 Structural Capabilities @ Zeus Numerix
 Zeus Numerix – an Introduction
 Journey started from engineering services in FEM
 No 1 Know-Why company for design optimization, failure analysis & build-to-spec products
 Non-confidential Case studies
 Structural analysis for strategic sector
 Structural analysis for industrial sector
 Design and coupled problems
 Team and Closure
 The presentation is non-confidential and some data may be masked
 Legends in the presentation are not shown purposefully
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3
2004
1st Project Completed
Large Defense Project
2005 2006
1st Software Export
System design software: Korea
2007
2008
CEM Software
UAV RCS Reduced
2009
1st Built-to-Spec project
Supersonic ground
vehicle developed
2010
Fire Safety & Comfort
Building fire and HVAC
2011
Control Software
In-house development
2012
2013
Parallel GPU code Devp
Visualize big data – 4 billion points
2015
Floating Panel Design
Solar Panels in Lake
2017
1st foreign missile project
Integration & Certification
2018
1st MSME TDF Winner
D&D of Composite Sea Water Pump
2019
Incubated at IIT Bombay
Journey Begins with India’s 1st
Commercial CFD software!
400th project completed
Lockheed Innovation
Medal & India Govt
R&D Certificate
CEM Software
CEMILAC Certification
1st Store Separation
project complete
www.zeusnumerix.com/portfolio
The Journey

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20-July-2019 Capabilities on Aerospace Systems @ Zeus Numerix
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Accolades

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5
Core Offerings
Product
Development
Initial sizing from first
principles
Detailed analysis
based design
Prototype
development
Testing and validation
Product
Approval
Performance
estimate by analysis
Detailed Report
Generation
Review with approval
agency
Final submission and
product approval
Engineering
Services
Design calculation
reports
Analysis – CFD, FEM,
CEM
Failure analysis and
design suggestions
Multi-disciplinary
design optimization
Software
Development
Pre-processing
Automation
Solver development
from Literature
survey
Visualization, parallel
code CPU/GPU & GUI
System simulation
tools

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FEM Capabilities
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Strategic
Sector
• Static and dynamic loads
• Random vibration, shock load, reliability
• MIL 810, JS5555 load certification
Industrial
Sector
• Static and cyclic loads, fatigue
• Vibration loads and Campbell curve
• Hoops stresses, thermo-structural loads
Design &
Coupled
• Coupled CFD+FEM simulations
• CFD+FEM+Dynamics of flexible structures
• Engineering software development in FEM
Product verification: Pressure Vessel
Von-Mises Stress Plot
Thermal and structural analysis
Hypersonic wind tunnel

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Case Studies: Strategic Sector
Non-confidential examples of completed projects in strategic
sector
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Design of Wire Rope slung system
 Certification of wire rope slung system used to lift light weight gun by helicopter
 Dynamic & fatigue analysis of wire rope for helicopter load factor and wind effect
 Analysis of positive locking system, hooks etc. found inadequate factor of safety
 Redesign of critical components as per MIL standards
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Structural Design & Certification
 Shock & Vibration loading on sub-surface vessel
 Enclosure breakage due to loading
 Redesigned – PDR/CDR conducted by DMDE
 Reliability, multi-body dynamics and fatigue studied
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Typicalsub-system
Multi-body with Fatigue

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FEM of Aircraft Armrest to Reduce Weight
 Estimate the Limit load for an aircraft armrest assembly
 Complex geometry required cleaning like flushing of rivets and removing holes
 Material properties assumed linear for various types of lightweight materials
 Local stresses high at very few places; product approved as safe
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Pivot
Bush
Printed Semi Armrest Left
Spring
Fine mesh StressesCAD

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Fatigue Analysis of Jet Engine Test Cell
 Augmenter Tube and Blast Bucket Setup
 Fatigue analysis to estimate the life of test set-up
 Random vibration to find the natural frequencies
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Acceleration vs. Frequency
Rough Schematic

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Composite Landing Gear
 Objective – Concept design of UAV composite landing gear
 Only structural perspective taken into account
 Main & nose landing gear design follow FAR 23 regulations
 Design consideration included one wheel landing
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Nose Landing Gear
Main Landing Gear
One Wheel Landing
Stress and deformation

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Non-Metal Mechanical Timer: Design Review
 Plastic use to prevent detection; design for shock, vibration & drop loading
 Math model developed to simulate escapement mechanism
 Calculated torque balance between gear elements to estimate time of operation
 FEM failure prediction matches physical observation
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Stress Distribution on gear teethPallet-Escape Wheel mechanism

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Product Approval for Missile Container
 Approval of missile storage container for static and vibrational loading
 Secure storage of the missile on the inside using metallic mechanisms
 External box made of FRP; to sustain drop and vibration load (MIL 210D & MIL 810F)
 Stacking, 12 m drop, air pressure test, lifting hooks & fasteners calculations etc.
 Design approval after extensive studies and end user review
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Case Studies: Industrial Sector
Non-confidential examples of completed projects in Industrial
sector
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Structural Approval of Control Valve
 Structural analysis of valve designs ranging from 2” to 12” diameter
 FEM based on ASME Section VIII, div 2: Pressure ~ 250 Bar and temperature ~ 300 C
 Product approval delivered to the customer
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Surge & Stress Analysis for Pump Piping Layout
 Surge load in pipes due to pumps stopped, started, switched-over or tripped
 ASME Boiler and Pressure Vessel Code, Section III to calculate stresses and reactions
 FEM for the supports and pipes
 Worst case scenario out of multiple stoppage scenarios found
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FEM Analysis of Fan Impellers
 Structural analysis of fan impellers at maximum load
 Entire impeller modelled along with the shaft
 FEM analysis used for design approval of the assembly
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CAD Model Deformation plot

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Artificial Palm Tree leaves
 Artificial trees installed on communication towers for aesthetic look
 ‘Tree leaves’ found to be breaking under wind load conditions
 FEM analysis to estimate the fatigue life of the leaves
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Mesh
Stress on the leaves

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FEM of Composite Material Engine Cover
 Modal analysis of the engine cover carried out for first 10 mode shapes
 Analysis showed that stiffness of few panels need to be enhanced
 FEM for forced due to ‘g’ load; spring force added to gravity
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Deflection
(Y-axis)

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Random Vibration for Automotive Component
 Automotive electronic component faces vibration loads in travel
 Modal analysis to find natural frequencies and mode shapes
 Calculate stresses and deformations under PSD (Power Spectral Density) acceleration input.
 Fatigue life estimation
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Case Studies: Special Problems
Non-confidential examples of completed projects for coupled
problems or software development
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Design of Winglet
 MDO framework built based on genetic algorithm (GA)
 Coupled CFD and FEA on computing grid of 256 nodes (2048 cores)
 14% drag reduction achieved w.r.t. base configuration
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Customized Aero Elasticity Analysis Software for
Slender Spinning Rockets
 Estimation of aero-elastic phenomena of spinning rocket
 Good comparison with Zeta factor and Q divergence
 Limited literature on the topic causes validation issues
 Inter-code comparison with DRDL data
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DRDL

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Multi-disciplinary Simulation for Parachute
 Multidisciplinary software for parachute design
 Dynamics of Parachute opening
 Coupled CFD & FEM for membranes (parachute cloth)
 Validation with wind tunnel experiment
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ADRDEwindtunneltestInflationinParaZ

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Bullet Resistant Jacket: Custom Software
 Effect of multiple bullet impact on jacket
 Study of various materials/insertions
 Custom software delivered to lab for extensive numerical testing of various configurations
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Software GUI
Bullet penetration animation

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Modal & Rigid Body Analysis for Chain Drive
 Modal analysis of the chain drive mechanism for structural integrity
 Rigid body analysis of the chain at different RPM and chain tension
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Design Modifications of Artillery Recoil System
20 May 2019 Capabilities on Land Systems @ Zeus Numerix
 To ascertain the failure of rings and small parts after firing
 Estimate the forces due to internal ballistics and movement of piston due to recoil
 Unsteady simulation for pressure & thermal stresses due to fluid and nitrogen compression
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Team and Closure
Details of the team and consultants and summary of
presentation
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Core Team
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 Prof Gopal Shevare (Chairman) – PhD IIT Bombay with 40+ years research exp
 Expert in MDO, fluid dynamics, numerical methods and simulation product development
 Basant Kumar Gupta (CEO) – Masters IIT Bombay with 16 years experience
 Expert in preliminary design, project management, and optimization
 Irshad Khan (COO) – Bachelor Mechanical with 22 years experience
 Expert in mesh generation, drawings, product development and vendor management
 Sumit Jana (Head – Solver Devp) – Masters IIT Kharagpur with 12 years exp
 Expert in parallel solver development for CFD, Electromagnetics and free surface flows
 Suman Mohandas (Head – Software Devp & Visualization) – Bachelors Computer
 Expert in new software development, visualization, parallelization and GUI
 Ten engineers certified by CEMILAC including above

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Consultants and Collaborations
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 MOUs and Collaborations
 Centre for development of advanced computing – HPC usage in Teraflops
 NIT Nagpur – Joint R&D projects in coupled problems (CFD+FEM)
 IIITDM – Joint projects of analysis adding to product development
 Expert Panel (partial)
 Mr. SG Joshi – 40+ years experience in pump design and manufacturing
 Prof S C Lakkad – 45+ years experience in composite design and manufacturing process
 Prof K Sinhamahapatra – 20+ years experience in acoustic prediction
 Mr S Panse and H Ketkar – 35+ year exp in tool room, jigs/fixture design, special projects
 Mr V Kamat – 40+ years experience in hydraulic machine design, fabrication & maintenance
 Mr A Patki – 40+ years experience in space systems for reliability and weight reduction

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Closure
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 Experience of 400+ high tech projects in both strategic and industrial sectors
 Engineers trained in Aerospace grade quality and confidentiality
 Robust engineering software development experience
 Modular code development with high reusability
 Experience of parallelization and cloud computing
 Domain expertise in aforementioned sectors
 Contribution by the engineering team enhanced to design suggestions
 Flexible engagement model
 Fixed cost, Time and Material, Cost plus or models as per problem statement
 Unafraid to take R&D projects – Test Us

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www.zeusnumerix.com
+91 98190 09836
Abhishek Jain
abhishek@zeusnumerix.com
Thank You !

FEA Structural Analysis @ Zeus Numerix

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