This document summarizes two major CAD and simulation projects completed by the author for their university studies. The first project involved modeling the Melbourne CBD in CAD to identify potential locations for wind turbines, with the author modeling several city blocks. The second was a race car front wing design project where the author designed and simulated a front wing in CAD and FEA/CFD software. Smaller additional projects involving an impact test rig and infrared spectroscopy sample holder are also mentioned.
Lead time reduction in CAE: Automated FEM Description ReportAltair
For each deliverable FE-Model a FEM description report needs to be generated. Since this document contains always the same type of information, it is an ideal candidate to automate the creation of this report. Based on the Hyper Report Tool from Altair, RUAG Space and Altair developed a tool to automatically generate the FEM Description Report. The tool requires the HyperMesh data base and the output files from FEM checks as inputs. Together with the tool template, guidelines are provided on how the data base needs to be set up, such that the report can be created automatically. The main structure of the FEM Description Report is dependent on the assembly structure of the HM data base.
Large scale topological optimisation: aircraft engine pylon caseAltair
An engine pylon holds the engine to the wing and ensures multiple others functions: aerodynamics, structure and systems. Moreover, it is designed to prevent a fire in the engine area from spreading to the wing. These multi-functions make the global pylon architecture design highly complex. Existing designs reach their limits regarding the aircraft performance requirements, with ever more powerful, bigger and hotter engines. Thus, the technological breakthrough becomes necessary to achieve better performance.
In the present work, we propose a new concept based on Additive Layer Manufacturing (ALM) process which eliminates many conventional constraints from the manufacturing process and can produce complex, precisely designed shapes.
Topological optimization, using ALTAIR’s finite element analysis software, is realized by integrating systems elements, fluid pipes mainly, to structural parts. Thus, these elements become structural unlike the existing design.
One objective of this work is to demonstrate the numerical feasibility of topology optimisation of large-size (5 m long, 0.83 m width and 1.19 m in height) and highly complex architecture design of an aeronautical structure.
The results show that a significant mass saving, more than 20%, can be achieved even with heavily constrained structure in terms of stresses, dimensions, interfaces, systems, etc. Furthermore, this study highlights benefits in the parts number which dropped by 97%.
Note that the existing engine pylon is made mostly of Titanium and Steel materials but for the topology optimisation a single material, Inconel 718, was chosen due to its best thermal and mechanical properties.
In order to ensure aerodynamic function, obtained organic shape structure is covered by custom-made cowls.
1/8 scale model is 3D printed by INITIAL company, using plastic material, can be exposed during the Altair Technology Conference.
Speakers
Abdelkader Salim, Innovation Engineer, SOGECLAIR Aerospace
Lead time reduction in CAE: Automated FEM Description ReportAltair
For each deliverable FE-Model a FEM description report needs to be generated. Since this document contains always the same type of information, it is an ideal candidate to automate the creation of this report. Based on the Hyper Report Tool from Altair, RUAG Space and Altair developed a tool to automatically generate the FEM Description Report. The tool requires the HyperMesh data base and the output files from FEM checks as inputs. Together with the tool template, guidelines are provided on how the data base needs to be set up, such that the report can be created automatically. The main structure of the FEM Description Report is dependent on the assembly structure of the HM data base.
Large scale topological optimisation: aircraft engine pylon caseAltair
An engine pylon holds the engine to the wing and ensures multiple others functions: aerodynamics, structure and systems. Moreover, it is designed to prevent a fire in the engine area from spreading to the wing. These multi-functions make the global pylon architecture design highly complex. Existing designs reach their limits regarding the aircraft performance requirements, with ever more powerful, bigger and hotter engines. Thus, the technological breakthrough becomes necessary to achieve better performance.
In the present work, we propose a new concept based on Additive Layer Manufacturing (ALM) process which eliminates many conventional constraints from the manufacturing process and can produce complex, precisely designed shapes.
Topological optimization, using ALTAIR’s finite element analysis software, is realized by integrating systems elements, fluid pipes mainly, to structural parts. Thus, these elements become structural unlike the existing design.
One objective of this work is to demonstrate the numerical feasibility of topology optimisation of large-size (5 m long, 0.83 m width and 1.19 m in height) and highly complex architecture design of an aeronautical structure.
The results show that a significant mass saving, more than 20%, can be achieved even with heavily constrained structure in terms of stresses, dimensions, interfaces, systems, etc. Furthermore, this study highlights benefits in the parts number which dropped by 97%.
Note that the existing engine pylon is made mostly of Titanium and Steel materials but for the topology optimisation a single material, Inconel 718, was chosen due to its best thermal and mechanical properties.
In order to ensure aerodynamic function, obtained organic shape structure is covered by custom-made cowls.
1/8 scale model is 3D printed by INITIAL company, using plastic material, can be exposed during the Altair Technology Conference.
Speakers
Abdelkader Salim, Innovation Engineer, SOGECLAIR Aerospace
Fatigue Analysis of a Pressurized Aircraft Fuselage Modification using Hyperw...Altair
Fatigue Analyses of modifications on pressurized aircraft fuselages are both necessary and tedious. Using the Hyperworks software suite and StressCheck, RUAG has developed a fatigue analysis method which streamlines the process from the creation of the spectrum up to the detailed analysis of selected fastener holes and delivers results quickly and efficiently.
This method was then used to certify the installation of two large windows in the floor of a single engine turboprop A/C for aerial survey applications.
Speakers
David Schmid, Manager Structural Analysis, RUAG Schweiz AG
Due to recurrent lack of on time delivery of Drilling grid (made of a 2cm thick aluminium pad), 3D printing can potentially propose an alternative enlightened solution in 3D printing (topology optimization).
Speakers
Sébastien Haudrechy, Engineer, Airbus Group Aerospace
Exploring the capabilities of the tight integration of HyperWorks and ESACompAltair
More than 3 years ago RUAG Space started to look into ways how the very powerful meshing and post-processing capabilities of Altair HyperWorks could be combined with the advanced composite failure analysis methods provided by the ESAComp software from Componeering. RUAG’s vision behind this idea was to streamline the time consuming composite analysis process by a tight integration of the two pieces of software, thus eliminating as much as possible unnecessary breaks in the data flow. Both Altair and Componeering carefully listened to RUAG’s needs and eventually it was decided to make a common effort in providing step by step the requested functionality. The initially slow process accelerated considerably when Componeering joined the Altair Partner Alliance in 2012. Today the bi-directional interface between HyperWorks and ESAComp is considered mature enough to be challenged by a demanding real world use case: the dimensioning and verification of the load carrying structure of the MetOp-SG satellite (Meteorological Operational Satellite - Second Generation). The presentation will focus on how HyperWorks and ESAComp were used to set up the finite element model, to run the quasi-static and dynamic load cases and to evaluate the results. It will be shown in which way HyperWorks and ESAComp can support the process, what the benefits of a tight integration are and which limitations still exist.
Speakers
Ralf Usinger, Product Lead Engineer Satellite Structures, RUAG Schweiz AG
Assessing the Aerodynamic Performance of a Formula SAE Model by means of CFD ...saeid ghaffari
A simplified race car model is used in this project to analyse the aerodynamic performance of a Formula SAE car by means of CFD simulation. First, the simulation workflow in Star-CCM+ will be demonstrated. Then, before applying volumetric controls and prism-layer mesh refinement to obtain more accurate results, tools to judge solution convergence are introduced.
*the first six pages of this project are presented here. If you are interested to study the rest of this document, please contact me via saeid.ghaffari@studenti.polito.it.
Design of Rear wing for high performance cars and Simulation using Computatio...IJTET Journal
The performance of a sports car is not only limited to its engine power but also to aerodynamic properties of the car. By decreasing the drag force it is possible to reduce the engine power required to achieve same top speed thus decreasing the fuel requirement. The stability of a sports car is considerably important at high speed. The provision of a rear wing increases the downforce thus reducing the rear axle lift and provides increased traction. In this study an optimum rear wing is designed for the high performance car so as to decrease drag and increase downforce. The CAD designed baseline model with or without rear wing is being analyzed in computational fluid dynamics software. The lift and drag coefficient are calculated for all the design thus an optimum rear wing is designed for the considered baseline model.
Drag Reduction of Front Wing of an F1 Car using Adjoint Optimisationyasirmaliq
The Project Poster summarizes the aims and objectives of the Final Year Dissertation. The project starts with a detailed study on the parameters that tend to affect the performance of front wings of an F1 car and goes through designing the front wings(3) with endplates and wheel, meshing it, solving/analysing the flow and finally optimising the selected geometry using Fluent Adjoint Solver for efficient performance.
Adjoint optimisation technique is used to achieve optimal performance from the front wings. It's the most successful shape optimisation method as it's independent of the number of design variables exponentially reducing computational time and cost. The emphasis has been put on optimising the shape of the front wings using the Adjoint method as it’s the most efficient and computationally inexpensive method for design optimisation. The approach towards shape optimisation is downforce constrained drag minimization as it would result in keeping a constraint on downforce and reducing the drag at the same time, thus producing optima for a given downforce/drag value.
Surrogate Model-Based Reliability Analysis of Composite UAV Wing facilitation...Altair
Numerical simulation becomes increasingly strategic to design innovative products and to set up their manufacturing processes, reducing simultaneously development costs and time to market while increasing quality and reliability.
To support this evolution, SILKAN develops a platform for the integration of various types of simulation software, named BUILDERTM.
BUILDERTM is an efficient, innovative and scalable simulation-based platform designed to deal with the increasing use of complex numerical simulations applied to part design, system design or manufacturing processes.
The principal objectives of this platform are to:
Promote and structure the use of simulation
Standardize, parameterize and automate simulation processes.
Capture and re-use the best practices.
Facilitate coupling between different simulation levels and tools.
Improve collaboration across different project teams.
Facilitate access to simulation means for the uninitiated.
Accelerate design and production cycles.
Democratize the use of optimization and reliability procedures and better control manufacturing processes and failure risks.
An application example using BUILDERTM is addressed in this paper. It deals with the robust design of a composite UAV wing. The associated simulation workflow includes two principal steps.
During the first step, Matlab is used to estimate aerodynamic loads applied to the wing when as a function of flight parameters: air flow speed, angle of attack of the wing and aileron deflection angles. A Design of Experiment (DoE) is built by varying the flight parameters in order to cover all the flight domain of the UAV.
The aerodynamic loads thus obtained are then injected into OptiStruct to estimate Tsai-Wu failure criteria for the composite material. An efficient surrogate model is then built from the obtained Tasi-Wu criteria and covers the entire flight domain. Finally to conclude this first part, a failure probability , based on Tsai-Wu criteria, is estimated using the produced surrogate model.
In the second step the following optimization problem is defined using some design variables of the wing (essentially thicknesses of composite layers of the wing):
Wing Mass is calculated by Optistruct, and being evaluated using the step1. An evolutionary algorithm implemented into Dakota is used to perform this surrogate-model -
based optimization.
The set up, parameterization and automation of this complex simulation workflow is facilitated and achieved through the use of the BUILDERTM platform. The combination of different software at different levels of the workflow is also made accessible by the use of BUILDERTM.
Speakers
Samir Ben Chaabane, Numerical Simulation Manager for EMEA, SILKAN S.A
Aircraft Finite Element Modelling for structure analysis using Altair ProductsAltair
The Airbus airframe design process has considerably evolved since 20 years with the constant improvement of numerical simulation capability and the computational means capacity. Today the size of Finite Element Models for aircraft structural behaviour study is exceeding the boundary of airframe components (fuselage section, wing); for the A350, a very large scale non-linear model of more than 60 million degrees of freedom has been developed to secure the static test campaign. This communication will illustrate the partnership with Altair and the use of Altair products for the creation and verification of very large models at Airbus. It will deal with: - Geometry preparation - Meshing - Property assignment - Assembly - Checking More generally, numerical simulation will play more and more a major role in the aircraft process, from the development of new concepts / derivatives to the support of the in-service fleet. Then, this presentation will also state the coming needs regarding model creation tools to cope with Airbus strategy.
Speakers
Marion Touboul, Ingénieur en Simulation Numérique - Calcul Structure, Airbus Opérations SAS
New HyperWorks Pedestrian Impact Tool for vehicle engineering and CAE simulationAltair
The engineering challenges according to the pedestrian safety requirements have an important impact on the vehicle development time line and on vehicle design. The different pedestrian safety regulations that a vehicle has to fulfill (legal (ECE, GTR…) or consumer (EuroNCAP)) represent a high number of impact points that have to be defined depending on the regulation protocol. For each impact point, a FEM simulation has to be performed in order to evaluate the overall pedestrian protection performances. The integration of this process into an innovative virtual prototyping method needs a CAE tool allowing the automatic definition of the impact points and the automatic generation of ready-to-run FE models for impact simulation. Moreover, pedestrian requirements have a direct influence on vehicle design. That’s the reason why, an automatic definition of the impact points based on CAD design surfaces is a key to allow engineering judgment and design changes in the early phase of the vehicle development. The new HyperWorks Pedestrian Impact Tool, developed by Altair Engineering in cooperation with the Ford of Europe Pedestrian Protection Team, offers a perfect solution to these challenges. During the presentation, an overview of the tool capabilities will be given as well as results of an application on a Ford vehicle model.
Speakers
Dany Tapigue, Engineer, Ford Werke GmbH
Voluntrme.com is a platform that connects people with volunteering projects. Voluntrme is crowd service similar like Kickstarter and Indiegogo. However, Voluntrme do crowdsourcing people. Project will be executed only when it has enough people.
Fatigue Analysis of a Pressurized Aircraft Fuselage Modification using Hyperw...Altair
Fatigue Analyses of modifications on pressurized aircraft fuselages are both necessary and tedious. Using the Hyperworks software suite and StressCheck, RUAG has developed a fatigue analysis method which streamlines the process from the creation of the spectrum up to the detailed analysis of selected fastener holes and delivers results quickly and efficiently.
This method was then used to certify the installation of two large windows in the floor of a single engine turboprop A/C for aerial survey applications.
Speakers
David Schmid, Manager Structural Analysis, RUAG Schweiz AG
Due to recurrent lack of on time delivery of Drilling grid (made of a 2cm thick aluminium pad), 3D printing can potentially propose an alternative enlightened solution in 3D printing (topology optimization).
Speakers
Sébastien Haudrechy, Engineer, Airbus Group Aerospace
Exploring the capabilities of the tight integration of HyperWorks and ESACompAltair
More than 3 years ago RUAG Space started to look into ways how the very powerful meshing and post-processing capabilities of Altair HyperWorks could be combined with the advanced composite failure analysis methods provided by the ESAComp software from Componeering. RUAG’s vision behind this idea was to streamline the time consuming composite analysis process by a tight integration of the two pieces of software, thus eliminating as much as possible unnecessary breaks in the data flow. Both Altair and Componeering carefully listened to RUAG’s needs and eventually it was decided to make a common effort in providing step by step the requested functionality. The initially slow process accelerated considerably when Componeering joined the Altair Partner Alliance in 2012. Today the bi-directional interface between HyperWorks and ESAComp is considered mature enough to be challenged by a demanding real world use case: the dimensioning and verification of the load carrying structure of the MetOp-SG satellite (Meteorological Operational Satellite - Second Generation). The presentation will focus on how HyperWorks and ESAComp were used to set up the finite element model, to run the quasi-static and dynamic load cases and to evaluate the results. It will be shown in which way HyperWorks and ESAComp can support the process, what the benefits of a tight integration are and which limitations still exist.
Speakers
Ralf Usinger, Product Lead Engineer Satellite Structures, RUAG Schweiz AG
Assessing the Aerodynamic Performance of a Formula SAE Model by means of CFD ...saeid ghaffari
A simplified race car model is used in this project to analyse the aerodynamic performance of a Formula SAE car by means of CFD simulation. First, the simulation workflow in Star-CCM+ will be demonstrated. Then, before applying volumetric controls and prism-layer mesh refinement to obtain more accurate results, tools to judge solution convergence are introduced.
*the first six pages of this project are presented here. If you are interested to study the rest of this document, please contact me via saeid.ghaffari@studenti.polito.it.
Design of Rear wing for high performance cars and Simulation using Computatio...IJTET Journal
The performance of a sports car is not only limited to its engine power but also to aerodynamic properties of the car. By decreasing the drag force it is possible to reduce the engine power required to achieve same top speed thus decreasing the fuel requirement. The stability of a sports car is considerably important at high speed. The provision of a rear wing increases the downforce thus reducing the rear axle lift and provides increased traction. In this study an optimum rear wing is designed for the high performance car so as to decrease drag and increase downforce. The CAD designed baseline model with or without rear wing is being analyzed in computational fluid dynamics software. The lift and drag coefficient are calculated for all the design thus an optimum rear wing is designed for the considered baseline model.
Drag Reduction of Front Wing of an F1 Car using Adjoint Optimisationyasirmaliq
The Project Poster summarizes the aims and objectives of the Final Year Dissertation. The project starts with a detailed study on the parameters that tend to affect the performance of front wings of an F1 car and goes through designing the front wings(3) with endplates and wheel, meshing it, solving/analysing the flow and finally optimising the selected geometry using Fluent Adjoint Solver for efficient performance.
Adjoint optimisation technique is used to achieve optimal performance from the front wings. It's the most successful shape optimisation method as it's independent of the number of design variables exponentially reducing computational time and cost. The emphasis has been put on optimising the shape of the front wings using the Adjoint method as it’s the most efficient and computationally inexpensive method for design optimisation. The approach towards shape optimisation is downforce constrained drag minimization as it would result in keeping a constraint on downforce and reducing the drag at the same time, thus producing optima for a given downforce/drag value.
Surrogate Model-Based Reliability Analysis of Composite UAV Wing facilitation...Altair
Numerical simulation becomes increasingly strategic to design innovative products and to set up their manufacturing processes, reducing simultaneously development costs and time to market while increasing quality and reliability.
To support this evolution, SILKAN develops a platform for the integration of various types of simulation software, named BUILDERTM.
BUILDERTM is an efficient, innovative and scalable simulation-based platform designed to deal with the increasing use of complex numerical simulations applied to part design, system design or manufacturing processes.
The principal objectives of this platform are to:
Promote and structure the use of simulation
Standardize, parameterize and automate simulation processes.
Capture and re-use the best practices.
Facilitate coupling between different simulation levels and tools.
Improve collaboration across different project teams.
Facilitate access to simulation means for the uninitiated.
Accelerate design and production cycles.
Democratize the use of optimization and reliability procedures and better control manufacturing processes and failure risks.
An application example using BUILDERTM is addressed in this paper. It deals with the robust design of a composite UAV wing. The associated simulation workflow includes two principal steps.
During the first step, Matlab is used to estimate aerodynamic loads applied to the wing when as a function of flight parameters: air flow speed, angle of attack of the wing and aileron deflection angles. A Design of Experiment (DoE) is built by varying the flight parameters in order to cover all the flight domain of the UAV.
The aerodynamic loads thus obtained are then injected into OptiStruct to estimate Tsai-Wu failure criteria for the composite material. An efficient surrogate model is then built from the obtained Tasi-Wu criteria and covers the entire flight domain. Finally to conclude this first part, a failure probability , based on Tsai-Wu criteria, is estimated using the produced surrogate model.
In the second step the following optimization problem is defined using some design variables of the wing (essentially thicknesses of composite layers of the wing):
Wing Mass is calculated by Optistruct, and being evaluated using the step1. An evolutionary algorithm implemented into Dakota is used to perform this surrogate-model -
based optimization.
The set up, parameterization and automation of this complex simulation workflow is facilitated and achieved through the use of the BUILDERTM platform. The combination of different software at different levels of the workflow is also made accessible by the use of BUILDERTM.
Speakers
Samir Ben Chaabane, Numerical Simulation Manager for EMEA, SILKAN S.A
Aircraft Finite Element Modelling for structure analysis using Altair ProductsAltair
The Airbus airframe design process has considerably evolved since 20 years with the constant improvement of numerical simulation capability and the computational means capacity. Today the size of Finite Element Models for aircraft structural behaviour study is exceeding the boundary of airframe components (fuselage section, wing); for the A350, a very large scale non-linear model of more than 60 million degrees of freedom has been developed to secure the static test campaign. This communication will illustrate the partnership with Altair and the use of Altair products for the creation and verification of very large models at Airbus. It will deal with: - Geometry preparation - Meshing - Property assignment - Assembly - Checking More generally, numerical simulation will play more and more a major role in the aircraft process, from the development of new concepts / derivatives to the support of the in-service fleet. Then, this presentation will also state the coming needs regarding model creation tools to cope with Airbus strategy.
Speakers
Marion Touboul, Ingénieur en Simulation Numérique - Calcul Structure, Airbus Opérations SAS
New HyperWorks Pedestrian Impact Tool for vehicle engineering and CAE simulationAltair
The engineering challenges according to the pedestrian safety requirements have an important impact on the vehicle development time line and on vehicle design. The different pedestrian safety regulations that a vehicle has to fulfill (legal (ECE, GTR…) or consumer (EuroNCAP)) represent a high number of impact points that have to be defined depending on the regulation protocol. For each impact point, a FEM simulation has to be performed in order to evaluate the overall pedestrian protection performances. The integration of this process into an innovative virtual prototyping method needs a CAE tool allowing the automatic definition of the impact points and the automatic generation of ready-to-run FE models for impact simulation. Moreover, pedestrian requirements have a direct influence on vehicle design. That’s the reason why, an automatic definition of the impact points based on CAD design surfaces is a key to allow engineering judgment and design changes in the early phase of the vehicle development. The new HyperWorks Pedestrian Impact Tool, developed by Altair Engineering in cooperation with the Ford of Europe Pedestrian Protection Team, offers a perfect solution to these challenges. During the presentation, an overview of the tool capabilities will be given as well as results of an application on a Ford vehicle model.
Speakers
Dany Tapigue, Engineer, Ford Werke GmbH
Voluntrme.com is a platform that connects people with volunteering projects. Voluntrme is crowd service similar like Kickstarter and Indiegogo. However, Voluntrme do crowdsourcing people. Project will be executed only when it has enough people.
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i m constantly looking for a job and this this portfolio is to give you a deeper insight into my experience and skills I have gained over my recent history.
CFD Simulation for Flow over Passenger Car Using Tail Plates for Aerodynamic ...IOSR Journals
This work proposes an effective numerical model based on the Computational Fluid Dynamics
(CFD) approach to obtain the flow structure around a passenger car with Tail Plates. The experimental work of
the test vehicle and grid system is constructed by ANSYS-14.0. FLUENT which is the CFD solver & employed in
the present work. In this study, numerical iterations are completed, then after aerodynamic data and detailed
complicated flow structure are visualized.
In the present work, model of generic passenger car has been developed in solid works-10 and
generated the wind tunnel and applied the boundary conditions in ANSYS workbench 14.0 platform then after
testing and simulation has been performed for the evaluation of drag coefficient for passenger car. In another
case, the aerodynamics of the most suitable design of tail plate is introduced and analysedfor the evaluation of
drag coefficient for passenger car. The addition of tail plates results in a reduction of the drag-coefficient
3.87% and lift coefficient 16.62% in head-on wind. Rounding the edges partially reduces drag in head-on wind
but does not bring about the significant improvements in the aerodynamic efficiency of the passenger car with
tail plates, it can be obtained. Hence, the drag force can be reduced by using add on devices on vehicle and fuel
economy, stability of a passenger car can be improved.
Computational steering Interactive Design-through-Analysis for Simulation Sci...SURFevents
Computational steering has evolved with advances in computing and visualization technologies. This session will showcase interactive design-through-analysis techniques that seamlessly integrate computer-aided design and simulation-based analysis tools. The approach replaces traditional simulation-based analysis with IgANets, which embeds physics-informed machine learning into the Isogeometric Analysis paradigm. IgANets train parametrized deep networks to predict solution coefficients of B-Spline/NURBS representations, enabling instantaneous evaluation and interactive feedback loops. A first-of-its-kind demonstrator coupling IgANets with a novel user frontend, developed at SURF, will be presented to initiate a new trend in computational steering towards interactive design-through-analysis.
How Accurate is Future Facilities 6Sigma DCXRobert Schmidt
We know that our customers need accurate results that they can rely on to make critical decisions. We understand these challenges, and we’ve worked hard to ensure that 6SigmaDCX achieves this. Since the first release of the software, we’ve used the expertise of our internal development and engineering teams to develop room-scale models and their individual components. Furthermore, independent audits have been carried out by R&D establishments and educational bodies to validate the 6SigmaDCX software. The results of these audits, along with positive messages from end users, show that 6SigmaDCX provides the accuracy needed to make critical decisions about your facility’s performance.
Towards smart and sustainable machiningLiu PeiLing
Computer Numeric Control (CNC) revolutionized the machining technology and has been the cutting edge of digital manufacturing since 1950s. CNC machining model, simulation, verification, and optimization have been a vivid research topic of Smart Machining that automated the CNC programming (CAM) and cutting process, hence greatly increased machining productivity since 1990s. This paper traces back the history of CNC simulation, analysis the different CNC machining models, tested with application examples, and listed different CNC verification industry applications for the last 20 years. The new challenge comes from sustainable manufacturing. Towards smart and competitive sustainable machining, CNC model and simulation will be used to optimize the machining process, where the raw material could be saved through First Part Correct technology, the energy could be saved through cutting speed optimization, and used parts could be saved by remanufacturing.
1. CAD Design Portfolio
KOK WEE SOON
ABSTRACT
The document will cover the two major CAD/ Simulation projects
undertaken in the final year of university of which comprises the
Beyond Zero Emissions Melbourne CBD Wind Turbine project,
Race Car Front Wing Design and Simulation competition, and also
smaller projects undertaken previously.
2. 2
Beyond Zero Emissions Melbourne
CBD Wind Turbine Project (2011)
This project focuses on the use of previously constructed CAD model of the
Melbourne CBD to run a wind simulation to identify possible viable spots on
rooftops to install wind turbines for green power generation. Due to the
complexity of the previous Autocad CAD models received, we were given
instructions as a team to construct the models in Gambit from scratch to clean
up the lines of which would lead to ease in future meshing for Computational
Fluid Dynamics (CFD) simulations.
The whole Melbourne CBD CAD model was split into various blocks of which
were assigned to each team member. This is then constructed again with the
Gambit software but measuring the pre-existing dimensions of the building
models provided. Samples of the constructed blocks can be seen as below in
Figure 1.
Figure 1: Google Maps (above) and Pre-existing AutoCAD model (below) of the Melbourne
CBD
3. 3
Each block is individually modelled to approximated heights obtained from the
AutoCAD model in the Gambit modelling environment for compatibility with
the CFD program of which will be used at a later date to simulate fluid flow
over the compiled blocks. I was made in charge of modelling blocks B13_14,
B27_28, B29_30 and B33_34.
Due to Gambit being a relatively new operating environment for me
personally, I had to put in the effort to seek online tutorials to operate the
software and towards the end I was able to competently manage the
modelling of the city blocks as shown below in Figure 2.
Figure 2: Gambit modelling of individually delegated blocks of Melbourne CBD
4. 4
The completed blocks are then compiled from all the team members for
further processing in Figure 3. The model has been passed on to the next
batch of volunteer engineers to pass it through CFD programs and ultimately
contribute to the study of viability of wind turbines in the CBD areas.
Figure 3: Compiled Melbourne CBD blocks as modelled by all team members
5. 5
Race Car Front Wing Design
Project (2010)
This is one of the major projects undertaken during the 3rd
year of university
and involved the CAD design of a racecar front wing based on given
specifications and constraints. The Unigraphics NX7 CAD model is then
imported into ANSYS CFD and FEA module for simulation at given loads.
At the start of the project, we were required to construct an NX7 CAD model
from scratch based on the information provided. With the construction of the
model, variables are assigned to the inserted constraints to simplify future
changes to the model.
Figure 4: Variables as needed to design and adjust dimensions according to specifications
After the initial aerofoil model is constructed, end plates were added to the
design to reduce wingtip vortices from forming during simulation that would
contribute to a reduction in downforce generated as shown below. The model
shows a rib and spar construction of the wing.
Figure 5: Initial aerofoil constructed based on rib and spar internal construction
6. 6
The designed wing, together with the car body and mounts, are imported into
ANSYS CFD and FEA modules to undergo simulations to check integrity and
performance of the wing. With the use of CFD, flow speeds and pressures
can be estimated with different wing designs, leading to a more efficient and
cost effective design of the wing. Downforce and drag coefficients on the wing
can be calculated and tabulated to generate a graph to select the best
designs.
Figure 6: ANSYS CFD Simulation of designed front wing and head
7. 7
With Finite Element Analysis (FEA) of the wing when subjected to operating
loads, the stress, strain and deflection of the element can be seen at various
points of the structure. This is an important step to check the integrity of the
design when subjected to loads with the inclusion of the appropriate safety
factors.
Figure 7: ANSYS FEA Structural testing of front wing
By working as a team, we were able come in 4th
out of 22 teams competing.
This project has enabled us to be competent in using Unigraphics NX7 as a
means of engineering modelling and also ANSYS for simulation of the models
to verify the integrity of the designs produced.
8. 8
Additional Projects
• Design of a Materials Impact Test Rig using Unigraphics NX7
(2009)
o CAD design work focusing on integrity of designed components
o Assembly with individually designed parts in the “ASSEMBLY”
mode into a final product
o Focused on the assembly constraint functions to limit the range
of motions of the components relative to each other
o Stress and strain on the components are calculated manually in
Excel
o Introduction to integration of variables into design for
streamlined change of specifications where applicable.
• Design of specimen holder for the Far-Infrared Beamline of the
Australian Synchrotron (2011)
o Designed a current specimen holder for spectroscopy machinery
with a higher aperture to allow higher transmitivity of far-infrared
x-rays (F-IR) from the beamline
o Drafted a CAD model of the holder to be passed onto the
mechanical workshop to be fabricated and PVD coated