Adhish Majumdar of GEONX delivered on 18th May 2016 a presentation on the "Simulation of the Surface Hardening of a Forged Crankshaft using High Performance Computing" at the second edition of the ICOMP conference held at Liège, Belgium.
Simulations of the Surface Heat Treatment of a forged crankshaft using Virfac®Geonx
The present work models the induction heating and quenching of a journal in the crankshaft – taking into account the physics of the thermal, mechanical and metallurgical phenomena.
Advanced Welding and Heat Treatment simulation using Virfac: split by sector ...Geonx
GeonX develops and distributes its integrated software solution Virfac® for simulations of welding (fusion and friction), additive manufacturing, machining, heat treatment, surface treatment, carburizing, and damage resistance (crack propagation based on the XFEM). GeonX has clients in Europe, Japan and North America, in the fields of aeronautics, automobile, naval, and nuclear sectors.
Simulation of chained processes: Laser Cladding, Heat Treatment and MachiningGeonx
The present lecture aims to:
1. Apply the welding simulation methodology to additive layer manufacturing simulation
2. Demonstrate the feasibility and pertinence of manufacturing chaining simulation using Virfac.
3. Perform sensitivity studies on the operating conditions and check the influence on quality criteria in terms of residual distortions.
Experimental verification and finite element analysis of a sliding door syste...Altair
A sliding door system is used in commercial vehicles and passenger cars to allow a larger unobstructed access to the interior for loading and unloading. The movement of a sliding door on vehicle body is ensured by mechanisms and tracks having special cross-section which is manufactured by rollforming and strech bending process. There are three tracks and three mechanisms which are called upper, central and lower on a sliding door system. There are static requirements as strenght on different directions, rigidity for mechanisms, door drop off, door sag; dynamic requirements as high energy slam opening-closing and durability requirement to validate these products. In addition, there is a kinematic requirement to find out force values from door handle during manuel operating. In this study, finite element analysis and physical test results which are realized for sliding door systems will be shared comparatively.
Speakers
Caner Güven, Analysis Engineer, Rollmech Automotive
Simulations of the Surface Heat Treatment of a forged crankshaft using Virfac®Geonx
The present work models the induction heating and quenching of a journal in the crankshaft – taking into account the physics of the thermal, mechanical and metallurgical phenomena.
Advanced Welding and Heat Treatment simulation using Virfac: split by sector ...Geonx
GeonX develops and distributes its integrated software solution Virfac® for simulations of welding (fusion and friction), additive manufacturing, machining, heat treatment, surface treatment, carburizing, and damage resistance (crack propagation based on the XFEM). GeonX has clients in Europe, Japan and North America, in the fields of aeronautics, automobile, naval, and nuclear sectors.
Simulation of chained processes: Laser Cladding, Heat Treatment and MachiningGeonx
The present lecture aims to:
1. Apply the welding simulation methodology to additive layer manufacturing simulation
2. Demonstrate the feasibility and pertinence of manufacturing chaining simulation using Virfac.
3. Perform sensitivity studies on the operating conditions and check the influence on quality criteria in terms of residual distortions.
Experimental verification and finite element analysis of a sliding door syste...Altair
A sliding door system is used in commercial vehicles and passenger cars to allow a larger unobstructed access to the interior for loading and unloading. The movement of a sliding door on vehicle body is ensured by mechanisms and tracks having special cross-section which is manufactured by rollforming and strech bending process. There are three tracks and three mechanisms which are called upper, central and lower on a sliding door system. There are static requirements as strenght on different directions, rigidity for mechanisms, door drop off, door sag; dynamic requirements as high energy slam opening-closing and durability requirement to validate these products. In addition, there is a kinematic requirement to find out force values from door handle during manuel operating. In this study, finite element analysis and physical test results which are realized for sliding door systems will be shared comparatively.
Speakers
Caner Güven, Analysis Engineer, Rollmech Automotive
The Team H2politO: vehicles for low consumption competitions using HyperWorks Altair
The Team H2politO is a group of students of the Politecnico di Torino. The student’s background and profiles are very diverse, everyone comes from a different discipline of engineering and together they compose a complete Team. The disciplines range from Automotive and Mechanical to Electronics, Aerospace, Energy, Mathematics, Computer Science, Mechatronics, Management, Cinema and Media and Industrial Design. The Team mission is to shape a new generation of engineers, leaders in their fields, who represent the educational excellence in regard of each of their competencies.
The results of Team passion and hard work are three low-energy consumption vehicles completely designed and made by the Team: IDRA - hydrogen powered prototype; XAM – bioethanol powered parallel hybrid urban concept; XAM 2.0 –EREV city vehicle.
The main goal is to take part and win in Shell Eco-marathon, a competition that every year involves more than one hundreds of students teams arriving from all over Europe. Especially we would like to spread the Shell Eco-marathon values through ours, combining the sustainable development with a vehicle that uses the least possible amount of energy.
H2politO is a different, innovative and somehow unique project, is not just a Team but something more: it is a new type of conceiving educational, professional and personal growth. Team members aim at being perceived as an experimental laboratory where competences, capabilities and potentialities of future’s engineers are fostered. Students strive to become not only solid and advanced technical experts but, equally important, down-to-earth managers having excellent communication, leadership and teamwork skills.
Practical and hands-on experiences are doubtlessly a complementary and enriching form of educational path where it is very important the use of simulation software like HyperWorks. Team members have a real opportunity to lead their educational path by building and crafting their own thesis. Final papers are indeed part of a cluster of thesis which combines all the technological and organizational areas of development H2politO has envisioned and embraced.
The Team believes in hard work as the basis of future success. Students crave for continuously improving and strive for exceeding expectations by nurturing the team spirit in order to create those synergies able to add value to individual performances and capabilities. As a consequence, passion and team-spirit are really the foundation of H2politO values.
Speakers
Prof. Massimiliana Carello, Politecnico di Milano
Thermostamping simulation for woven thermoplastic composites (PA) with HyperFormAltair
The thermostamping process of thermoplastic composites can be analyzed with simulation software. In addition to the optimization that can be brought to process (defects, raw material quantity …), the main interest is to integrate results from process into the performance simulation. This article presents an approach to simulate thermostamping of thermoplastic composites (PA) with HyperForm.
The material law is identified from Bias test trials, then, the simulation is performed by HyperForm with the solver Radioss or Ls-Dyna. Fiber orientations (for non-linear anisotropic behavior) and defects (global wrinkles, and wrinkles in the thickness, area with failure risk, thickness variation…) are identified and mapped on structural mesh for mechanical simulation.
Based on this approach, several test/simulation comparisons were performed on both static and dynamic. They demonstrate the necessity of considering the process phase, especially for complex geometries.
Regarding advanced application for such simulation tool: Faurecia Automotive Exterior is developing technologies to produce one-shot visible parts (CFRT thermostamping + overmolding injection in one step). This case study is the most challenging application we are working on. Combining thermostamping simulation and one-shot process brings benefits to both sides thanks to cross results on complex application.
Globaly, to improve the prediction of this simulation tool, next steps are the computation of local density; the consideration of thermal exchanges with the mold during the production process; the modelization improvement of boundary conditions during process (woven holding …, frames…).
Speakers
Guillaume CHAMBON, Product Research & Advanced Simulation Manager, FAURECIA Automotive Exterior
Thin low coal seam mining technology alpha sophie★ Sophie Guan
We have rich experience in low coal seam mechanization mining engineering, complete equipment supply and technical support for more than 50 low coal seam projects, more than 60 projects of coal washing plant design, construction, project delivery in mining, materials handling.
Developed haulage off pan shearer ,for the first time achieved a minimum limit of thin seam mining height 0.56m mechanized mining. Successfully wide used in ultra low coal seam below 800mm. The application of the technology, coal face yields 1.8 times, mining efficiency increased by 3.38 times, tons of coal production cost was reduced by 63%.
For more information, get in touch with us:
sophie.guan@alpha-technology.com.au
Torque is part of the basic specification of an engine: the power - output of an engine is expressed as its torque multiplied by its rotational speed. Digital Torque Meter is an intellectualized and digital measuring instrument, which is specially designed for testing and measuring of varied torque to be applied to caps of bottles, and is of use to Pharmaceuticals and Food and Beverage Industry.For More Information Please Logon http://goo.gl/QsvLfC
GeonX is a high-tech start-up company specializing in virtual manufacturing. Created in 2012 from the enthusiasm of its two founders, and an investment by a group of private investors, GeonX develops and markets its VIRTUAL FACTORY, Virfac®. This product is based on the finite element solver Morfeo, which has been actively developed since 2003, with the aim of carrying out massively parallel simulations of various manufacturing processes.
GeonX develops and distributes its integrated software solution Virfac® for simulations of welding (fusion and friction), additive manufacturing, machining, heat treatment, surface treatment, and damage resistance (crack propagation based on the XFEM). GeonX has clients in Europe, Japan, North America, in the aeronautics, automobile, naval, and nuclear sectors. GeonX’s leading aerospace client is the SAFRAN Group (France).
The Team H2politO: vehicles for low consumption competitions using HyperWorks Altair
The Team H2politO is a group of students of the Politecnico di Torino. The student’s background and profiles are very diverse, everyone comes from a different discipline of engineering and together they compose a complete Team. The disciplines range from Automotive and Mechanical to Electronics, Aerospace, Energy, Mathematics, Computer Science, Mechatronics, Management, Cinema and Media and Industrial Design. The Team mission is to shape a new generation of engineers, leaders in their fields, who represent the educational excellence in regard of each of their competencies.
The results of Team passion and hard work are three low-energy consumption vehicles completely designed and made by the Team: IDRA - hydrogen powered prototype; XAM – bioethanol powered parallel hybrid urban concept; XAM 2.0 –EREV city vehicle.
The main goal is to take part and win in Shell Eco-marathon, a competition that every year involves more than one hundreds of students teams arriving from all over Europe. Especially we would like to spread the Shell Eco-marathon values through ours, combining the sustainable development with a vehicle that uses the least possible amount of energy.
H2politO is a different, innovative and somehow unique project, is not just a Team but something more: it is a new type of conceiving educational, professional and personal growth. Team members aim at being perceived as an experimental laboratory where competences, capabilities and potentialities of future’s engineers are fostered. Students strive to become not only solid and advanced technical experts but, equally important, down-to-earth managers having excellent communication, leadership and teamwork skills.
Practical and hands-on experiences are doubtlessly a complementary and enriching form of educational path where it is very important the use of simulation software like HyperWorks. Team members have a real opportunity to lead their educational path by building and crafting their own thesis. Final papers are indeed part of a cluster of thesis which combines all the technological and organizational areas of development H2politO has envisioned and embraced.
The Team believes in hard work as the basis of future success. Students crave for continuously improving and strive for exceeding expectations by nurturing the team spirit in order to create those synergies able to add value to individual performances and capabilities. As a consequence, passion and team-spirit are really the foundation of H2politO values.
Speakers
Prof. Massimiliana Carello, Politecnico di Milano
Thermostamping simulation for woven thermoplastic composites (PA) with HyperFormAltair
The thermostamping process of thermoplastic composites can be analyzed with simulation software. In addition to the optimization that can be brought to process (defects, raw material quantity …), the main interest is to integrate results from process into the performance simulation. This article presents an approach to simulate thermostamping of thermoplastic composites (PA) with HyperForm.
The material law is identified from Bias test trials, then, the simulation is performed by HyperForm with the solver Radioss or Ls-Dyna. Fiber orientations (for non-linear anisotropic behavior) and defects (global wrinkles, and wrinkles in the thickness, area with failure risk, thickness variation…) are identified and mapped on structural mesh for mechanical simulation.
Based on this approach, several test/simulation comparisons were performed on both static and dynamic. They demonstrate the necessity of considering the process phase, especially for complex geometries.
Regarding advanced application for such simulation tool: Faurecia Automotive Exterior is developing technologies to produce one-shot visible parts (CFRT thermostamping + overmolding injection in one step). This case study is the most challenging application we are working on. Combining thermostamping simulation and one-shot process brings benefits to both sides thanks to cross results on complex application.
Globaly, to improve the prediction of this simulation tool, next steps are the computation of local density; the consideration of thermal exchanges with the mold during the production process; the modelization improvement of boundary conditions during process (woven holding …, frames…).
Speakers
Guillaume CHAMBON, Product Research & Advanced Simulation Manager, FAURECIA Automotive Exterior
Thin low coal seam mining technology alpha sophie★ Sophie Guan
We have rich experience in low coal seam mechanization mining engineering, complete equipment supply and technical support for more than 50 low coal seam projects, more than 60 projects of coal washing plant design, construction, project delivery in mining, materials handling.
Developed haulage off pan shearer ,for the first time achieved a minimum limit of thin seam mining height 0.56m mechanized mining. Successfully wide used in ultra low coal seam below 800mm. The application of the technology, coal face yields 1.8 times, mining efficiency increased by 3.38 times, tons of coal production cost was reduced by 63%.
For more information, get in touch with us:
sophie.guan@alpha-technology.com.au
Torque is part of the basic specification of an engine: the power - output of an engine is expressed as its torque multiplied by its rotational speed. Digital Torque Meter is an intellectualized and digital measuring instrument, which is specially designed for testing and measuring of varied torque to be applied to caps of bottles, and is of use to Pharmaceuticals and Food and Beverage Industry.For More Information Please Logon http://goo.gl/QsvLfC
GeonX is a high-tech start-up company specializing in virtual manufacturing. Created in 2012 from the enthusiasm of its two founders, and an investment by a group of private investors, GeonX develops and markets its VIRTUAL FACTORY, Virfac®. This product is based on the finite element solver Morfeo, which has been actively developed since 2003, with the aim of carrying out massively parallel simulations of various manufacturing processes.
GeonX develops and distributes its integrated software solution Virfac® for simulations of welding (fusion and friction), additive manufacturing, machining, heat treatment, surface treatment, and damage resistance (crack propagation based on the XFEM). GeonX has clients in Europe, Japan, North America, in the aeronautics, automobile, naval, and nuclear sectors. GeonX’s leading aerospace client is the SAFRAN Group (France).
Subsea pipelines the remotely welded retrofit tee for hot tap applications ...Neil Woodward
Over the last 10 years Statoil has developed subsea remote hot tap technology. The first use of the remote hot tap technology was the Tampen Link hot tap in 2008. The hot tap cutting operation itself was performed without the use of divers; however, the preparatory works including hyperbaric welding of the hot tap tee was performed with saturation divers. The world’s deepest hot tap operations on a pressurized pipeline were performed on the Ormen Lange field in the Norwegian Sea in August 2009. Two Hot Taps were conducted in a water depth of 860 meters on pre-installed tees. The development of the Pipeline Repair System Remote Hot Tap equipment is the result of targeted research and development effort and extensive qualification work over many years. The Retrofit Tee remote installation, welding and cutting equipment has now been employed as part of a production installation: the Åsgard Subsea Compression project to extend the Åsgard gas-field lifetime.
This paper describes the dry hyperbaric GMA weld procedure development and qualification performed in the laboratory, using the Corrosion Resistant Alloy consumable filler material Alloy 59, for the Remote Hot Tapping application using the Retrofit Tee. Specific attention was paid to areas of concern prior to performing the formal Weld Procedure Qualification work, particularly with regard to the effects of moisture and temperature upon the resultant weld quality. Weld procedures developed in the laboratory were successfully tested subsea in representative environments using the Remote Tee Welding Tool (RTWT) equipment in the Sognefjord, Norway, with offshore tests performed at 265 and 350msw in 2011. Further tests were performed in 2012 at 265msw and in the Retrofit Tee itself at 316msw in the Nedstrandfjord.
The hyperbaric GMA weld procedures have now been applied for the production application for the Åsgard Subsea Compression project, with the installation of a Retrofit Tee, associated valve module and gooseneck spool to enable a cost-effective modification to the existing pipeline network without interfering with ongoing production. The Retrofit Tee will be connected with a Subsea Compressor station to extend the gas-field lifetime.
This milestone represents the world’s first application of diverless dry hyperbaric GMA welding for a subsea production application.
Computational modelling and optimization for EPM for solid state processesLeonardo ENERGY
The next course in our techwatch series on Electromagnetic Processing of Materials (EPM) deals with the use of computational modelling and optimization for designing EPM solid state processes. Strong multiphysics couplings involved in these processes make their design and optimisation rather tricky.
In this course you'll learn about the kind of modelling techniques used in software modelling tools, which techniques can be suited to deal with the processes you wish to model, and how you can improve your design stage with these tools.
Course details
You will first get an introduction to modelling of electromagnetic couplings in forming processes; electromagnetic/heat transfer couplings as in induction heating processes, electromagnetic/solid couplings as in magnetic pulse forming processes.
We shall then introduce some numerical techniques commonly used in commercial software to deal with these processes. Space discretization techniques (full finite element vs. coupled finite element/boundary element) as well as time discretization schemes (full time integration vs. harmonic approaches) will be discussed. The issue of computational time reduction techniques will also be addressed.
Practical examples of use for design in industrial applications will then be described. We shall first introduce a case regarding induction mass heating processes aiming at minimizing energy losses. A second example will deal with optimisation of induction heat treatment applications aiming at controlling the final metallurgy of the part produced. A last example will focus on the control of magnetic pulse welding processes in order to ensure final quality of the welded product.
This presentation is about my academic project on generating electricity using thermoelectric generator (TEG), to harvest the thermal energy dissipated by combustion gases. The current project discusses the optimal design of the thermoelectric generator (TEG) and the design is conducted analytically based on the idea of air cooled TEG system using fins and an experimental system is fabricated and tested by attaching to exhaust pipe of a two wheeler IC engine for the heat source to verify the validity of the proposed system.
On the effects of advanced end-winding cooling on the design and performance ...Vincenzo Madonna
For citing this work:
V. Madonna, P. Giangrande, A. Walker and M. Galea, "On the Effects of Advanced End-Winding Cooling on the Design and Performance of Electrical Machines," 2018 XIII International Conference on Electrical Machines (ICEM), Alexandroupoli, 2018, pp. 311-317.
Abstract:
High performance and reliable electrical machines
are often required in modern applications and an appropriate
thermal management allows to fulfil such demand. Thermal
management is crucial for improving performance, reducing size
and preserving the insulation lifetime of electrical machines.
From this prospective, a novel cooling method for machine
end-windings is proposed in the present work. Its cooling action
focuses on the end-windings, since they are commonly identified
as the machine hot-spot. The effectiveness of the proposed
cooling method is experimentally proved and the improvement,
in terms of current density, for a given wire insulation thermal
class, is quantified.
A previously designed permanent magnet synchronous
machine, implementing a traditional housing water jacket, is
used as a case study. The influence of the improved current
density on machine torque density is investigated, through finite
element simulations, when the proposed cooling method is
integrated to the existing housing water jacket.
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block diagram and signal flow graph representation
Simulation of the Surface Hardening of a Forged Crankshaft
1. Virfac® | The Virtual Factory
Virtual Manufacturing Made Real
Simulations of the Surface Heat Treatment of a forged
crankshaft using High Performance Computing
ICOMP’16, 18/05/2016
A. Majumdar, J. Barboza, L. D’Alvise
adhish.majumdar@geonx.com
www.geonx.com