Engineering

Static analysis

In FEM area we offer expertise in both linear analysis and geometrical/material/contact nonlinear analysis, or even quasi-static analysis. Based on the results of these analyses, we are able to provide guidance on any modifications to the construction or systems that will exactly meet our clients requirements.

Our experience is based on the long-term cooperation with leading Czech and European partners in the automotive, aircraft and railway industries.

We offer expertise with a wide range of solvers, but we mainly use Radioss and OptiStruct. The preprocessor that we usually use is HyperMesh, Simlab.

Analyses examples

Modal analysis of the compressor blade

Eigen frequencies and the corresponding Eigen shapes are important in determining the operating modes that can cause restless operation, noise and possible component damage. The video shows the compressor blade Eigen shape.


Static analysis of the lorry chassis

Static analysis of a lorrys chassis, done to validate results of the optimization from the OptiStruct. This analysis confirms a theoretical material saving and stiffness rising.


Static analysis of the lorry chassis

Static analysis of the electromobile chassis

Static analysis of electromobile chassis indicates the critical areas in the whole structure.

Static analysis of the rear part of a bicycle frame

Static analysis of the rear part of a bicycle frame

Static structural analysis of the bicycle frame is at the place where the chain and seats stay connected. This analysis shows the maximal stress of a part. Results are further used for the optimization process that leads to the stress reduction in the critical area.

Dynamic analysis

We offer both small and larger dynamic analysis solutions to our clients. We have long-term experience based on the FEM simulation of crash tests and buckling analysis. Issues are usually solved with Radioss, but our portfolio offers a series of other software possibilities. We are able to create a model either in HyperMesh for the dynamic analysis or in HyperCrash for the crash analysis.

Analyses examples

Structural analysis

Structural analysis

This analysis type is one of the basic tools for evaluating parts and their properties. On the picture there is a detail of the bending plastic part. The analysis shows the stress peaks that can lead to damage when exceeding allowed material properties.

Plastic strain

Solver Radioss Block can solve the dynamic analysis which can be output (e.g. plastic strain). Picture shows plastic strain on steel tube.


Composite materials

Material sampling is one of the most important parts of composite modeling. This video shows the tensile test. There is visible graduating necking till its damage; a contour of the stress and a vector of the nodal displacement are shown.


Composites headstock: Composite materials are still commonly used. Modeling composite material is very difficult because of the material definition. In case of a composite part crashing with a rigid obstacle, a brittle crack is usually initiated depending on various factors (e.g. stacking). This and a lot of other parameters affect the complex behavior of the composite model. The next levels of composite materials are sandwich materials. Radioss accepts a few material models suitable for composite materials.


Crash analysis

Crash analyses are done to investigate the possibility of future damage if any part fails. There is a possibility to include the failure model to improve detailed analysis of the critical state. With a satisfactory amount of input data, it is possible to define the material failure and thus localize the analysis to the specific critical case. Here, a pipe failure is shown followed by a crash with a barrier.


Optimization

For the optimization of mechanical components we use the well-known optimizer called OptiStruct. Its optimization algorithm enables more effective material distribution (mass saving) or stiffening across the whole structure. In many cases both these aspects are improved. The benefit for the customer is to gain insight into recommended changes to the structure in the static or fatigue load-cases point of view. This offers the following advantages:

  • Mass saving while keeping the stiffness properties (production costs savings)
  • Increasing the strength while saving on material costs via shape modification of the component
  • Finding the optimal thicknesses of shell structures in order to setup the proper frequencies with the aim to increase the structure strength, decrease the noise, etc.

All of the optimization disciplines can be freely combined with one another.

Analyses examples

Topology optimization

Topology optimization provides the conceptual design proposal of the optimized component. Principally the optimizer finds the optimal material distribution in the given design space. Based on such results the next optimization steps follow to tune the component design in a more detailed manner (shape, size optimization). The picture shows an optimization example of a bicycle component.

Shape optimization allows defining and computing with various possible shapes of the component and in a way to find the optimal combination among them. While using this optimization discipline the HyperMorph tool is needed and utilized in order to create desired shapes.

Shape optimization The size optimization

The size optimization is the discipline used for the final tuning of the component design. For the design variables, each property of the model can be parameterized and used (component thickness, flexibility, etc.). The picture shows an optimization of a bicycle component indicating the decreased stress.

free shape optimalizace vidlice

The example of the seat frame shape optimization is shown.

Multibody simulations

  • computing complex systems using MBD method
  • crash simulation
  • vehicle dynamic analysis

As evidenced by the excellent references from our clients, we also offer a full range of experience and consulting in creating, solving and analyzing systems calculated by MBD. We specialize in MBD tasks in the biomechanical, passive and active safety fields. Outputs of our work are recommendations on how to change the design in order to decrease human injury.

Second special group of MBD tasks is analysis of dynamic systems.

A typical example of our services in this area is recommendations on how to set, analyze, and optimize the chassis of road and rail vehicles. MotionSolve enables the user to correctly set the chassis geometry.

Analyses examples

Madymo model of the child

Madymo model of the child: Dummy is positioned on the FE model of a seat with a combined model of the safety belt. Simulation model was used to crash according to the directives and analyzing the potential on injury on the human baby.

Side impact according to the EEVC in Madymo

Side impact according to the EEVC in Madymo: Barrier, moving against the vehicle, is the model of MultiBody. Conditions at the moment of the crash are defined exactly. The side structure is attached to the MultiBody parts of the interior. A child seat with a child inside is positioned on the MultiBody seat.

Simulating real test

Madymo model for simulating real test according the ECER44 directive: Model was created according to the directive ECER44. Seat behavior with the child in the seat corresponds with the real test. The analysis provides data to consider and mitigate the risk of a child injury in the child seat.

MB child seat in Madymo

MB child seat in Madymo: Model copies the real seat. Base part of the model is framework. Inside the framework there are cushions that make space for the child. This model consists of the MultiBody child seat and FE model of the child seat belts. This FE model is connected to the child seat.

Child seat in the sloped position

Child seat in the sloped position: We are able to simulate the child seat in the reclined position and determine possible outcomes.

Simulating a car crash with a pedestrian in Madymo

Simulating a car crash with a pedestrian in Madymo: This case of a car crash with a pedestrian uses a model from the Madymo database 50% Hybrid III. This model is situated to simulate the human’s walk. Car model contains the so called “facet frame” with MultiBody chassis. For better matching with a real-world scenario, there is an implemented element of suspension and damping. In the final effect this implementation allows a certain “slope” when the car hit the pedestrian.

Influence of the secondary place shape study with the software Madymo: Simulating the impact of a pedestrian to the secondary part gives the information about the pedestrian’s injury. Purpose of this study is to evaluate if the secondary impact can evoke higher injury than primary collision with the car.

Simulating the car crash with a city tram: The purpose of these crash types is to qualify the crew injury when the average city crash occurs. Vehicles are done by the MultiBody method. On each vehicle’s chassis there is an accelerometer, which outputs acceleration in the three axes (x, y, and z).

Madymo model Inside the car

Car interior Madymo model with seated dummy: This model allows a full study of crew injury in case of frontal impact. Based on the model behavior we can optimize the settings of the passive safety elements.

Simulation models of cars in Madymo environment: Vehicles are done by a combination of the FE and MultiBody approach. MultiBody is applied on the chassis. To the chassis are assigned wheels using the suspensions and the dampers. Body is made of FE, by which is reached a high geometrical accuracy.

On each car body are accelerometers to scan the acceleration in each direction.

Inside the car is a fully equipped interior with all main elements like in the real car. This includes an instrument panel, seats, airbag inside the steering wheel, and the complete safety belts system including pre-tensioner.


Frontal crash simulations of the two different car classes: This is one of the main types of accident which occurs during overtaking. Initial velocities are considered equal.


Frontal impact with overlap: Simulation of frontal impact with an overlap is done for the same reason as the simple frontal impact. In this case it takes into account the driver’s effort to avoid the crash. These cars are overlapped to 40% of their width.


Lateral impact: In the simulation scene, one car stays and the second car hits the first one at the predefined velocity. Impact is always realized on the left side, because of the bigger injury coefficient of the driver.

Validation barrier model

Validation barrier model: Validation was done by hitting certified impactor to the barrier. The barrier deformation and the contact force were obtained. Both results are compared with the FE barrier model that is very close to the situation in reality.

Validation of the simulation car: Behavior of the simulation model must be almost the same as the real model. This is the reason why the models are validated. Validation is according to the results from EuroNCAP.

Validation of the simulation car Validation of the simulation car

Frontal car crash with a scooter, using the airbag: MultiBody model of a car and rider on a scooter with an FE model of airbag.

Frontal car crash with a scooter Frontal car crash with a scooter
Useful links

CFD

Integral part of our services is fluid dynamics in static systems and in systems with moving parts. Problems like Fluid-Structure Interaction (FSI), Free Surface, incompressible and weakly compressible flow, we can solve in collaboration with competent CFD partners. We also offer optimizing concepts using HyperStudy, (e.g., to improve the flow through the part). To evaluate the data, we use AcuSolve and also HyperView.

Thermal analysis

We provide analysis of heat transfer, the affect of heat flow, and optimizing from the viewpoint of a thermal load. We specialize in combination of the thermal load analysis with recommendations for a new design.

To do the new solution we usually use analysis together with an optimizing task, eventually DOE studies.

We are also able to solve a combination of the thermal analysis and other problems. Typical example is the combination of thermal and structural analysis.

Analyses examples

Thermal analysis

Thermal analysis: We can provide the static and transient thermal analysis. Outputs of these analyses can be the heat flow or temperature deformation.


Specific services

  • Preparation of models for several purposes (FEM+MBD), post-processing of finite element analyses and multi-body simulations
  • Consulting in the field of passive safety and vehicle dynamics
  • DOE studies
  • Other unconventional studies, simulations and contemplation verification

Customization

Even over the permanent developing of HyperMesh and HyperView applications there is very often the request to increase the work efficiency by using special tools which are not included in the default HyperWorks installation. Thanks to the HyperWorks software architecture it is possible to use and work with various scripts, allowing users to customize processes exactly in the way they need. Currently our database contains hundreds of tcl scripts. A lot of those scripts have their own user button or the keyboard shortcut.

CAE Technology

For our engineering projects we typically use:

In case of client preference, we also work in the following software applications:

  • ANSA
  • PAMCRASH
  • LS-DYNA
  • Abaqus
  • and others

References

Advanced Engineering Ltd. has several successful projects and customers, including


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