Engineering Analyses. Activities & Examples
- Steady State Mechanics
- Fatigue
- Implicit Dynamics: Modal, Harmonic, Transient
- Explicit Dynamics: Drop, Shock, Impact, Crash Test
- Random Vibration, Response Spectrum, Earthquake
- Fracture Mechanics
- Contact and Material Nonlinearities
Static & Fatigue: Boat transmanipulator
Project Definition: The target is to assess reliability parameters of frame and carriage through a fatigue analysis under various work load cases (acceleration/deceleration with/without boat).
Fatigue analysis is performed over results of several steady-state analyses of different characteristic load cases.
Static: Crab Crane Frame
Project Definition: The target is to assess force-deflection behavior parameters of a crab crane frame components at various emergency load cases. The model consists of over 200 different components.
All components are examined under specified load case conditions and are assessed for possible damages. Buckling analyses are performed for the most critical components.
Modal: Powertool housings assembly
Modal analysis enables to review rigidity and mass distributions for certain structure. Analysis results shows directions for design improvement with major impact on overall product performance.
Transient: Temperature Sensor under Impact
Project Definition: Temperature Sensor is exposed work loads environment and its response to impact load is examined. Contact behaviour between the elastic connection and carrier is examined as well as complete structure response.
Deformation and stress distributions over time helps understanding possible product faults during exploitation and is a basis for design optimisation.
Drop Test: Location Pad Holder
Project Definition: A Location Pad Holder is examined by drop test from 1m height. The target is to evaluate product for possible damages and to identify weak components.
Several load cases are examined having different drop directions. Equivalent stress distributions are determined and assessed and possible critical components are marked.
Earthquake: Power Plant Crane
Project Definition: Examined crane structure is simulated under seismic loads. Response spectrum analyses results (der Kiureghian) are used to perform Newmark combinations.
Six load cases (loaded/unloaded crane and three directions of base excitation) are combined by Newmark combinations. Wheel stiffness and possible sliding is included in the model as well as spectrum damping. General review of part of results is shown below.
Fracture Mechanics: Substrate Scribing
Project Definition: Laser scribing process for ceramic substrate forms side walls cavities. Possible crack propagations need to be assessed as a source for future product failures. Crack initiation and growth are simulated under thermal loads, based on detailed model of cavities.
Both models with and without cracks are modeled and assessed. Crack propagation is evaluated through calculation of characteristic points displacement over up and down side edges.
Nonlinear contact: Worm gearset optimisation
Project Definition: High loaded worm gearset is optimised at work conditions. The target is to minimize stresses at fixed centre distance and overall dimensions of examined assembly. Detailed mesh and proper nonlinear contact models are used to achieve accurate results.
Initial and optimised designs are compared and shown on figures below. Major criterion was equivalent stresses that are minimized for the new proposed design.
Multibody Dynamics: Rotary hammer impact mechanism optimisation
Project Definition: Rotary hammer uses pneumatic mechanism to produce impact. Maximal output for impact energy is the objective of this multiparametric optimisation. A multibody dynamics model is created as to research possibilities for mechanism optimisation.
Each parameter influence is evaluated and optimal design variant is choosen. Additionally, robust analysis is performed, based on already defined design.
Thermo-fluid Analysis: Convection Oven for Microelectronics
Project Definition: The target is to evaluate and improve the efficiency of convective oven for microelectronics industry. Thermal convection process is examined in detail and fluid flows and temperature fields are determined.
The complete structure have been simulated and inhomogeneous fluid flow at the turbine exit is established. Several design variants are examined to increase homogeneity and efficiency of the turbine by improving fluid flow characteristics.
The impact of the diffuser design change have been searched mainly for better temperature field distribution over the processed parts. Dynamics of the process have been explored too.
Thermo-fluid Analysis: Table-height refrigerator optimisation
Project Definition: Table-height refrigerator is optimised and especially – its evaporator subassembly. Several steps are performed in this project, as the firs is a simulation of the existing design at work loads to determine the physics of its performance.
Next step is to explore various designs. Several different evaporator designs are examined to reach better efficiency and performance.
Dynamic transient simulations are performed as to obtain a comparison of the final optimized and initial variants efficiency in time.
Electromagnetics: MEMS design exploration
Project Definition: A new design of micro-electromechanical system (Lorentz actuator) is examined in order to evaluate and optimize its work parameters.
A detailed study of the existing actuator device lead to developed new optimized design, having improved work parameters (acting force) amd reduced device heating.
Presented data are extracted from various industrial projects, property of (in order of appearance):