Manufacturing Simulation Reduces Development Costs and Time in Cold Forming Tool Design

Omni-Lite Industries is an advanced material company. They recently designed a new part that was exhibiting a unique material flow. The part was cold formed out of 1100 aluminum material.

The initial tool design was completed and reviewed using the Simufact.forming simulation. Upon initial review, everything seemed to be acceptable, with the exception of the volume of material in the flange of the part. The second station trap extrusion die radius was then reduced in order to accommodate the material volume requirements.


Rigorous, Transient 3D CFD Models of Unusually Complicated Fluid Networks/Circuits

The role of fluid dynamics simulation in the design and development of various products has recently undergone what is arguably a paradigm shift due to the ability to simulate unusually complicated, multi-component, hydraulics flow circuits using three dimensional (3D) computational fluid dynamics (CFD) models.  The example shows a lubrication system model (developed using the Simerics-Sys / PumpLinx CFD software) for a 16 cylinder reciprocating internal combustion engine.  This represents an advance in system-level modeling of hydraulic fluid networks over the current state of the art which is a blend of zero and one-dimensional models.  This also represents continued progress in the role of CFD from the traditional component level modeling to system level modeling.  System level modeling provides insight into interactions between components.  Finally, it is equally important that model setup and run times are reasonable relative to development time scales.


Use of FEA in Elevator Design and Test

Schindler Elevator’s offerings range from passenger elevators suitable for small blocks of apartments to sophisticated transport solutions for skyscrapers. Service elevators ensure the stress-free movement of goods and people in shopping centers, office buildings and railway stations. Bed elevators provide for the smooth and vibration-free movement of patients and equipment in hospitals. In industrial buildings, many of the hoists and small good elevators in use are supplied by Schindler, while glass cabin elevators in tall buildings offer both a novel experience and a feeling of safety. It is hard to imagine public transport without elevators, which are often heavily used and must therefore meet demanding requirements in availability and serviceability.

The company’s research and development facility in Switzerland devises complete elevator systems as well as components for all applications. Here, CAE is used to find reliable and energy-efficient solutions which make the most efficient use of materials. The programs SimXpert and MSC Nastran from MSC Software are used for structural calculations using the finite element method (FE). These are used, for example, to simulate the wall fixings of elevators and determine whether deformations and loadings remain within the permissible range. The resulting design and its verification encompass the guiding system and the cabin, counterweight and drive components. In addition to static (strength) calculations, dynamic and vibration analyses are also carried out with the aid of FE methods. The field of nonlinear FE calculations is also of central significance.


Where’s the Dirt? – Use Realistic Material Loads in Adams

The world of heavy equipment is full of big machinery digging and moving dirt. Millions of tons of bulk material are moved every day by excavators, bull dozers, ploughs and trucks. The challenge faced by engineers who are designing such equipment is to understand how their machines will perform in the material environment they operate in. 


Weight Reduction of an Engine Mount

Trelleborg is a global automotive supplier that offers sealing, damping, and protection solutions to the automotive industry. To reach their goal of complying with CO2 regulation, Trelleborg uses material modeling and simulation software.   Challenge To comply with CO2 regulations (2015: 130g   2020: 95g) To reduce the average weight of a car by 200 kg ...

Finding the Solution to a Noise Problem

A nighttime noise complaint was issued from the residential area near one of Wärtsiläs main large 4-stroke medium speed engine factories located in downtown Vaasa.  The facility produces about 500 engines per year and every engine is subjected to a test run. An investigation found that the likely source of the intolerable noise was from the exhaust from an engine 1000 hour endurance test. Although they discovered the source of the noise, they were unable to solve the noise problem completely. 

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