�ݺ�ߣshows by User: SIMULIA

�ݺ�ߣshows by User: SIMULIA / http://www.slideshare.net/images/logo.gif �ݺ�ߣshows by User: SIMULIA / Thu, 01 Sep 2011 12:10:34 GMT �ݺ�ߣShare feed for �ݺ�ߣshows by User: SIMULIA Multi-Physics Analysis of a Refractory Metal ACOperated High Temperature Heater with Abaqus /SIMULIA/multi-physicsanalysisofarefractorymetalac2011f multi-physics-analysis-of-a-refractory-metal-ac-2011-f-110901121038-phpapp01
Electrically operated high temperature furnaces and reactors are used in many industrial manufacturing processes such as sintering or single crystal growth in order to allow for the required process conditions. In view of their outstanding characteristics refractory metals are ideally suited as materials for the resistive heating elements. Nevertheless, significant and lifetime- limiting irreversible deformations of these elements can be frequently observed which are assumed to be caused by a combination of temperature expansion, electromagnetic forces, and high temperature creep effects. In order to study this undesired behavior, a multi-physics model of a particular three-phase AC heating element of a sintering furnace is formulated and implemented within Abaqus. It accounts for the primary involved coupled physical mechanisms such as the harmonic electrical field problem, the thermal problem governed by Joule's law, thermal expansion, high temperature creep and harmonic forces caused by the electromagnetic field along with field dependent constitutive behavior. Since in general solving the fully coupled problem on a 3D domain is computationally demanding and Abaqus lacks functionality in the field of electromagnetism, a semi-analytical approach for consideration of time-harmonic electromagnetic forces within mechanical analysis is developed in the present work. The model implemented as a userdefined extension for Abaqus is computationally very attractive since it avoids discretization of the medium surrounding the heater. Furthermore, some aspects of modeling coupled physical problems of different characteristic time-scale are briefly discussed. Results from application of the model are in good qualitative agreement with in-situ observations and confirm the relevance of considering electromagnetic forces within analysis of high temperature furnaces.]]>
Electrically operated high temperature furnaces and reactors are used in many industrial manufacturing processes such as sintering or single crystal growth in order to allow for the required process conditions. In view of their outstanding characteristics refractory metals are ideally suited as materials for the resistive heating elements. Nevertheless, significant and lifetime- limiting irreversible deformations of these elements can be frequently observed which are assumed to be caused by a combination of temperature expansion, electromagnetic forces, and high temperature creep effects. In order to study this undesired behavior, a multi-physics model of a particular three-phase AC heating element of a sintering furnace is formulated and implemented within Abaqus. It accounts for the primary involved coupled physical mechanisms such as the harmonic electrical field problem, the thermal problem governed by Joule's law, thermal expansion, high temperature creep and harmonic forces caused by the electromagnetic field along with field dependent constitutive behavior. Since in general solving the fully coupled problem on a 3D domain is computationally demanding and Abaqus lacks functionality in the field of electromagnetism, a semi-analytical approach for consideration of time-harmonic electromagnetic forces within mechanical analysis is developed in the present work. The model implemented as a userdefined extension for Abaqus is computationally very attractive since it avoids discretization of the medium surrounding the heater. Furthermore, some aspects of modeling coupled physical problems of different characteristic time-scale are briefly discussed. Results from application of the model are in good qualitative agreement with in-situ observations and confirm the relevance of considering electromagnetic forces within analysis of high temperature furnaces.]]> Thu, 01 Sep 2011 12:10:34 GMT /SIMULIA/multi-physicsanalysisofarefractorymetalac2011f SIMULIA@slideshare.net(SIMULIA) Multi-Physics Analysis of a Refractory Metal ACOperated High Temperature Heater with Abaqus SIMULIA Electrically operated high temperature furnaces and reactors are used in many industrial manufacturing processes such as sintering or single crystal growth in order to allow for the required process conditions. In view of their outstanding characteristics refractory metals are ideally suited as materials for the resistive heating elements. Nevertheless, significant and lifetime- limiting irreversible deformations of these elements can be frequently observed which are assumed to be caused by a combination of temperature expansion, electromagnetic forces, and high temperature creep effects. In order to study this undesired behavior, a multi-physics model of a particular three-phase AC heating element of a sintering furnace is formulated and implemented within Abaqus. It accounts for the primary involved coupled physical mechanisms such as the harmonic electrical field problem, the thermal problem governed by Joule's law, thermal expansion, high temperature creep and harmonic forces caused by the electromagnetic field along with field dependent constitutive behavior. Since in general solving the fully coupled problem on a 3D domain is computationally demanding and Abaqus lacks functionality in the field of electromagnetism, a semi-analytical approach for consideration of time-harmonic electromagnetic forces within mechanical analysis is developed in the present work. The model implemented as a userdefined extension for Abaqus is computationally very attractive since it avoids discretization of the medium surrounding the heater. Furthermore, some aspects of modeling coupled physical problems of different characteristic time-scale are briefly discussed. Results from application of the model are in good qualitative agreement with in-situ observations and confirm the relevance of considering electromagnetic forces within analysis of high temperature furnaces. <img style="border:1px solid #C3E6D8;float:right;" alt="" src="https://cdn.slidesharecdn.com/ss_thumbnails/multi-physics-analysis-of-a-refractory-metal-ac-2011-f-110901121038-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds" /> Electrically operated high temperature furnaces and reactors are used in many industrial manufacturing processes such as sintering or single crystal growth in order to allow for the required process conditions. In view of their outstanding characteristics refractory metals are ideally suited as materials for the resistive heating elements. Nevertheless, significant and lifetime- limiting irreversible deformations of these elements can be frequently observed which are assumed to be caused by a combination of temperature expansion, electromagnetic forces, and high temperature creep effects. In order to study this undesired behavior, a multi-physics model of a particular three-phase AC heating element of a sintering furnace is formulated and implemented within Abaqus. It accounts for the primary involved coupled physical mechanisms such as the harmonic electrical field problem, the thermal problem governed by Joule's law, thermal expansion, high temperature creep and harmonic forces caused by the electromagnetic field along with field dependent constitutive behavior. Since in general solving the fully coupled problem on a 3D domain is computationally demanding and Abaqus lacks functionality in the field of electromagnetism, a semi-analytical approach for consideration of time-harmonic electromagnetic forces within mechanical analysis is developed in the present work. The model implemented as a userdefined extension for Abaqus is computationally very attractive since it avoids discretization of the medium surrounding the heater. Furthermore, some aspects of modeling coupled physical problems of different characteristic time-scale are briefly discussed. Results from application of the model are in good qualitative agreement with in-situ observations and confirm the relevance of considering electromagnetic forces within analysis of high temperature furnaces.

Multi-Physics Analysis of a Refractory Metal ACOperated High Temperature Heater with Abaqus from SIMULIA

]]> 848 2 https://cdn.slidesharecdn.com/ss_thumbnails/multi-physics-analysis-of-a-refractory-metal-ac-2011-f-110901121038-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds document Black http://activitystrea.ms/schema/1.0/post

http://activitystrea.ms/schema/1.0/posted

0 Welding Simulation with Abaqus /slideshow/industrial-simuliatechbrief05weldingsimulationfull/9099057 industrial-simulia-tech-brief-05-welding-simulation-full-110901121034-phpapp02
Metal welding processes are employed in various indus-tries. Gas welding techniques use the heat from a flame to melt the parts to be joined and a filler material simulta-neously. Extreme thermal loading is applied to the parts being joined, and complex material responses are initi-ated. The steep, localized thermal gradients result in stress concentrations in the welding zone. Consequently, modeling and simulation of welding processes are often complex and challenging. In this technology brief the use of Abaqus for this class of problems is discussed and an example analysis is presented.]]>
Metal welding processes are employed in various indus-tries. Gas welding techniques use the heat from a flame to melt the parts to be joined and a filler material simulta-neously. Extreme thermal loading is applied to the parts being joined, and complex material responses are initi-ated. The steep, localized thermal gradients result in stress concentrations in the welding zone. Consequently, modeling and simulation of welding processes are often complex and challenging. In this technology brief the use of Abaqus for this class of problems is discussed and an example analysis is presented.]]> Thu, 01 Sep 2011 12:10:30 GMT /slideshow/industrial-simuliatechbrief05weldingsimulationfull/9099057 SIMULIA@slideshare.net(SIMULIA) Welding Simulation with Abaqus SIMULIA Metal welding processes are employed in various indus-tries. Gas welding techniques use the heat from a flame to melt the parts to be joined and a filler material simulta-neously. Extreme thermal loading is applied to the parts being joined, and complex material responses are initi-ated. The steep, localized thermal gradients result in stress concentrations in the welding zone. Consequently, modeling and simulation of welding processes are often complex and challenging. In this technology brief the use of Abaqus for this class of problems is discussed and an example analysis is presented. <img style="border:1px solid #C3E6D8;float:right;" alt="" src="https://cdn.slidesharecdn.com/ss_thumbnails/industrial-simulia-tech-brief-05-welding-simulation-full-110901121034-phpapp02-thumbnail.jpg?width=120&height=120&fit=bounds" /> Metal welding processes are employed in various indus-tries. Gas welding techniques use the heat from a flame to melt the parts to be joined and a filler material simulta-neously. Extreme thermal loading is applied to the parts being joined, and complex material responses are initi-ated. The steep, localized thermal gradients result in stress concentrations in the welding zone. Consequently, modeling and simulation of welding processes are often complex and challenging. In this technology brief the use of Abaqus for this class of problems is discussed and an example analysis is presented.

Welding Simulation with Abaqus from SIMULIA

]]> 6945 6 https://cdn.slidesharecdn.com/ss_thumbnails/industrial-simulia-tech-brief-05-welding-simulation-full-110901121034-phpapp02-thumbnail.jpg?width=120&height=120&fit=bounds document Black http://activitystrea.ms/schema/1.0/post

http://activitystrea.ms/schema/1.0/posted

0 Determination of Critical Flaw Size in Gun Launched 40mm Grenade /slideshow/determination-criticalflawsizegunlaunch40mm2010f/9099052 determination-critical-flaw-size-gun-launch-40mm-2010-f-110901121015-phpapp02
The inspection and screening of flaws in high explosive filled gun fired projectiles are crucial to ensure safety for soldiers using these items. In bore failure of structural components are sure to produce lethal consequences, therefore it is of great importance to determine what the maximum permissible crack size is for a given component coming off of the production floor. The analytical process to determine critical flaw size occurs in two stages. First, ABAQUS Explicit finite element analysis code is used to conduct interior ballistic simulation of a 40mm shape charge projectile. The modeling scope includes interior gun tube geometry with drive band engraving and spin up effects. Pressure load inputs, which were derived from live fire test data, are used to drive the model. Secondly, the explicit model results are passed to NASGRO software for critical flaw size determination using linear-elastic fracture mechanics theory. The modeling information and approach to the problem will be presented in this paper as well as explicit model results and proposed inspection criteria.]]>
The inspection and screening of flaws in high explosive filled gun fired projectiles are crucial to ensure safety for soldiers using these items. In bore failure of structural components are sure to produce lethal consequences, therefore it is of great importance to determine what the maximum permissible crack size is for a given component coming off of the production floor. The analytical process to determine critical flaw size occurs in two stages. First, ABAQUS Explicit finite element analysis code is used to conduct interior ballistic simulation of a 40mm shape charge projectile. The modeling scope includes interior gun tube geometry with drive band engraving and spin up effects. Pressure load inputs, which were derived from live fire test data, are used to drive the model. Secondly, the explicit model results are passed to NASGRO software for critical flaw size determination using linear-elastic fracture mechanics theory. The modeling information and approach to the problem will be presented in this paper as well as explicit model results and proposed inspection criteria.]]> Thu, 01 Sep 2011 12:10:13 GMT /slideshow/determination-criticalflawsizegunlaunch40mm2010f/9099052 SIMULIA@slideshare.net(SIMULIA) Determination of Critical Flaw Size in Gun Launched 40mm Grenade SIMULIA The inspection and screening of flaws in high explosive filled gun fired projectiles are crucial to ensure safety for soldiers using these items. In bore failure of structural components are sure to produce lethal consequences, therefore it is of great importance to determine what the maximum permissible crack size is for a given component coming off of the production floor. The analytical process to determine critical flaw size occurs in two stages. First, ABAQUS Explicit finite element analysis code is used to conduct interior ballistic simulation of a 40mm shape charge projectile. The modeling scope includes interior gun tube geometry with drive band engraving and spin up effects. Pressure load inputs, which were derived from live fire test data, are used to drive the model. Secondly, the explicit model results are passed to NASGRO software for critical flaw size determination using linear-elastic fracture mechanics theory. The modeling information and approach to the problem will be presented in this paper as well as explicit model results and proposed inspection criteria. <img style="border:1px solid #C3E6D8;float:right;" alt="" src="https://cdn.slidesharecdn.com/ss_thumbnails/determination-critical-flaw-size-gun-launch-40mm-2010-f-110901121015-phpapp02-thumbnail.jpg?width=120&height=120&fit=bounds" /> The inspection and screening of flaws in high explosive filled gun fired projectiles are crucial to ensure safety for soldiers using these items. In bore failure of structural components are sure to produce lethal consequences, therefore it is of great importance to determine what the maximum permissible crack size is for a given component coming off of the production floor. The analytical process to determine critical flaw size occurs in two stages. First, ABAQUS Explicit finite element analysis code is used to conduct interior ballistic simulation of a 40mm shape charge projectile. The modeling scope includes interior gun tube geometry with drive band engraving and spin up effects. Pressure load inputs, which were derived from live fire test data, are used to drive the model. Secondly, the explicit model results are passed to NASGRO software for critical flaw size determination using linear-elastic fracture mechanics theory. The modeling information and approach to the problem will be presented in this paper as well as explicit model results and proposed inspection criteria.

Determination of Critical Flaw Size in Gun Launched 40mm Grenade from SIMULIA

]]> 1208 3 https://cdn.slidesharecdn.com/ss_thumbnails/determination-critical-flaw-size-gun-launch-40mm-2010-f-110901121015-phpapp02-thumbnail.jpg?width=120&height=120&fit=bounds document Black http://activitystrea.ms/schema/1.0/post

http://activitystrea.ms/schema/1.0/posted

0 Design of Different Types of Corrugated Board Packages Using Finite Element Tools /slideshow/design-differenttypescorrugatedboardpackages2010f/9099050 design-different-types-corrugated-board-packages-2010-f-110901121002-phpapp01
From a structural point of view, corrugated board would fit on the category of sandwich structures, which in sectors as aeronautics or construction are today commonly analysed using simulation tools that are based on the Finite Element Method. However, in spite of similarities to applications in other materials, FEM simulation of corrugated board is a high challenging modelling task due not only to the need of addressing properly the complex mechanical modelling of paper itself, but also because of phenomena that are directly related to the corrugated structure, as the relationships between local and global instability failure modes. The present paper, through a set of application examples, shows how different Abaqus modeling capabilities (SC8R elements, composite sections, connector elements, …) can be applied for solving the different difficulties that arise when modelling corrugated board. The integration of these capabilities has led to the development of virtual prototypes for the two most common corrugated board packages: B1 boxes and agricultural trays. From the experience in these box types, and taking advantage from the inherent modelling simplicity of the composite layered models together to the flexibility offered by the available modelling techniques in Abaqus, these virtual prototypes have been extended as a design tool for very different types of corrugated board packages.]]>
From a structural point of view, corrugated board would fit on the category of sandwich structures, which in sectors as aeronautics or construction are today commonly analysed using simulation tools that are based on the Finite Element Method. However, in spite of similarities to applications in other materials, FEM simulation of corrugated board is a high challenging modelling task due not only to the need of addressing properly the complex mechanical modelling of paper itself, but also because of phenomena that are directly related to the corrugated structure, as the relationships between local and global instability failure modes. The present paper, through a set of application examples, shows how different Abaqus modeling capabilities (SC8R elements, composite sections, connector elements, …) can be applied for solving the different difficulties that arise when modelling corrugated board. The integration of these capabilities has led to the development of virtual prototypes for the two most common corrugated board packages: B1 boxes and agricultural trays. From the experience in these box types, and taking advantage from the inherent modelling simplicity of the composite layered models together to the flexibility offered by the available modelling techniques in Abaqus, these virtual prototypes have been extended as a design tool for very different types of corrugated board packages.]]> Thu, 01 Sep 2011 12:09:58 GMT /slideshow/design-differenttypescorrugatedboardpackages2010f/9099050 SIMULIA@slideshare.net(SIMULIA) Design of Different Types of Corrugated Board Packages Using Finite Element Tools SIMULIA From a structural point of view, corrugated board would fit on the category of sandwich structures, which in sectors as aeronautics or construction are today commonly analysed using simulation tools that are based on the Finite Element Method. However, in spite of similarities to applications in other materials, FEM simulation of corrugated board is a high challenging modelling task due not only to the need of addressing properly the complex mechanical modelling of paper itself, but also because of phenomena that are directly related to the corrugated structure, as the relationships between local and global instability failure modes. The present paper, through a set of application examples, shows how different Abaqus modeling capabilities (SC8R elements, composite sections, connector elements, …) can be applied for solving the different difficulties that arise when modelling corrugated board. The integration of these capabilities has led to the development of virtual prototypes for the two most common corrugated board packages: B1 boxes and agricultural trays. From the experience in these box types, and taking advantage from the inherent modelling simplicity of the composite layered models together to the flexibility offered by the available modelling techniques in Abaqus, these virtual prototypes have been extended as a design tool for very different types of corrugated board packages. <img style="border:1px solid #C3E6D8;float:right;" alt="" src="https://cdn.slidesharecdn.com/ss_thumbnails/design-different-types-corrugated-board-packages-2010-f-110901121002-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds" /> From a structural point of view, corrugated board would fit on the category of sandwich structures, which in sectors as aeronautics or construction are today commonly analysed using simulation tools that are based on the Finite Element Method. However, in spite of similarities to applications in other materials, FEM simulation of corrugated board is a high challenging modelling task due not only to the need of addressing properly the complex mechanical modelling of paper itself, but also because of phenomena that are directly related to the corrugated structure, as the relationships between local and global instability failure modes. The present paper, through a set of application examples, shows how different Abaqus modeling capabilities (SC8R elements, composite sections, connector elements, …) can be applied for solving the different difficulties that arise when modelling corrugated board. The integration of these capabilities has led to the development of virtual prototypes for the two most common corrugated board packages: B1 boxes and agricultural trays. From the experience in these box types, and taking advantage from the inherent modelling simplicity of the composite layered models together to the flexibility offered by the available modelling techniques in Abaqus, these virtual prototypes have been extended as a design tool for very different types of corrugated board packages.

Design of Different Types of Corrugated Board Packages Using Finite Element Tools from SIMULIA

]]> 2317 9 https://cdn.slidesharecdn.com/ss_thumbnails/design-different-types-corrugated-board-packages-2010-f-110901121002-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds document Black http://activitystrea.ms/schema/1.0/post

http://activitystrea.ms/schema/1.0/posted

0 Earth Penetration Simulation using Coupled Eulerian-Lagrangian Analysis /slideshow/defense-simuliatechbrief09earthpenetrationsimulationfull/9099048 defense-simulia-tech-brief-09-earth-penetration-simulation-full-110901120954-phpapp01
In earth penetration events the projectile generally strikes the target at an oblique angle. As a result, the projectile is subjected to a multi-axial force and acceleration history through impact. The effectiveness of an earth penetration system is enhanced by the ability to withstand severe lateral loading. Consequently, it is important to understand how such loads develop during an impact event. In this Technology Brief, Abaqus/Explicit is used to simulate the impact of a high-strength steel penetrator into a concrete target. The penetrator/target interaction is analyzed using the coupled Eulerian-Lagrangian methodology. Specifically, the penetrator is modeled in a traditional Lagrangian framework while the concrete target is modeled in an Eulerian framework. It will be shown that Abaqus/Explicit results are in good agreement with published experimental data.]]>
In earth penetration events the projectile generally strikes the target at an oblique angle. As a result, the projectile is subjected to a multi-axial force and acceleration history through impact. The effectiveness of an earth penetration system is enhanced by the ability to withstand severe lateral loading. Consequently, it is important to understand how such loads develop during an impact event. In this Technology Brief, Abaqus/Explicit is used to simulate the impact of a high-strength steel penetrator into a concrete target. The penetrator/target interaction is analyzed using the coupled Eulerian-Lagrangian methodology. Specifically, the penetrator is modeled in a traditional Lagrangian framework while the concrete target is modeled in an Eulerian framework. It will be shown that Abaqus/Explicit results are in good agreement with published experimental data.]]> Thu, 01 Sep 2011 12:09:53 GMT /slideshow/defense-simuliatechbrief09earthpenetrationsimulationfull/9099048 SIMULIA@slideshare.net(SIMULIA) Earth Penetration Simulation using Coupled Eulerian-Lagrangian Analysis SIMULIA In earth penetration events the projectile generally strikes the target at an oblique angle. As a result, the projectile is subjected to a multi-axial force and acceleration history through impact. The effectiveness of an earth penetration system is enhanced by the ability to withstand severe lateral loading. Consequently, it is important to understand how such loads develop during an impact event. In this Technology Brief, Abaqus/Explicit is used to simulate the impact of a high-strength steel penetrator into a concrete target. The penetrator/target interaction is analyzed using the coupled Eulerian-Lagrangian methodology. Specifically, the penetrator is modeled in a traditional Lagrangian framework while the concrete target is modeled in an Eulerian framework. It will be shown that Abaqus/Explicit results are in good agreement with published experimental data. <img style="border:1px solid #C3E6D8;float:right;" alt="" src="https://cdn.slidesharecdn.com/ss_thumbnails/defense-simulia-tech-brief-09-earth-penetration-simulation-full-110901120954-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds" /> In earth penetration events the projectile generally strikes the target at an oblique angle. As a result, the projectile is subjected to a multi-axial force and acceleration history through impact. The effectiveness of an earth penetration system is enhanced by the ability to withstand severe lateral loading. Consequently, it is important to understand how such loads develop during an impact event. In this Technology Brief, Abaqus/Explicit is used to simulate the impact of a high-strength steel penetrator into a concrete target. The penetrator/target interaction is analyzed using the coupled Eulerian-Lagrangian methodology. Specifically, the penetrator is modeled in a traditional Lagrangian framework while the concrete target is modeled in an Eulerian framework. It will be shown that Abaqus/Explicit results are in good agreement with published experimental data.

Earth Penetration Simulation using Coupled Eulerian-Lagrangian Analysis from SIMULIA

]]> 595 1 https://cdn.slidesharecdn.com/ss_thumbnails/defense-simulia-tech-brief-09-earth-penetration-simulation-full-110901120954-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds document Black http://activitystrea.ms/schema/1.0/post

http://activitystrea.ms/schema/1.0/posted

0 Warping and Residual Stress Analysis using the Abaqus Interface for Moldflow /slideshow/cpg-simuliatechbrief07warpingandresidualstressfull/9099043 cpg-simulia-tech-brief-07-warping-and-residual-stress-full-110901120932-phpapp01
Residual stresses may be introduced into plastic parts produced by the injection molding process. As a result, the part may warp or experience a reduction in strength. The design of an injection molded product can be improved if the effect of residual stresses on the final shape and performance of the product are predicted accurately. Abaqus and Moldflow can be used for this purpose. The residual stresses generated by the solidifi-cation of the plastic material are computed by Moldflow and transferred to Abaqus using the Abaqus Interface for Moldflow. The component can then be structurally analyzed with Abaqus to determine warpage and/or response to in-service loading. In this Technology Brief, this methodology is demonstrated with two case studies.]]>
Residual stresses may be introduced into plastic parts produced by the injection molding process. As a result, the part may warp or experience a reduction in strength. The design of an injection molded product can be improved if the effect of residual stresses on the final shape and performance of the product are predicted accurately. Abaqus and Moldflow can be used for this purpose. The residual stresses generated by the solidifi-cation of the plastic material are computed by Moldflow and transferred to Abaqus using the Abaqus Interface for Moldflow. The component can then be structurally analyzed with Abaqus to determine warpage and/or response to in-service loading. In this Technology Brief, this methodology is demonstrated with two case studies.]]> Thu, 01 Sep 2011 12:09:29 GMT /slideshow/cpg-simuliatechbrief07warpingandresidualstressfull/9099043 SIMULIA@slideshare.net(SIMULIA) Warping and Residual Stress Analysis using the Abaqus Interface for Moldflow SIMULIA Residual stresses may be introduced into plastic parts produced by the injection molding process. As a result, the part may warp or experience a reduction in strength. The design of an injection molded product can be improved if the effect of residual stresses on the final shape and performance of the product are predicted accurately. Abaqus and Moldflow can be used for this purpose. The residual stresses generated by the solidifi-cation of the plastic material are computed by Moldflow and transferred to Abaqus using the Abaqus Interface for Moldflow. The component can then be structurally analyzed with Abaqus to determine warpage and/or response to in-service loading. In this Technology Brief, this methodology is demonstrated with two case studies. <img style="border:1px solid #C3E6D8;float:right;" alt="" src="https://cdn.slidesharecdn.com/ss_thumbnails/cpg-simulia-tech-brief-07-warping-and-residual-stress-full-110901120932-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds" /> Residual stresses may be introduced into plastic parts produced by the injection molding process. As a result, the part may warp or experience a reduction in strength. The design of an injection molded product can be improved if the effect of residual stresses on the final shape and performance of the product are predicted accurately. Abaqus and Moldflow can be used for this purpose. The residual stresses generated by the solidifi-cation of the plastic material are computed by Moldflow and transferred to Abaqus using the Abaqus Interface for Moldflow. The component can then be structurally analyzed with Abaqus to determine warpage and/or response to in-service loading. In this Technology Brief, this methodology is demonstrated with two case studies.

Warping and Residual Stress Analysis using the Abaqus Interface for Moldflow from SIMULIA

]]> 1888 5 https://cdn.slidesharecdn.com/ss_thumbnails/cpg-simulia-tech-brief-07-warping-and-residual-stress-full-110901120932-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds document Black http://activitystrea.ms/schema/1.0/post

http://activitystrea.ms/schema/1.0/posted

0 Coupled Euler Lagrangian Approach Using Abaqus /Explicit in the Bird Strike Aircraft Damage Analysis /slideshow/cel-approachabaqusexplicitbirdstrikeanalysis2010f/9099041 cel-approach-abaqus-explicit-bird-strike-analysis-2010-f-110901120930-phpapp01
Bird impact damage in complex aircraft structure has been investigated using explicit transient dynamic analysis by Abaqus/Explicit in order to fully employ its large library of elements, material models and the ability of implementing user defined materials. The numerical procedure has been applied on the very detailed large airplane secondary structure consisting of sandwich, composite and metallic structural items that have been modeled with 3D, shell and continuum shell elements, coupled with appropriate kinematic constraints. Bird has been modeled using Coupled Euler Lagrangian approach, in order to avoid the numerical difficulties connected with the mesh. The impact has been applied in the area that is the most probably subjected to the impact damage during the exploitation. The application point and velocity vector have been varied and the comparisons between total, kinetic, internal and damage energies have been performed. Various failure modes, such as CFRP face layer rupture, failure of composite matrix, damage initiation / evolution in the Nomex core and elastoplastic failure of a metallic structure have been investigated. Besides, general contact has been applied as to efficiently capture the contact between impactor and structure, as well as large deformations of the different structural components. Visualization of failure modes has been performed and damaged area compared to the available references. Compared to the classic Lagrangian modeling of the bird, the analysis has proven to be more stable, and the results, such as and damage areas, physically more realistic.]]>
Bird impact damage in complex aircraft structure has been investigated using explicit transient dynamic analysis by Abaqus/Explicit in order to fully employ its large library of elements, material models and the ability of implementing user defined materials. The numerical procedure has been applied on the very detailed large airplane secondary structure consisting of sandwich, composite and metallic structural items that have been modeled with 3D, shell and continuum shell elements, coupled with appropriate kinematic constraints. Bird has been modeled using Coupled Euler Lagrangian approach, in order to avoid the numerical difficulties connected with the mesh. The impact has been applied in the area that is the most probably subjected to the impact damage during the exploitation. The application point and velocity vector have been varied and the comparisons between total, kinetic, internal and damage energies have been performed. Various failure modes, such as CFRP face layer rupture, failure of composite matrix, damage initiation / evolution in the Nomex core and elastoplastic failure of a metallic structure have been investigated. Besides, general contact has been applied as to efficiently capture the contact between impactor and structure, as well as large deformations of the different structural components. Visualization of failure modes has been performed and damaged area compared to the available references. Compared to the classic Lagrangian modeling of the bird, the analysis has proven to be more stable, and the results, such as and damage areas, physically more realistic.]]> Thu, 01 Sep 2011 12:09:26 GMT /slideshow/cel-approachabaqusexplicitbirdstrikeanalysis2010f/9099041 SIMULIA@slideshare.net(SIMULIA) Coupled Euler Lagrangian Approach Using Abaqus /Explicit in the Bird Strike Aircraft Damage Analysis SIMULIA Bird impact damage in complex aircraft structure has been investigated using explicit transient dynamic analysis by Abaqus/Explicit in order to fully employ its large library of elements, material models and the ability of implementing user defined materials. The numerical procedure has been applied on the very detailed large airplane secondary structure consisting of sandwich, composite and metallic structural items that have been modeled with 3D, shell and continuum shell elements, coupled with appropriate kinematic constraints. Bird has been modeled using Coupled Euler Lagrangian approach, in order to avoid the numerical difficulties connected with the mesh. The impact has been applied in the area that is the most probably subjected to the impact damage during the exploitation. The application point and velocity vector have been varied and the comparisons between total, kinetic, internal and damage energies have been performed. Various failure modes, such as CFRP face layer rupture, failure of composite matrix, damage initiation / evolution in the Nomex core and elastoplastic failure of a metallic structure have been investigated. Besides, general contact has been applied as to efficiently capture the contact between impactor and structure, as well as large deformations of the different structural components. Visualization of failure modes has been performed and damaged area compared to the available references. Compared to the classic Lagrangian modeling of the bird, the analysis has proven to be more stable, and the results, such as and damage areas, physically more realistic. <img style="border:1px solid #C3E6D8;float:right;" alt="" src="https://cdn.slidesharecdn.com/ss_thumbnails/cel-approach-abaqus-explicit-bird-strike-analysis-2010-f-110901120930-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds" /> Bird impact damage in complex aircraft structure has been investigated using explicit transient dynamic analysis by Abaqus/Explicit in order to fully employ its large library of elements, material models and the ability of implementing user defined materials. The numerical procedure has been applied on the very detailed large airplane secondary structure consisting of sandwich, composite and metallic structural items that have been modeled with 3D, shell and continuum shell elements, coupled with appropriate kinematic constraints. Bird has been modeled using Coupled Euler Lagrangian approach, in order to avoid the numerical difficulties connected with the mesh. The impact has been applied in the area that is the most probably subjected to the impact damage during the exploitation. The application point and velocity vector have been varied and the comparisons between total, kinetic, internal and damage energies have been performed. Various failure modes, such as CFRP face layer rupture, failure of composite matrix, damage initiation / evolution in the Nomex core and elastoplastic failure of a metallic structure have been investigated. Besides, general contact has been applied as to efficiently capture the contact between impactor and structure, as well as large deformations of the different structural components. Visualization of failure modes has been performed and damaged area compared to the available references. Compared to the classic Lagrangian modeling of the bird, the analysis has proven to be more stable, and the results, such as and damage areas, physically more realistic.

Coupled Euler Lagrangian Approach Using Abaqus /Explicit in the Bird Strike Aircraft Damage Analysis from SIMULIA

]]> 3890 7 https://cdn.slidesharecdn.com/ss_thumbnails/cel-approach-abaqus-explicit-bird-strike-analysis-2010-f-110901120930-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds document Black http://activitystrea.ms/schema/1.0/post

http://activitystrea.ms/schema/1.0/posted

0 Simulation of Airbag Deployment Using the Coupled Eulerian-Lagrangian Method in Abaqus/Explicit /slideshow/automotive-simuliatechbrief11simulationairbagdeploymentcel/9099040 automotive-simulia-tech-brief-11-simulation-airbag-deployment-cel-110901120924-phpapp01
The uniform pressure method (UPM) approach to simulat-ing airbag deployment has been widely used in the auto-mobile safety industry. The defining assumption of UPM, specifically that pressure in the airbag is spatially uniform during inflation, makes the approach most applicable for „in-position‟ (IP) analyses with fully inflated airbags. In contrast, an analysis may be characterized as „out-of-position‟ (OoP) if the occupant interacts with the airbag before it is fully deployed. Prior to complete inflation, large spatial pressure gradients can exist in the airbag, violating the assumptions of the UPM approach. The advancement of airbag regulations and technology necessitates the consideration of OoP scenarios. An ac-curate analysis thus requires a tool capable of simulating the flow of gas during the inflation process. Abaqus/Explicit offers a sophisticated coupled Eulerian-Lagrangian (CEL) technique that can be used to simulate dynamic gas flow in the airbag. The flow-based CEL method offers a more realistic prediction of airbag shape and pressure distribution during all stages of deployment.]]>
The uniform pressure method (UPM) approach to simulat-ing airbag deployment has been widely used in the auto-mobile safety industry. The defining assumption of UPM, specifically that pressure in the airbag is spatially uniform during inflation, makes the approach most applicable for „in-position‟ (IP) analyses with fully inflated airbags. In contrast, an analysis may be characterized as „out-of-position‟ (OoP) if the occupant interacts with the airbag before it is fully deployed. Prior to complete inflation, large spatial pressure gradients can exist in the airbag, violating the assumptions of the UPM approach. The advancement of airbag regulations and technology necessitates the consideration of OoP scenarios. An ac-curate analysis thus requires a tool capable of simulating the flow of gas during the inflation process. Abaqus/Explicit offers a sophisticated coupled Eulerian-Lagrangian (CEL) technique that can be used to simulate dynamic gas flow in the airbag. The flow-based CEL method offers a more realistic prediction of airbag shape and pressure distribution during all stages of deployment.]]> Thu, 01 Sep 2011 12:09:24 GMT /slideshow/automotive-simuliatechbrief11simulationairbagdeploymentcel/9099040 SIMULIA@slideshare.net(SIMULIA) Simulation of Airbag Deployment Using the Coupled Eulerian-Lagrangian Method in Abaqus/Explicit SIMULIA The uniform pressure method (UPM) approach to simulat-ing airbag deployment has been widely used in the auto-mobile safety industry. The defining assumption of UPM, specifically that pressure in the airbag is spatially uniform during inflation, makes the approach most applicable for „in-position‟ (IP) analyses with fully inflated airbags. In contrast, an analysis may be characterized as „out-of-position‟ (OoP) if the occupant interacts with the airbag before it is fully deployed. Prior to complete inflation, large spatial pressure gradients can exist in the airbag, violating the assumptions of the UPM approach. The advancement of airbag regulations and technology necessitates the consideration of OoP scenarios. An ac-curate analysis thus requires a tool capable of simulating the flow of gas during the inflation process. Abaqus/Explicit offers a sophisticated coupled Eulerian-Lagrangian (CEL) technique that can be used to simulate dynamic gas flow in the airbag. The flow-based CEL method offers a more realistic prediction of airbag shape and pressure distribution during all stages of deployment. <img style="border:1px solid #C3E6D8;float:right;" alt="" src="https://cdn.slidesharecdn.com/ss_thumbnails/automotive-simulia-tech-brief-11-simulation-airbag-deployment-cel-110901120924-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds" /> The uniform pressure method (UPM) approach to simulat-ing airbag deployment has been widely used in the auto-mobile safety industry. The defining assumption of UPM, specifically that pressure in the airbag is spatially uniform during inflation, makes the approach most applicable for „in-position‟ (IP) analyses with fully inflated airbags. In contrast, an analysis may be characterized as „out-of-position‟ (OoP) if the occupant interacts with the airbag before it is fully deployed. Prior to complete inflation, large spatial pressure gradients can exist in the airbag, violating the assumptions of the UPM approach. The advancement of airbag regulations and technology necessitates the consideration of OoP scenarios. An ac-curate analysis thus requires a tool capable of simulating the flow of gas during the inflation process. Abaqus/Explicit offers a sophisticated coupled Eulerian-Lagrangian (CEL) technique that can be used to simulate dynamic gas flow in the airbag. The flow-based CEL method offers a more realistic prediction of airbag shape and pressure distribution during all stages of deployment.

Simulation of Airbag Deployment Using the Coupled Eulerian-Lagrangian Method in Abaqus/Explicit from SIMULIA

]]> 1109 1 https://cdn.slidesharecdn.com/ss_thumbnails/automotive-simulia-tech-brief-11-simulation-airbag-deployment-cel-110901120924-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds document Black http://activitystrea.ms/schema/1.0/post

http://activitystrea.ms/schema/1.0/posted

0 Analysis of Casing Connections Subjected to Thermal Cycle Loading /slideshow/analysis-casingconnectionsthermalcycleloading2010f/9099037 analysis-casing-connections-thermal-cycle-loading-2010-f-110901120912-phpapp02
Production of heavy oil and bitumen, which is increasing around the world as conventional oil resources are depleted, often uses thermal well technologies such as Cyclic Steam Stimulation (CSS) and Steam Assisted Gravity Drainage (SAGD). Casing connections are one of the most critical components in thermal wells. Historically, the literature shows that over 80% of reported uphole casing failures experienced in thermal wells occurred at connections. Typical connection failure mechanisms include structural damages, such as parting, thread rupture, and shoulder plasticity, and serviceability damages, such as leakage. One of the critical load conditions causing casing and casing connection failures is the thermal cycle loading, with high peak temperatures typically in excess of 200°C, which can cause the well casing and casing connections to deform plastically. There are generally three types of connections used in intermediate or production casing of thermal wells: API (American Petroleum Institute) round, API buttress and proprietary premium connections. This paper presents finite element analysis of these three types of casing connections subjected to thermal cycle loading. Based on analysis results, this paper demonstrates that the premium connection, which has a metal-to-metal seal region, is the most suitable of these three connection designs for the use in thermal wells, in terms of structural integrity and sealability. This paper also presents recommendations for casing connection design for successful service in thermal well applications.]]>
Production of heavy oil and bitumen, which is increasing around the world as conventional oil resources are depleted, often uses thermal well technologies such as Cyclic Steam Stimulation (CSS) and Steam Assisted Gravity Drainage (SAGD). Casing connections are one of the most critical components in thermal wells. Historically, the literature shows that over 80% of reported uphole casing failures experienced in thermal wells occurred at connections. Typical connection failure mechanisms include structural damages, such as parting, thread rupture, and shoulder plasticity, and serviceability damages, such as leakage. One of the critical load conditions causing casing and casing connection failures is the thermal cycle loading, with high peak temperatures typically in excess of 200°C, which can cause the well casing and casing connections to deform plastically. There are generally three types of connections used in intermediate or production casing of thermal wells: API (American Petroleum Institute) round, API buttress and proprietary premium connections. This paper presents finite element analysis of these three types of casing connections subjected to thermal cycle loading. Based on analysis results, this paper demonstrates that the premium connection, which has a metal-to-metal seal region, is the most suitable of these three connection designs for the use in thermal wells, in terms of structural integrity and sealability. This paper also presents recommendations for casing connection design for successful service in thermal well applications.]]> Thu, 01 Sep 2011 12:09:10 GMT /slideshow/analysis-casingconnectionsthermalcycleloading2010f/9099037 SIMULIA@slideshare.net(SIMULIA) Analysis of Casing Connections Subjected to Thermal Cycle Loading SIMULIA Production of heavy oil and bitumen, which is increasing around the world as conventional oil resources are depleted, often uses thermal well technologies such as Cyclic Steam Stimulation (CSS) and Steam Assisted Gravity Drainage (SAGD). Casing connections are one of the most critical components in thermal wells. Historically, the literature shows that over 80% of reported uphole casing failures experienced in thermal wells occurred at connections. Typical connection failure mechanisms include structural damages, such as parting, thread rupture, and shoulder plasticity, and serviceability damages, such as leakage. One of the critical load conditions causing casing and casing connection failures is the thermal cycle loading, with high peak temperatures typically in excess of 200°C, which can cause the well casing and casing connections to deform plastically. There are generally three types of connections used in intermediate or production casing of thermal wells: API (American Petroleum Institute) round, API buttress and proprietary premium connections. This paper presents finite element analysis of these three types of casing connections subjected to thermal cycle loading. Based on analysis results, this paper demonstrates that the premium connection, which has a metal-to-metal seal region, is the most suitable of these three connection designs for the use in thermal wells, in terms of structural integrity and sealability. This paper also presents recommendations for casing connection design for successful service in thermal well applications. <img style="border:1px solid #C3E6D8;float:right;" alt="" src="https://cdn.slidesharecdn.com/ss_thumbnails/analysis-casing-connections-thermal-cycle-loading-2010-f-110901120912-phpapp02-thumbnail.jpg?width=120&height=120&fit=bounds" /> Production of heavy oil and bitumen, which is increasing around the world as conventional oil resources are depleted, often uses thermal well technologies such as Cyclic Steam Stimulation (CSS) and Steam Assisted Gravity Drainage (SAGD). Casing connections are one of the most critical components in thermal wells. Historically, the literature shows that over 80% of reported uphole casing failures experienced in thermal wells occurred at connections. Typical connection failure mechanisms include structural damages, such as parting, thread rupture, and shoulder plasticity, and serviceability damages, such as leakage. One of the critical load conditions causing casing and casing connection failures is the thermal cycle loading, with high peak temperatures typically in excess of 200°C, which can cause the well casing and casing connections to deform plastically. There are generally three types of connections used in intermediate or production casing of thermal wells: API (American Petroleum Institute) round, API buttress and proprietary premium connections. This paper presents finite element analysis of these three types of casing connections subjected to thermal cycle loading. Based on analysis results, this paper demonstrates that the premium connection, which has a metal-to-metal seal region, is the most suitable of these three connection designs for the use in thermal wells, in terms of structural integrity and sealability. This paper also presents recommendations for casing connection design for successful service in thermal well applications.

Analysis of Casing Connections Subjected to Thermal Cycle Loading from SIMULIA

]]> 1263 1 https://cdn.slidesharecdn.com/ss_thumbnails/analysis-casing-connections-thermal-cycle-loading-2010-f-110901120912-phpapp02-thumbnail.jpg?width=120&height=120&fit=bounds document Black http://activitystrea.ms/schema/1.0/post

http://activitystrea.ms/schema/1.0/posted

0 Achieving a more Accurate Prediction of a Polymer Snap Deformation Pattern /slideshow/achieving-moreaccuratepredictionpolymersnap2011f/9099035 achieving-more-accurate-prediction-polymer-snap-2011-f-110901120907-phpapp01
A variety of polymers are used extensively for both medical applications and consumer products. Most of these polymers exhibit time-dependant behavior which varies significantly with environmental conditions. Injection molding technologies generally offer application design freedom and options for several functions build into each component. Meanwhile analysts are often faced with the difficulties of predicting the response of the final product.]]>
A variety of polymers are used extensively for both medical applications and consumer products. Most of these polymers exhibit time-dependant behavior which varies significantly with environmental conditions. Injection molding technologies generally offer application design freedom and options for several functions build into each component. Meanwhile analysts are often faced with the difficulties of predicting the response of the final product.]]> Thu, 01 Sep 2011 12:09:04 GMT /slideshow/achieving-moreaccuratepredictionpolymersnap2011f/9099035 SIMULIA@slideshare.net(SIMULIA) Achieving a more Accurate Prediction of a Polymer Snap Deformation Pattern SIMULIA A variety of polymers are used extensively for both medical applications and consumer products. Most of these polymers exhibit time-dependant behavior which varies significantly with environmental conditions. Injection molding technologies generally offer application design freedom and options for several functions build into each component. Meanwhile analysts are often faced with the difficulties of predicting the response of the final product. <img style="border:1px solid #C3E6D8;float:right;" alt="" src="https://cdn.slidesharecdn.com/ss_thumbnails/achieving-more-accurate-prediction-polymer-snap-2011-f-110901120907-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds" /> A variety of polymers are used extensively for both medical applications and consumer products. Most of these polymers exhibit time-dependant behavior which varies significantly with environmental conditions. Injection molding technologies generally offer application design freedom and options for several functions build into each component. Meanwhile analysts are often faced with the difficulties of predicting the response of the final product.

Achieving a more Accurate Prediction of a Polymer Snap Deformation Pattern from SIMULIA

]]> 558 2 https://cdn.slidesharecdn.com/ss_thumbnails/achieving-more-accurate-prediction-polymer-snap-2011-f-110901120907-phpapp01-thumbnail.jpg?width=120&height=120&fit=bounds document Black http://activitystrea.ms/schema/1.0/post

http://activitystrea.ms/schema/1.0/posted

0 Optimisation of Welds with Manufacturing Considerations /slideshow/optimisation-ofweldswithmanufacturingconsider2011f/9099032 optimisation-of-welds-with-manufacturing-consider-2011-f-110901120857-phpapp02
Fatigue is the main in-service failure mode for automotive chassis & suspension parts, especially weld fatigue. Over the years, Tata Steel Automotive Engineering (TSAE) has developed techniques for CAE durability assessment including the optimisation of seam-welded chassis/suspension structures. Seam weld optimisation at TSAE has previously been based on a constant weld length and constant gap between welds for each weld run. This method has two drawbacks; weld patterns generated are regular in nature, reducing the flexibility to position welds where they are most effective and• excessively short welds are often left at the end of a run of welds. The objective was to develop an improved optimisation technique using Isight that always produced a manufacturing feasible design and allowed more flexible and irregular positioning of welds. Manufacturing constraints considered were minimum weld length, minimum gap length and minimising the number of start/stop operations. To reduce the number of design variables, a new load-case-weighted optimisation scheme was developed using a single weighting factor for each load case. These factors were used to generate weld patterns by scaling the strain energy density in finite elements from an initial fully welded design. Weld elements were selected for retention/deletion by comparing a weighted sum across all load cases with a threshold value. During each optimisation, Isight varied the weighting factors as “design variables” to minimise overall weld length, while achieving stiffness and fatigue life targets. The process has been extended to function for laser weld designs where an intermittent weld pattern is generally the most effective.]]>
Fatigue is the main in-service failure mode for automotive chassis & suspension parts, especially weld fatigue. Over the years, Tata Steel Automotive Engineering (TSAE) has developed techniques for CAE durability assessment including the optimisation of seam-welded chassis/suspension structures. Seam weld optimisation at TSAE has previously been based on a constant weld length and constant gap between welds for each weld run. This method has two drawbacks; weld patterns generated are regular in nature, reducing the flexibility to position welds where they are most effective and• excessively short welds are often left at the end of a run of welds. The objective was to develop an improved optimisation technique using Isight that always produced a manufacturing feasible design and allowed more flexible and irregular positioning of welds. Manufacturing constraints considered were minimum weld length, minimum gap length and minimising the number of start/stop operations. To reduce the number of design variables, a new load-case-weighted optimisation scheme was developed using a single weighting factor for each load case. These factors were used to generate weld patterns by scaling the strain energy density in finite elements from an initial fully welded design. Weld elements were selected for retention/deletion by comparing a weighted sum across all load cases with a threshold value. During each optimisation, Isight varied the weighting factors as “design variables” to minimise overall weld length, while achieving stiffness and fatigue life targets. The process has been extended to function for laser weld designs where an intermittent weld pattern is generally the most effective.]]> Thu, 01 Sep 2011 12:08:55 GMT /slideshow/optimisation-ofweldswithmanufacturingconsider2011f/9099032 SIMULIA@slideshare.net(SIMULIA) Optimisation of Welds with Manufacturing Considerations SIMULIA Fatigue is the main in-service failure mode for automotive chassis & suspension parts, especially weld fatigue. Over the years, Tata Steel Automotive Engineering (TSAE) has developed techniques for CAE durability assessment including the optimisation of seam-welded chassis/suspension structures. Seam weld optimisation at TSAE has previously been based on a constant weld length and constant gap between welds for each weld run. This method has two drawbacks; weld patterns generated are regular in nature, reducing the flexibility to position welds where they are most effective and• excessively short welds are often left at the end of a run of welds. The objective was to develop an improved optimisation technique using Isight that always produced a manufacturing feasible design and allowed more flexible and irregular positioning of welds. Manufacturing constraints considered were minimum weld length, minimum gap length and minimising the number of start/stop operations. To reduce the number of design variables, a new load-case-weighted optimisation scheme was developed using a single weighting factor for each load case. These factors were used to generate weld patterns by scaling the strain energy density in finite elements from an initial fully welded design. Weld elements were selected for retention/deletion by comparing a weighted sum across all load cases with a threshold value. During each optimisation, Isight varied the weighting factors as “design variables” to minimise overall weld length, while achieving stiffness and fatigue life targets. The process has been extended to function for laser weld designs where an intermittent weld pattern is generally the most effective. <img style="border:1px solid #C3E6D8;float:right;" alt="" src="https://cdn.slidesharecdn.com/ss_thumbnails/optimisation-of-welds-with-manufacturing-consider-2011-f-110901120857-phpapp02-thumbnail.jpg?width=120&height=120&fit=bounds" /> Fatigue is the main in-service failure mode for automotive chassis & suspension parts, especially weld fatigue. Over the years, Tata Steel Automotive Engineering (TSAE) has developed techniques for CAE durability assessment including the optimisation of seam-welded chassis/suspension structures. Seam weld optimisation at TSAE has previously been based on a constant weld length and constant gap between welds for each weld run. This method has two drawbacks; weld patterns generated are regular in nature, reducing the flexibility to position welds where they are most effective and• excessively short welds are often left at the end of a run of welds. The objective was to develop an improved optimisation technique using Isight that always produced a manufacturing feasible design and allowed more flexible and irregular positioning of welds. Manufacturing constraints considered were minimum weld length, minimum gap length and minimising the number of start/stop operations. To reduce the number of design variables, a new load-case-weighted optimisation scheme was developed using a single weighting factor for each load case. These factors were used to generate weld patterns by scaling the strain energy density in finite elements from an initial fully welded design. Weld elements were selected for retention/deletion by comparing a weighted sum across all load cases with a threshold value. During each optimisation, Isight varied the weighting factors as “design variables” to minimise overall weld length, while achieving stiffness and fatigue life targets. The process has been extended to function for laser weld designs where an intermittent weld pattern is generally the most effective.

Optimisation of Welds with Manufacturing Considerations from SIMULIA

]]> 800 2 https://cdn.slidesharecdn.com/ss_thumbnails/optimisation-of-welds-with-manufacturing-consider-2011-f-110901120857-phpapp02-thumbnail.jpg?width=120&height=120&fit=bounds document Black http://activitystrea.ms/schema/1.0/post

http://activitystrea.ms/schema/1.0/posted

0 https://public.slidesharecdn.com/v2/images/profile-picture.png https://cdn.slidesharecdn.com/ss_thumbnails/multi-physics-analysis-of-a-refractory-metal-ac-2011-f-110901121038-phpapp01-thumbnail.jpg?width=320&height=320&fit=bounds SIMULIA/multi-physicsanalysisofarefractorymetalac2011f Multi-Physics Analysis... https://cdn.slidesharecdn.com/ss_thumbnails/industrial-simulia-tech-brief-05-welding-simulation-full-110901121034-phpapp02-thumbnail.jpg?width=320&height=320&fit=bounds slideshow/industrial-simuliatechbrief05weldingsimulationfull/9099057 Welding Simulation wit... https://cdn.slidesharecdn.com/ss_thumbnails/determination-critical-flaw-size-gun-launch-40mm-2010-f-110901121015-phpapp02-thumbnail.jpg?width=320&height=320&fit=bounds slideshow/determination-criticalflawsizegunlaunch40mm2010f/9099052 Determination of Criti...