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A new approach to generate Approximation model for CAE analysis using Isight

A product development and evaluation using the simulation technology now is a standard process. Approximation models are now frequently used as an efficient design tool. Isight, an automation and optimization tool of SIMULIA, offers a several methods to generate Approximation model. Using Approximation model, as it is well known, the exploration time can be shortened, especially when a simulation takes long time for a single run. Generally, it is important to provide effective sampling points as Teacher data. In most of methods, a sampling matrix is generated taking no account of any response and the more parameters one has, the more Teacher data one needs.

Customer Papers

A new approach to generate Approximation model for CAE analysis using Isight
Bushing connector application in Suspension modeling

The Suspension Assembly modeling in utility vehicles is a challenge in terms of representing various bushings used for joints and in general there are multiple bushings in any suspension assemblies. These bushings have typically hyper elastic material bonded between metal sleeves and thus nonlinear in behavior. Also, the joint is very likely coupled with bolt joint which causes additional complexity in capturing the local behavior of the joint. The connector elements available in Abaqus/Standard enables us to capture the appropriate Bushing stiffness in all three axes and the simplified bolt model can accurately capture the local coupled stiffness of the Bushing and Bolt joint. A simplified suspension assembly for upper control arm was analyzed, tested and correlated for loaddeflection data.

Customer Papers

Bushing connector application in Suspension modeling
Strength analysis on load rejection working condition of steam turbine

The load rejection is regarded as a vital process for a steam turbine performing commission operation or encountering some emergent accidents. Under the combination of the boiler and the turbine control valve, the steam temperature could be rapidly reduced and the turbine load could be cut back. In order to analyze the stress of the steam turbine during load rejection, the first stage rotating blades and grooves are taken as research subjects and the commercial software “Abaqus” is employed to perform the FEA process.

Customer Papers

Strength analysis on load rejection working condition of steam turbine
Prediction of Damage Evolution in Composites Using Abaqus

In recent years Fokker Landing Gear has developed a proprietary material model to more accurately model composites. In this material model the fibers and resin are included as separate materials with their own specific material and failure behavior, both with a limited number of material parameters and with clear physical meaning. The interaction between the fibers and resin is accounted for using a new analytical approach. Because the inclusion of fibers is done using a vector based approach the model is valid for any fiber structure.

Customer Papers

Prediction of Damage Evolution in Composites Using Abaqus
Using Abaqus/Standard and Abaqus/Explicit for the Development of New Bi-Level Trains at Stadler Rail

In the development of the new bi-level train KISS Abaqus/Standard and Abaqus/Explicit have been intensively applied to optimize the structure with respect to stiffness and strength as well as to crashworthiness. Models up to 3 million shell elements have been used to prove the strength of the load carrying structure with respect to the standard EN12663-1. By using Abaqus/Standard the calculation times were minimized allowing for a significant number of iterations to optimize the structure with respect to lightweight engineering and with respect to a reduction of manufacturing time. Additionally, the Abaqus/Standard result files were used to investigate the fatigue strength of the structure, especially of the welds, with FEMFAT, a postprocessor code from Magna Powertrain.

Customer Papers

Using Abaqus/Standard and Abaqus/Explicit for the Development of New Bi-Level Trains at Stadler Rail
Multi-mode Failure Analysis of Scratched Laminated Carbon Fiber/Epoxy Composites

Composite structures can be vulnerable to several types of damage. Abrasion and low to mid velocity impacts can result in deep scratches impacting the surface plies. In this study, the delamination which is induced by scratches under tensile loading are investigated using experimental and finite element techniques. A finite element approach based on progressive damage analysis implemented in VUMAT subroutine and a cohesive zone model using Abaqus are performed to simulate the behavior in the composite specimen. Scratches at different depths with different angles in carbon fiber-epoxy laminates are modeled to study the influence of the scratch size and the stacking sequence effects. Experimental results show the delamination propagates between layers.

Customer Papers

Multi-mode Failure Analysis of Scratched Laminated Carbon Fiber/Epoxy Composites
Stress analysis and modal analysis of the largest bearing test rig in the world - Astraios

The use of renewable energy sources is being expanded strongly all over the world. Wind power plays an important role in this field. In recent years, the output of wind turbines has increased continuously. In such plants, the important mechanical components include bearings which, with increasing output, are becoming increasingly larger. Therefore the Schaeffler Group took the decision to build the largest bearing test rig in the world. This makes it possible to strongly drive forward the development of large size bearings for wind turbine manufacturers. With a maximum bearing outside diameter of approx. 3.5 m, the highly versatile test rig can also be used to test all other large size bearings.

Customer Papers

Stress analysis and modal analysis of the largest bearing test rig in the world - Astraios
A 3D Discrete Damage Modeling Methodology for Abaqus for Fatigue Damage Evaluation in Bolted Composite Joints

A discrete multi-mode damage initiation, propagation, and interaction tool is implemented within Abaqus’ implicit solver for residual strength and life prediction of bolted joints with a given initial damage resulting from the fabrication and installation process. A discrete crack network model (DCN) for damage progression prediction has been developed by combining mesh independent matrix cracking with cohesive zone delamination models at the ply interfaces. A regularized X-FEM (Rx-FEM) framework maintaining the distribution of the Gauss integration points without element slicing has been utilized for implementation of the solution module for residual strength prediction under monotonic loading.

Customer Papers

A 3D Discrete Damage Modeling Methodology for Abaqus for Fatigue Damage Evaluation in Bolted Composite Joints
Fluid-Structure Interaction Simulations of Rocket Engine Side Loads

The goal of this work was to simulate both the flow in a rocket engine nozzle and the resulting flow-induced transient loads on the nozzle. This unsteady nozzle flow results in structural dynamic excitation, which contributes not only to nozzle stress and deformation but also to the dynamic loads that are transmitted to the rest of the engine. This paper demonstrates the capability of a coupled fluid-structure interaction (FSI) simulation for predicting side loads on a rocket engine nozzle. The capability was demonstrated using the space shuttle main engine (SSME) during a portion of the engine startup sequence.

Customer Papers

Fluid-Structure Interaction Simulations of Rocket Engine Side Loads
Simulation creep behavior of plastic parts during complex thermo-mechanical loading

The paper describes using of Abaqus for evaluating the behavior of car plastic parts which are exposed to high temperature and self weight (plus another load) for long time. Car plastic parts (inside and outside) are subjected to complex loads – temperature, vibration and environmental conditions. It is a challenge to prepare simulations which correctly describe the complex behavior - temperature dependent, time dependent of stress-strain behavior. To capture visco-elastic behavior we chose a creep description of the material.

Customer Papers

Simulation creep behavior of plastic parts during complex thermo-mechanical loading
Fatigue Assessment of Welded Structures Using Continuum Element Meshes

Regarding FEM for welded structures, shell elements are mostly used to capture the structural behavior very efficiently. Depending on the choice of the element order, mesh size, etc. local nominal or even hot spot stresses can be calculated. These values can be assessed directly according to typical standards, i.e. Eurocode, DVS, FKM-Guideline etc. In our contribution we will present a method, which allows an efficient fatigue assessment of welded structures, based on deriving relevant stress quantities from the results of continuum models. This method has been implemented in the commercial software LIMIT for typical standards.

Customer Papers

Fatigue Assessment of Welded Structures Using Continuum Element Meshes
Development of Realistic Simulation Techniques to Predict Cure-Induced Microcracking in 3D Woven Composites

Three-dimensional woven composites that are becoming increasingly popular in aerospace applications have superior through-the-thickness strength, stiffness, and thermal conductivity compared to conventional 2D laminated composites. However, despite their advantages, many details regarding the mechanical behavior of 3D woven composites are not as well-known as they are for traditional laminated composites. Microcracking of carbon-epoxy composites during resin curing is one important example. The main goal of this study is to improve the understanding of cure-induced microcracking through the development of realistic numerical models validated with experimental data.

Customer Papers

Development of Realistic Simulation Techniques to Predict Cure-Induced Microcracking in 3D Woven Composites
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