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This paper describes some of the major contents of the set up and technical coupled simulations within an extended enterprise as developed during the European FP7 research project CRESCENDO (2009-2012). Focus is given on the execution of simulation processes (workflows) for collaborative engineering design tasks in the aeronautical industry towards the ability to perform optimization and robust design studies. Different types of simulation workflows will be explained, such as event or process driven under the aspects of low, medium or high frequency access and execution. An industrial example of the implementation of a high frequency process driven workflow in the extended enterprise shall give an impression of the developed workflow execution capabilities in the case of an aero engine design application.

Customer Papers

Finite Element Analysis (FEA) has been widely used to analyze the in vivo structural response of implantable medical devices and assess device performance, reliability and durability. Take stents for example. Several characteristics like radial force, peak stresses and strains and fatigue safety factors can be determined using these modeling techniques. As all physical phenomena are stochastic, all design parameters have built-in variability. On the other hand, stents are typically modeled with nominal dimensions and material properties. Minimum and maximum dimensions are used in certain instances, while other dimensional variances are often not considered. In addition, the in vivo boundary conditions also vary widely across patient population.

Customer Papers

The turbine housing of an exhaust turbocharger is exposed to extensive cyclic thermomechanical loading. Consequently, the design of the turbine housing becomes a major challenge in ensuring the guaranteed lifetime in relation to the high-temperature behavior of the materials. In a first step, a phenomenological lifetime approach together with a rate-independent constitutive plasticity model of Chaboche-type was developed and validated for application on casting materials. The present study deals with the more detailed analysis of rate-dependent plasticity applied in the finite-element analysis with respect to the subsequent creep-fatigue damage calculation procedure.

Customer Papers

In high temperature metal forming processes strong mechanical and thermal gradients in the formed material and in the tooling coexist. Such gradients have a negative influence in the tool life cycle. That influence occurs due to mechanical and thermal cyclic loads undergone during the production process. This factor leads to the appearance of cracks on the tool surface because of thermomechanical fatigue phenomenon. The presented work is focused on a specific manufacturing process of seamless steel tubes which includes three basic steps: backward extrusion, perforation and Pilger rolling mill. The objective of this paper is to present thermomechanical fatigue FE analysis.

Customer Papers

Sealable ammunition containers are widely used by the U.S. Army to ensure safe transport and storage of various types of munitions for the warfighter. In the case of accidental ignition, ammunition containers are designed to fail in a way that minimizes danger to nearby personnel. In the constant effort to improve the performance and safety of such containers, extensive experimental testing is required to assess new or modified designs. This testing is timeconsuming, costly, and often yields only pass/fail results with little or no data for failure analysis. Recent efforts were taken to apply modeling and simulation to down-select design concepts and help focus testing efforts for these designs.

Customer Papers

Abaqus/Standard simulation of Lamb waves in smart composite plates is investigated for detecting delamination type damage. Composite plates typical of aerospace structures are used and a PZT actuator is surface bonded to excite Lamb waves. Abaqus model of composite plate uses layered solid elements. Piezoelectric (PZT-5H) actuator is modeled using piezoelectric elements that have both displacement and electric potential degrees of freedom. Perfect bonding between composite plate and PZT actuator is assumed. Simulation results obtained with appropriate level of structural damping are correlated with experimental measurements. The effect of delamination size on the structural response is studied. It is shown that the size and the location of delamination can be quantified using Lamb wave measurements.

Customer Papers

As a rule, compression spring shapes are designed to conform to the required compression force using general theories. Under some conditions, lateral forces on the springs can be an issue. Lateral forces are greatly affected by contact conditions between springs and structures and the spring’s self-contact. Numerical calculations to determine the spring shape must take these factors into consideration. However, the manufacturing method causes a high degree of plastic deformation by a process called “prestressing” which means that the final shape of the spring is different from the coiled metal piece required for manufacturing.

Customer Papers

To evaluate if a crack may cause structural failure, the failure assessment diagram (FAD) method uses two ratios: brittle fracture and plastic collapse. The objective of this paper is to use Abaqus/Standard to compute elastic-plastic J-integral results along the crack front. These results are then used to calculate the plastic collapse crack reference stress, especially for cases when the reference stress solution is not available for a structural component.

Customer Papers

The presented work intends to illustrate how Beretta approaches the study of automatic small arms’ firing cycles, from the launch of firing pin to locking mechanism being subjected to the gas pulse, to the recoiling of the moving parts operating the extraction and ejection of the spent cartridge case, and finally the feeding of a fresh cartridge into the firearm’s chamber. Using finite element analysis for the study of such engineering problems benefits the product development cycle for its ability to provide key insights in the areas of reliability and durability.

Customer Papers

Extraction from oil and gas from an underground reservoir alters the pore pressure distribution in the reservoir strata. Modifications in pore pressure can lead to plastic deformation in the strata, which can in turn modify the pore fluid flow and lead to ground subsidence. Since subsidence can affect the operability of equipment on the ground as well as the safety of buildings and structures, it needs to be accurately predicted and kept within limits. In this Technology Brief, we present a method for predicting the rock deformation and ground and ground subsidence resulting from oil and gas extraction.

Solution Briefs

The latest release of Abaqus version 6.10 includes Abaqus/CFD. The inclusion of this software makes it possible for users to perform a fluid analysis in a more user-friendly manner. Independent single software solely for CFD is currently available from many developers, and many attempts have been made to link software of CFD to structural analysis system using some specific procedures such as fluid structure interfaces (FSI). Direct implementation of CFD in FE structural analysis software offers ease of access to CFD. Adopting the position of a mechanical engineer trying to use CFD for the first time, a series of fundamental analyses were performed using Abaqus/CFD.

Customer Papers

Usually the development of a new engine is initialized by the request of an aircraft manufacturer who formulates basic requirements for the propulsion system. Preliminary engine design is then the first design phase at the aero-engine manufacturer where the engineer’s task is to develop a proper engine concept fulfilling all requirements and to respond to the aircraft company in a short time. At this early design stage only simple models can be used, but the decisions made are far-reaching and need to be precise. Therefore, engine component scaling tools are applied to increase prediction accuracy.

Customer Papers