Fatigue Simulation

Fatigue Simulation is at the heart of what our team of FEA consultants does at our Singapore FEA consultancy office in BroadTech Engineering. BroadTech surveyed Almost over 160 manufacturers and FEA Consulting Companies about their FEM simulation Actions. The End results were Tabulated and analyzed to identify Out the top Most Confrontations Commonly associated with FEA preprocessing, preparing for the solver, and postprocessing.
 
Fatigue Simulation
 
FEA Structural Analysis Enables Finite Element Consulting engineers to effectively simulate the Operational characteristics of their designs Virtually, well in advance of Physical prototype tooling Fabrication. Unlimited Company dollars can be Conserved by identifying Engineering design Challenges Way before entering into the Actual Fabrication process. They also now have the Additional capability of Total product data management.
With the Full integration of CAE, finite element analysis (FEA) can be Cost-Effectively during the Product Development process, closing the Post Engineering design-analysis Discrepancy, minimizing Excessive Number of Engineering design iterations, and Practically eliminating the Requirements for Costly physical prototyping Fabrication and Experimental testing.
 

Examine the Value of FEA Fatigue Simulation Analysis

When Bringing In the 3D model into CAE Nonlinear FEA Software, some CAD geometry Might not translate Exactly; this can Create Extreme problems with the FEA Structural analysis. Finding these problems Zones Takes a lot of time, and was rated by 44% as a top Confrontation. In some cases, the geometry cannot be fixed and must be Regenerated which Doubles efforts and wastes Precious time.
FEA Finite Element Analysis Simulation represents one product development investment that can support the Objectives Presented in Advanced Dynamic FEA Simulation tools provide insight into product strength and quality as well as cost drivers such as the amount of material needed. They can help Discover problems early when it is more cost-effective to fix them. They also allow efficient Assessment of Various design options to support innovation. In fact, BroadTech Engineering’s study, The Business Value of Simulation Finds, FEA Pipe Stress Analysis Simulation allows FEA Structural Consulting Services Enterprises to meet the demands for lower cost and faster time to market, but without compromising product quality.
Some of our related failure analysis services include
 

 

Capabilities and Advantages of Siemens FEA Fatigue Simulation 

Femap and Solid Edge Simulation were Especially designed with all types of engineers And Design Engineering Application in Focus – both the Product Structural Engineer Professional and the FEA Engineering Consultants Professional Performing the FEA Modeling Services – and support the most common FEM Modeling analysis needs as well as more advanced highly Unique FEA Analysis types. With both product Solutions, the CAE Product Offering offers a built-in upgrade path Enabling for expanded FEA Finite Element Analysis and Finite Element Analysis Simulation Modeling capabilities as business and simulation Demands expand.
 
 

 

Featured FEA Fatigue Simulation Case Studies

Ugine Traction Motor frame FEA Fatigue Simulation analysis

1. Tools:

Hypermesh,Abaqus/ Standard, Viewer.

 

2. FEA Simulation Methodology and Approach:

• Modelling of Front cover casing, Housing, Rear Cover casing using Tetrahedron Elements as per required Quality Criteria using Hyper mesh.
• Assigning  Material Data for the parts.
• Defining the contact pairs in the model.
• Creating Bolt Pretension and defining Pre-tension Load step.
• Applying Service loads like  Bearing Pressure and Torque in Housing casing.
• Applying appropriate Boundary conditions and defining service load step.
• Running a Nonlinear static Analysis using Abaqus/Standard and solving both load steps.


3. Outcome & Conclusion

• Post-processing the results using the Abaqus Viewer, plotting contact pressures across Interface regions and Vonmises stress distribution and Max Principal Stress.
• Report submission.

Shock Robustness Improvement of 2.5″ Hard Disk Drive (HDD)

1. FEA Simulation objective:
The objective is to improve the shock input (drop height) that can be tolerated by 2.5″ HDD in operating condition
2. FEA Simulation Methodology:
– The method used was to conceptualize the solution that can improve the shock robustness, then the ideas were tested by means of simulation in two steps: (1) simple model simulation in MATLAB and (2) full model simulation using FEA in ANSYS and finally the idea were tested on real 2.5″ HDD and shock tested in the laboratory. Our FEA Consultant is the only researcher that involves in this project, so Our FEA Consultant did the conceptualization, simulation, and experiments on my own.
3. Outcome & Conclusion
The conclusion is that the proposed solution improves the shock robustness of the 2.5″HDD, the simulation in MATLAB and ANSYS really helps in determining the best solution while the experimentation serves as means to fine-tune the selected solution.

Fatigue Simulation

Fatigue Analysis of Rubberized Concrete

1. Simulation objective:
Fatigue analysis of rubberized concrete (master thesis)
 
2. Methodology:
Using Acoustic Emission (AE) to monitor and locate the cracking during the fatigue process of common concrete and rubberized concrete using commercially available FEM software;
 
3. Conclusion:
Rubberized concrete has a better fatigue performance than common concrete.
During the initial stages of the FEM modeling and investigative FEA simulation, FE-SAFE was used to analyze the fatigue process, but this FEA software is not suitable for concrete. However, I learn FE-SAFE and did some examples for steel structures.

Optimization Design of Centrifugal Pump to Improve Efficiency

1. FEA Simulation Objective:
to reduce energy loss and improve the efficiency of the given centrifugal pump by optimizing the outer casing design
2. FEA Simulation Methodology and Approach:
Online-based simulation tool SIMSCALE is employed. Different iterations of casing design are prepared. Simulation constraints: impeller rotating speed is 1500 rpm, 0.1m^3/s flow rate at inlet and open outlet. A cell zone in the mesh is created to represent the rotating region. Newtonian viscosity model is applied for water fluid. The results of pressure and velocity are shown in post-processing. Efficiency is calculated by hand.
3. Outcome & Conclusion
Sharp corners in the casing design may increase energy loss. The worm shape casing can improve efficiency performance. The design of the impeller needs to be studied for efficiency improvement.

 

Overview

About Us

BroadTech Engineering is a Leading Engineering Simulation and Numerical Modelling Consultancy in Singapore.
We Help Our Clients Gain Valuable Insights to Optimize and Improve Product Performance, Reliability, and Efficiency.
 

 

Questions?

Contact Us!

Please fill out the form below. Our friendly customer service staff will get back to you as soon as we can.
1. Powerful Simulation Software Tools

1. Powerful Simulation Software Tools

2. Simulation Consultants with Extensive Research & Professional Experience

2. Simulation Consultants with Extensive Research & Professional Experience

3. Simulation projects Completed in a Timely and Cost-effective Manner

3. Simulation projects Completed in a Timely and Cost-effective Manner

4. Proven Track Record

4. Proven Track Record

5. Affordable

5. Affordable

6. Full Knowledge Transfer

6. Full Knowledge Transfer

FEA Software Solution partners

 Several customers have All invested in 3rd party Software tools developed by External parties that Build-on Simcenter Femap FEA Software from Siemens PLM is committed to Refining the Fully open and productive nature of our Working relationships with a Broad variety of inde­pendent Professional Software Code developers that are Closely working to develop Client-and-industry-specific func­tionality In Addition To Simcenter Femap NX Nastran.
 

FEA Software Module Advantages

• Utilize the FEA Finite Element Analysis Ansys software to Determine operational Loading forces which are Challenging or Challenging to Physically measure directly
• Through Professional FEA Services it helps to Assess and develop optimal in-service Engineering design modifications to increase production Workflow Operational throughput of rotating equipment systems 
• Get more realistic FEA Simulation by Using more Precise Force Force using the FEA Structure Wind Load Simulation Software
• Use FEA Software to Rapidly Assess and improve the dynamic performance of rotating systems prior to physical Prototype Fabrication and production Schedule commit in a Totally integrated CAE Workflow environment
• Combine Experimentally measured loading data with FEA simulations
 
Boosting product Performance Reliability and Built Robustness
Simcenter Femap Nastran enables Both FEA Consultants, professional FEA engineering Consultants, and R&D Managers to Quickly & Reliably evaluate many more Engineering design Variants that can be Actually Achieved with physical Prototyping.
FEM Software Simulation Enables engineers in Fatigue Analysis Services Companies to Quickly Comprehend and optimize Engineering design Compromise for General Engineering Design quality, cost and performance Reliability.
 

 

Featured Fatigue Simulation Case Studies

Static Structural and Fatigue analysis of Journal Box assembly

1. FEA Simulation objective:
The objective of this project was to carry out structural and fatigue analysis and of the Journal box under given loading conditions, and to validate the design.
Project Name: Modal Analysis of GE9X Engine Turbine Blade
2. FEA Simulation Methodology and Approach:
Description: FE Model prepared in Hypermesh and Ansys. Material properties and boundary conditions are applied to the model by using Ansys APDL. Structural analysis is performed for the load conditions then Evaluated natural frequency and mode shape and investigated the resonance by Campbell diagram.
 
 
 

Fatigue analysis of load-carrying components of the truck

1: Fatigue analysis of load-carrying components of the truck such as Frames and cross members.
Calculating mean and amplitude stress and identifying the hotspot regions for product development.
FE Tools: Abaqus-Hypermesh-Matlab
FE-analysis: Non-linear Static analysis (Linear material properties for high cycle fatigue and plastic material model for Low cycle Fatigue)
 
 

FEA Simulation of Steel Culvert Bridge

In one smaller project, Our FEA Consultant tried to model the behavior of a short-span steel culvert bridge, approx. 4m. This kind of bridge is constructed with a very thin layer of steel buried in the soil. Thanks to the interaction between soil and steel, it can transfer significant load while providing attractive economic solutions, largest spans for this kind of structure can reach up to 20m. A crucial part of this kind of structure is soil thickness above the steel structure so the arch effect can be observed in soil.
  1. The project was done with Abaqus using 3D soil elements and 2D shell elements
  2. Sheets of corrugated steel were modeled as flat shell elements.
  3. The behavior of soil under large load was studied to understand the Drucker-Prager yield criterion
  4. Interaction between soil and steel was modeled
  5. Influence of soil thickness was investigated to estimate thickness were soil arch effect stops being beneficial
1. FEA Simulation Objective:
1. Simulation objective was to evaluate all three mount systems for 3 different platforms based on NVH to determine system stiffness and identify better design solutions
2. FEA Simulation Methodology:
2. Methodology was to study structural benefit, material and mass studies, complete system targets based on NVH and sub-system fatigue evaluations
3. Studies for various platforms were evaluated to determine if targets for all assemblies were met and if there was scope for further design improvements as the primary objective was to meet NVH metrics
 

Layered panel simulation under impact using LS-DYNA

· The objective is to build a FEM model to simulate layered panel simulation under impact.
· LS-DYNA was used to simulate blast loading for a multi-arch-surface double-layered panel with verification against published experimental results.
· Our FEA Consultant conducted a parametric study to develop a stronger panel
 

FEA Reverse engineering of Aircraft Spoiler

1. FEA Simulation objective:
Validate the static and dynamic behavior of FE model created for incumbent (existing) design and to generate an alternate design with composite skins and spars which can be manufactured
2. FEA Simulation Methodology and approach:
  1. Achieve a good understanding of existing design along with sub-components and their functionality
  2. Use 3D scanned model and designer’s CAD model to generate FE mesh using Hypermesh.
  3. Make appropriate assumptions and FE idealizations for connections as 1st iteration.
  4. Understand the physics of component and assembly interfaces for boundary conditions.
  5. Identify different loading conditions in which components can be loaded in practical conditions.
  6. Validate the results of the Incumbent FE model in terms of stiffness (static) and mass distribution (Dynamics) using experimental test conditions using MSC Nastran SOL 101 and SOL 103 (Free-Free, Fixed). Modify the FE model (as different iterations) to match the results of experimental results by sorting out initial assumptions and idealizations as per mode shape differences.
  7. Upon freezing incumbent design create an alternate Composite box structure (CBS) which should have enough stiffness as incumbent design and mode shapes similar to incumbent model as per the component working condition.
3. Outcome & Conclusion
A CBS model design has been created by considering existing design philosophies which are both statically and dynamically equivalent to incumbent design.
 
 

Truck cabin development

1. FEA Simulation objective:
To validate the cabin design by coordinating with all stakeholders
2. FEA Simulation Methodology and Approach:
FEA for concept design using loads from previous experience & Co-relations
Design validation and project results to all stakeholders
Addressing the failures and attending design review meetings
3. Outcome & Conclusion:
providing CAE support to the designers till the product reach final release
 

CAE Topology Optimization of Mission mount

1. FEA Simulation objective: 
The objective of Topology optimization is to get the improvised model for better PI performance.
In this particular project, Mission mount’s PI performance has to be improved with the Y – Y-direction unit load condition. Displacement of Y direction is the design constraint bound and Volume Mass fraction is the design response. Based on the topology design outputs, the Stiffness of the component will be increased by adding mass or ribs.
2. FEA Simulation Methodology and Approach:
Topology Optimization using Optistruct and Sol200 of Nastran
3. Outcome & Conclusion
we have achieved the PI value target by reducing the Y displacement from 0.028 to 0.014. 50% reduction in Y displacement has been achieved
 

About Us

BroadTech Engineering is a Leading Engineering Simulation and Numerical Modelling Consultancy in Singapore.
We Help Our Clients Gain Valuable Insights to Optimize and Improve Product Performance, Reliability, and Efficiency.
 

 

Questions?

Contact Us!

Please fill out the form below. Our friendly customer service staff will get back to you as soon as we can.

 

Call Us for a Free Consultation

All FEA consulting customers will be provided with fully tailored Fatigue simulation and FEA analysis reports which outline the Methodology, in-depth analysis, and recommendations. This FEM simulation insight allows our clients to optimize performance and make informed engineering decisions in a scientific, proven manner.
 
If you are still interested in learning more about fatigue simulation services and to see what it can do for you, call to contact us today at +6581822236 for a no obligation discussion of your FEA consulting services needs.
Have a questions/queries? Our knowledgeable and friendly simulation consultants will be happy to
answer any of your queries and understand more about your needs and requirements
 
Alternatively, for quote request on our FEA services, simply email us your technical specifications & requirements to info@broadtechengineering.com