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Finite Element Simulation

Finite element simulation is at the core of what our FEA consultants do at our Singapore FEA consultancy offices in BroadTech Engineering.

Featured Finite Element Simulation Case Studies

Finite Element Simulation

Finite Element (FE) Simulation of Chassis Main Frame

This finite element simulation project involves the structural analysis of an automotive Chassis mainframe
Tools & Methodology Used: Hypermesh and Optistruct
1. To analyze the stiffness of the latest Chrysler JL Frame
2. Displacement values are obtained from contour plot at local grid points.
3. Bending and torsional stiffness are calculated from the displacement values (k=uP) and concluded that the frame is successfully designed to meet the requirements.

Finite Element Simulation of Front Subframe

Geely KC2 Front Subframe Stiffness Analysis was done as part of our FEA consulting services
Tools & Methodology Used: Hypermesh and Optistruct was used during the Finite element analysis
1. To analyze the stiffness of the subframe of Geely KC2.
2. Displacement values are obtained from contour plot at local grid points.
3. Bending and torsional stiffness are calculated from the displacement values (k=uP) and concluded that the frame is successfully designed to meet the requirements.

Maximization of Dynamic Stiffness of Mounting Bracket of Engine

Tools & Methodology Used: Hypermesh and Nastran was used for the fatigue simulation
1.Improving the Frequency and dynamic stiffness of the Bracket reduces the engine transferring vibration.
2. In previous iteration Engin, RH mounting Bracket assembly has the frequency level of 450Hz.
Two ribs were added to the mounting plate and modal analysis carried with appropriate boundary conditions.
3. Dynamic stiffness is improved and the frequency level obtained is 570Hz.

Elastic and Elastic-Plastic Analysis of Thick Wall Pressure Vessel

Objective: To investigate the Von misses stresses, 1st yield, strain hardening and the plastic collapse of the thick-walled pressure vessel for purpose of carrying out a numerical optimization of the vessel design.
Methodology: Finite element analysis was carried out by our structural engineering consultants to investigate the behavior of the stress against time.
Outcome & Results: The first yield occurred in the inner knuckle and top crown of the vessel.
After yield point, if the load applied to the vessel increases (strain hardening), the material of the vessel will deform permanently.
From the structural analysis, the maximum stresses are concentrated at the top of the vessel representing the plastic collapse

Simulation of Pressure of Fluid through Orifice Plate

Objective: To investigate the nature of the flow which can be determined by the Reynolds number. At a low Reynolds number laminar flow is witnessed while at high Reynolds number turbulent flow is witnessed.
Tools & Methodology Used: FEA analysis was conducted for a different type of orifice plate. Circular, flat, forward and backward.
Outcome & Conclusion:
Circular orifice plate produced superior results due to the reduced amount of change in pressure. FEA analysis for venturi tube was also performed and the results were more promising due to smaller head losses compared to the orifice plate.

FEA Simulation of Disc Brake Assembly

Disc Brake Assembly
Tools & Methodology Used: Hypermesh and Nastran
1. To carry out structural optimization and analysis for Automotive Disc Brake assembly.
2. The stresses generated in the caliper components and contact (interface) pressure distributions at the rotor and piston-pad interface taking into consideration dynamic condition of the assembly.
3. It has been observed during the FEA simulation that higher pressure occurred on the leading side when the disc starts to slide, which again states that more wear appears on the leading side than the trailing side of the pad. So the study of dynamic pad pressure distribution helps in order to minimize and/or eliminate tapered wear in pads.

Design Optimization of Heavy Industrial Vehicle (Loader Bucket Assembly)

Tools & Methodology Used: The FE model was prepared for ABAQUS solver commonly used in stress engineering services companies.
2D and 3D elements were used to build the FE model according to the requirement defined for the required structural engineering services.
The FEM modeling used the bar elements to connect the bolt locations using the tool Hypermesh. A Modal Analysis and topology optimization were performed using the solver Optistruct in the FEA software.

Buckling of Tori-Spherical Domes (Thin Pressure Vessel)

1. Algor Fem Pro was used to conduct FEA finite element simulation on tori-spherical domes. The objective of the engineering simulation project was to investigate the effects of the thickness of the vessel against buckling and linear stress.
2. FEA analysis, Fatigue analysis, Fracture analysis, and Buckling analysis was performed for varying thickness to study the critical buckling pressure and yield pressure.
Observation:
During the rendering of the failure analysis services, it was noted that with the increase in thickness of the pressure vessel the higher buckling loads it could withstand and a logarithmic relationship was observed. With the increase in thickness, a higher yield pressure was observed and the relationship was linear.

Finite Element Simulation of Thermal Stresses on Fin

Objective: The objective of the design optimization project was to investigate the effectiveness of the shape and number of fins (used in heat exchanger etc) subjected thermal stresses
Tools & Methodology Used:
FEA analysis was performed on a model without a fin and model with fin.  (Model 1: No fin, Model 2:1 Triangular fin, Model 3: 1 Rectangular fin, Model 4: 2 Triangular fins, Model 5: 2 Rectangular Fins). The effectiveness was calculated by comparing the max heat flux of model without fin vs models with fin (i.e max heat flux of model 3/max heat flux of model 1)
Outcome & Conclusion:
Fins are capable of transferring more heat outside than pipes without fins.
Enhanced heat transfer rates are increased by greater no of fins due to more surface area to the surrounding to compensate for higher resistance.
The model with the two parallel rectangular fins produced the best results. The FEA results were compared with the results from theoretical formulae to validate the results and calculate the error ineffectiveness.

Stress Analysis of Semi-Elliptic Edge Crack in a DNVX65 Steel Specimen

To investigate numerically the stress intensity factors of semi-elliptic edge crack in a DNVX65 steel specimen that has progressed beyond the width of the specimen under a four-point bending load, and to investigate via failure assessment diagram if the existing flaw is acceptable.
2. eXtended FEM enrichment was used in analyzing the crack propagation, to capture singularity of the crack tip.  Numerical modeling results were used to compare with benchmarks from BS7910 solutions.
R6-K solutions were supplemented on top of BS7910 considering the validity limits of its solutions.
Results for 4PB loads were also compared with past literature from Gross & Srawley’s beam bending analysis.
3. SIF distribution along the crack front showed consistency with the profile of the crack, with higher SIR at the extremities – kink points of the crack
 
Fatigue Analysis
Stress analysis simulation was conducted on engines stators and fan blades. Structural analysis report memos were produced to incorporate information on high-stress points.
As part of the analysis for a client project, fatigue crack growth (FCGR) was also analyzed.
Cyclic stress intensity factor range relating t the amount of crack propagation during every fatigue cycle was also part of the project.

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1. Powerful Simulation Software Tools

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2. Simulation Consultants with Extensive Research & Professional Experience

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

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

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Customers will be provided with fully tailored Finite Element Simulation reports which outline the Methodology, in-depth analysis, and recommendations. These insights allow our customers to optimize performance and make informed engineering decisions in a scientific, proven manner.
Discover what Finite Element Simulation can do for your company today by calling us today at +6581822236 for a no obligation discussion of your needs.
if you have any queries, our knowledgeable and friendly FEA consulting engineers will be happy to answer any of your queries and understand more about your needs and requirements
For quote request on our FEA services, simply email us your technical specifications & requirements to info@broadtechengineering.com