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Projects by Industry

The following section presents a number of selected projects completed by SimuTech Group Canada, and how the technology is utilized to solve complex problems. If you would like to learn more about any one of these projects or about FE Consulting, FEA Consutling or CFD Consulting in general, please contact us.

Industrial Equipment
Transportation
Oil & Gas
Construction
Healthcare
Power Generation
Electronics

Industrial Equipment

Rubber Track Analysis :
Industrial Products : Explicit Dynamics : ANSYS / LS-DYNA :
Rubber tracks are used on many types of vehicles. Durability is the most important feature for rubber tracks in order to function most effectively while maintaining aesthetics. We thus closely worked with our customer in an R&D effort with the goal to implement FEA in their rubber track design process.

Protective Casing Impact Analysis :
Safety Equipment: Explicit Dynamics : ANSYS / LS-DYNA / Workbench / AI*Environment :
A protective casing surrounding a six-blade cutting fan needed to be modified in order to contain a flying broken blade. Impact simulations helped the customer find the required casing configuration. Geometries were created from technical drawings with ANSYS DesignModeler. ANSYS AI*Environment was used to generate the structured mesh of the manufacturing system. The simulations were solved with ANSYS LS-DYNA. By the use of ANSYS LS-DYNA computer simulations, the customer was able to quickly investigate multiple design configurations.

Windage losses in a shaft-bearing gap:
Mechanical Engineering: CFD Fluid Dynamics: ANSYS/CFX
Auxiliary (backup) bearings that are not in contact with a spinning shaft are used for safety reasons. Their presence incurs a drag force on the spinning which translates into additional power requirements. CFD was used to observe resulting Taylor-Couette Instabilities in the gap, and quantified the drag forces. A better understanding of these phenomena helps minimize drag and increase the product's efficiency.

CFD Analysis of a industrial fan:
Manufacture: CFD Fluid Dynamics: ANSYS/CFX:
A CFD analysis was conducted for a cooling fan to optimize its performance.

Finite Element Analysis of Lifter Plate Assembly:
Automotive: Structural Mechanics: Stress:ANSYS/Mechanical.
In the transportation industry, components are subject to cyclic loads that can be detrimental to its long term durability. A FEA was conducted for a window motion lifter plate assembly to find the maximum stress and deflection.

Optimization of a Race Car Front Suspension Arm :
Automotive : Structural Mechanics: Stress / Deflection : Workbench / Optimization :
A multi-objective optimization with desired goals conflicting with one another was done on a front suspension arm of a race car. The Design of Experiment (DOE) method was used and trade off plots were generated. The Goal Driven Optimization helped the customer find the best design candidate. The project clearly demonstrated how easy it is to do such analyses in Workbench.

Reciprocal Compressor Fatigue Analysis :
Industrial/Mechanical Engineering : Fatigue : ANSYS Workbench and Fatigue Module :
Fatigue is an important consideration in the design of reciprocal compressors which undergo many cycles of alternating loading. Analysis of the structure identified the areas most likely to fail. Multiple rounds of design and analysis resulted in dramatic improvements before the costly construction and testing of prototypes.

Aesthetic and safety design of a faucet and overflow ports:
Plumbing: CFD Fluid Dynamics : ANSYS/CFX
For proper design of faucets and overflow ports, it is imperative that fill flow rates do not exceed overflow capacity.  CFD was used to obtain drain rates through primary drain ports as well as overflow ports under different fill conditions and pressure-head heights. Furthermore, aesthetic shaping of fill flow patterns for high end commercial faucets was performed.

Transportation

Pickup TL2 Crash Simulations :
Safety Equipment : Explicit Dynamics : ANSYS / LS-DYNA :  
The security of workers is important. Crash simulations were performed to help find an acceptable barrier configuration used in work zone. The simulations involved a Chevrolet C2500 pick-up truck impacting a longitudinal barrier at 25 degrees of the centerline and moving with a nominal velocity of 70 km/h. ANSYS ICEM CFD was used to generate the structured mesh of the barricade system. The simulations were solved with ANSYS LS-DYNA. By the use of ANSYS LS-DYNA computer simulations, the customer was able to ascertain design strengths and weaknesses and make changes accordingly.

Bird Strike Analysis :
Aerospace : Explicit Dynamics / FSI : ANSYS / LS-DYNA :
Minimum bird ingestion standards for jet engines were developed by the FAA in the 60’s. Currently testing is mainly conducted with computer simulation, although final testing usually involves some physical experiments. The particularity of the bird strike analyses done was the non-standard fan blade material used i.e. aluminum.

Dynamic Analysis of Ship Collisions :
Marine : Explicit Dynamics : ANSYS / LS-DYNA / Workbench / AI*Environment:
International standards force ship owners and builders to have double hull ships. A costly methodology is to generate cofferdams in the region of ship impact to protect the main hull. The use of a composite structural laminate was proposed by one of our customers. CAD models were modified with ANSYS DesignModeler. ANSYS AI*Environment was used to generate the structured mesh. The dynamic simulations of the ship collisions were solved with ANSYS LS-DYNA. By the use of ANSYS LS-DYNA computer simulations, our customer was able to demonstrate that the use of its technology on a FPSO not only meets but exceeds the authorities’ requirements and therefore should be considered as a secure solution.

Plastic Molded Boat Impact Analysis :
Military : Explicit Dynamics / FSI : ANSYS / LS-DYNA / Workbench / AI*Environment :
The Navy is currently using small boats for different operations. The current solutions are very heavy and have relatively low durability. A much lighter and more durable plastic molded boat was proposed by our customer. By the use of ANSYS LS-DYNA computer simulations, the customer was able to evaluate the strength of his design.

Pressure and Thermal Mapping Macros:
Aerospace Gas Turbine/Energy Production: Structural Mechanics: Advanced macro Programming : ANSYS Mechanical:
Macros were written to map pressure and thermal data into ANSYS structural finite elements models. The pressure and thermal data existed in formats not immediately usable by ANSYS. Body force interpolation and other methods were employed to move data into ANSYS models. Both direct 3-D to 3-D mapping, and 2-D to 3-D sweeping of data was implemented.

CFD Analysis of an Automotive Air Duct :
Automotive: CFD Fluid Dynamics:ANSYS/CFX :
Pressure drop through an automotive ventilation system is critical to performance. A CFD analysis was conducted to optimize the geometry in order to meet the design specification.

Exhaust Manifold CFD Optimization :
Automotive :CFD Fluid Dynamics/Optimization :ANSYS/CFX:
A CFD analysis was conducted to optimize an engine exhaust pipe to lower pressure drop and optimize performance.

Finite element analysis of open jet:
Civil: Structural Mechanics: Stress/Modal Dynamics: ANSYS/Mechanical:
The aerospace industry utilizes large cross-section wind tunnels to verify designs. Due to the size of these tunnels they can be subject to aerodynamic excitation due to the hydrodynamic forces generated by the high velocity air flow through them. FEA Model Simulations were used to examine the primary natural frequencies of the main structure in order that the stiffening members be designed in order to prevent this type of response.

Finite element analysis of a Ratchet/Striker/Bracket Assembly:
Automotive: Structural Mechanics: Stress: ANSYS/Mechanical:
Many components on a vehicle are subject to abuse loads. From a warranty aspect, these conditions must be accounted for. To substantiate the latch system, an FEA was conducted to predict the ultimate loads the system could sustain.

Finite Element Analysis of a casting die assembly:
Industrial equipment: Structural Mechanics: Stress/Thermal: ANSYS WB:
A thermal and structural analysis was done for a casting die assembly to predict the state of stress in the die inserts caused by pressure and thermal loads.

FEA analysis of a turbine blade:
Aerospace: Structural Stress/Advanced Meshing:ANSYS/ICEM CFD:
The quality of finite element results is related to the quality of the finite element mesh The aerospace industry often analyzes complex assemblies In order to maintain the model at a reasonable size and obtain high fidelity results, a hexa mesh is often required. Such a mesh was created for a turbine blade. Transient thermal and stress analyses were also done to find the maximum stress and strain in the blade.

Structural Analysis of a Bus :
Transportation : Structural Mechanics: Stress / Deflection : ANSYS / Mechanical :  
Many considerations have to be taken into account when designing a low-floor urban transit bus. A bus frame will be subjected to many types of load during its life. Road tests are very expensive and time consuming. Structural analyses done on the bus helped the engineers find and eliminate design issues not foreseen by standard design methods.

Structural Analysis of an Engine Support :
Aerospace : Non Linear Structural Mechanics: Stress / Deflection : ANSYS / Mechanical:  
Many engineers worked on the engineering analysis of the Airbus A380. We are part of them. The goal of the structural analyses was to assess the integrity of an engine support after yielding. In other words, what would be the extent of plastic deformation.

Oil & Gas

Volatile gas dispersion upon accidental release in a chemical processing plant:
HVAC/Chemical Engineering: CFD Fluid Dynamics: ANSYS/CFX:
Part of a well designed chemical plant ventilation system is the effective dispersion of volatile gases upon sudden accidental release. CFD determined the gas bubble sizes that correspond to the Lower Flammability Limit, ensuring that workers and equipment are not threatened.

Construction

Explosive Blast Inside Reinforced Chamber :
Military/Chemical Processing : Explicit Dynamics: ANSYS/AUTODYN :
The disposal of recovered ordnance is an important step in the clearing of mine fields. Safe disposal requires that the mines and other explosives be rendered inert by detonation in a reinforced chamber. Simulation of the explosive blast allowed for verification of the design before construction of a prototype and resulted in significant savings and a faster time to market.

Transient Thermal Analysis in a Geothermal Heating System: HVAC/Civil Engineering: Structural Mechanics: Transient Thermal Analysis: ANSYS Mechanical:
Feasibility of 3D modeling heat transfer to and from the earth via fluid flow in piping with FLUID116 and thermal surface effect elements was illustrated in a transient geothermal model during a multi-year plan. Heat transfer via groundwater flow was added. Solid elements were used in a fully 3-dimensional model of the earth with an array of piping elements. Temperature fluctuations were simulated over time, with variation in air temperature and heat transfer into and out of the fluid pumped into the piping. The ANSYS finite element model was generated automatically via an APDL input file that could be modified to explore system design alternatives.

Pedestrian Level Wind study for new high-rise urban development projects:
Environmental Engineering: CFD Fluid Dynamics: ANSYS/CFX
The development of a high-rise structure changes the wind patterns in its vicinity. To ensure pedestrian safety, wind pattern modifications due to proposed structures are studied. Areas exhibiting a drastic increase in wind speed due to the structure were observed and mitigation procedures were proposed.

Modal analysis of Air Filter:
Automotive : Modal Dynamics: Structural Mechanics: ANSYS/Mechanical:
In order to ensure optimal performance, Automotive parts must not resonate during service. A modal analysis is often necessary to ensure that the Natural Frequencies are suitably high to ensure a lack of resonance.

Flow distribution through a catalytic oxidizer vessel:
Chemical Engineering: CFD Fluid Dynamics: ANSYS/CFX:
To efficiently process and clean hot gases through an oxidization process, flow must be uniformly distributed in an oxidizer vessel, as it passes across banks of catalytic blocks. Flow deflectors were optimized to help obtain proper distribution of flow through this vessel.

Wind Loading on Building Housing a Wind Tunnel :
Civil Engineering : Structural Mechanics Analysis : ANSYS Workbench :
The building housing an environmental wind tunnel has some special requirements. The doors need to be large enough for vehicles, light enough to be easily opened, they need to form an airtight seal, and they need to be stiff enough to maintain that seal under pressure loading. ANSYS Workbench was used to construct a model of the unique door structure and simulate the door’s ability to maintain a seal under various loadings.

Healthcare

Structural Analysis of Mobile Heart Scanner :
Medical : Structural Mechanics Analysis: ANSYS Workbench :
A mobile heart scanning device was designed for use in clinics and hospitals. Safety is critical and the light weight mobile structure needs to be able to support the weight of patients. Various load cases were examined in ANSYS Workbench to determine the safety margins in the structural components.

Power Generation

Thermal Transient Analysis and Linearized Stresses in Fillet Welds in a Gas Turbine Casing Nozzle:
Industrial Gas Turbine/Energy Production: Structural Mechanics: Coupled Transient Thermal and Structural Finite Element Analysis: ANSYS Mechanical:
Peak thermal stresses attained during thermal transients often occur midway through an operating cycle of a pressure vessel or gas turbine. Transient finite element analysis forced solutions to be saved at time history “corner points” and at well-distributed time points in the interior of the operating cycle. Under the ANSYS macro, stresses were calculated at all saved time results points. Linearized stresses were automatically formed at a variety of paths through welds, and time-history data was formed for the linearized stress histories at those paths. The stress histories were graphed time and values of maximum linearized stresses identified, avoiding tedious time-consuming review by a user. The resulting data would be used in other software to assess fatigue results.

Automated Generation, Solving, and Postprocessing of 3-D ANSYS Finite Element Models of Feeder Piping for CANDU Nuclear Reactors using APDL:
Nuclear Power/Energy Production: Structural Mechanics Analysis: ANSYS Mechanical: APDL
A very complex ANSYS macro was programmed to read customer data files and automatically generate 3-D models of Feeder tubes for CANDU nuclear reactors. Variable wall thickness data was represented in ANSYS geometry that was then map meshed to achieve through-wall element layers with detailed representation of wall thinning. Stresses were linearized by the macro and mapped to the model for contour plot presentation. Peak linearized stresses were plotted on graphs as functions of axial position. The macro permitted restriction of portions of the model to 3-D element representation and transition to PIPE16/PIPE18 elements for the remainder. New /POST1 Surface Operations commands of ANSYS were employed to find linearized stresses on cross sections of pipes, with these stresses graphed versus axial position. Optional NASTRAN output was added.  

Critical Speeds of a Feeder and a Refiner :
Industrial Equipment : Rotordynamics Structral Mechanics: ANSYS / Workbench :
Feeders and refiners are typical equipment used by the Pulp & Paper industry.  It is common to modify available equipment in order to increase the productivity instead of buying replacements. We thus did several analyses on feeders and refiners to make sure that the operation window of the equipment does not interfere with its critical speed(s). The analyses could include pre-stress effects, bearings and the static structures. The analyses output were Campbell plots, whirl direction and stability status.

Guide Tool Forced Deflection Simulations :
Nuclear : Non Linear Structural Stress / Deflection Fluid Dynamics: Workbench :
A guide tool used in the nuclear industry needed to be straightened after it had been welded. The welding process induced unacceptable permanent deflection. The straightening process was simulated to assess the structural integrity of the guide tool and also to evaluate its straightness in service. The particularity of the analyses done was the inclusion in the model of the Heat Affected Zones (HAZ).

Electronics

Crimping simulation of a wire assembly:
Electronics: Explicit Dynamics: ANSYS/LS-DYNA:
An explicit dynamics analysis was conducted to simulate the material failure of a wire crimping process.

Industrial sensor optimization using vacuum forces to control a membrane product:
Industrial Engineering: Optimization: Fluid Structure Interaction (FSI): ANSYS Mechanical / CFX / WORKBENCH
Aerodynamic forces can be used to align membranes with sensor apparatus. Knowledge of pressure forces and their interaction with the membrane drives the designs of these sensor devices. The fluid structure interaction was investigated, where membrane shapes were predicted under different pressures and tensions.

Plastic Molded Protective Device Impact Analysis :
Military : Electromagnetics/Explicit Dynamics : ANSYS / LS-DYNA / Workbench / AI*Environment :
Electronic equipment always needs protection against impacts (drops). A current solution used is effective but very expensive. A much cheaper plastic molded protective device was proposed by our customer. Drop test simulations of the device before molding a prototype were performed. CAD models were modified with ANSYS DesignModeler. ANSYS AI*Environment was used to generate the structured mesh of the device. The simulations were solved with ANSYS LS-DYNA. By the use of ANSYS LS-DYNA computer simulations, the customer was able to quickly get a final prototype design.