Transcript

South Eastern Applied Materials

Research Centre

Using Finite Element Analysis

In Industrial Research

Presentation Outline

• Introduction to SEAM

• Cost of Design and Development

• Finite Element Analysis Introduction

• Various Application Examples

• Some typical case studies.

Who we are....• SEAM is a materials science and engineering research centre, which acts both in

industrial and academic spheres, with the aim of bridging the gap between

academia and industry.

• SEAM aims to be highly customer focused; serving a wide range of industrial

sectors in the south eastern region and throughout Ireland.

• SEAM’s goal lies in becoming an integral part of the R & D activities of

multinational companies based in Ireland, as well as aiding Small-Medium Sized

Enterprises in their transition from a purely manufacturing base into the realm of

research and development.

• SEAM will have a strong research focus and develop independent research

initiatives which have a strong commercial focus.

3

Industrial Sectors Served

4

• Broad range of Industrial sectors

served with a high degree of

expertise in the Precision

Engineering and Medical Device

sectors.

• SEAMs guiding ethic is to provide

companies in Ireland with the edge

required to be successful.

• Serves over 85 different clients

across the country.

• SEAM is highly proficient in

obtaining funding for industrial

collaborations and development

projects.

• SEAM is skilled in the arts of failure

analysis and product design

optimisation for industry.

Specialist Technologies Provided

5

X-ray Micro-tomographyMicro-sectional

AnalysisSurface Roughness

AnalysisFinite Element

Analysis

Tensile and

Material TestingSEM Inspection Development of Custom

Solutions for IndustryFailure Analysis

6

• Since its launch in 2009 SEAM’s

client base has grown from

strength to strength.

• Clients include SMEs, indigenous

companies, as well as large

multinationals.

• SEAM provides access to cutting

edge equipment and expertise to

these clients.

• The fact that we are based within

the country makes it very easy for

customers to approach and

discuss projects, results, and

obtain advice from SEAM. This

point has added to the popularity

of SEAM as a supplier of industry

solutions.

• We are always ready to help!

Clients

Product Development Costs

Product Development Costs Overview

Time

Money +

Money -

Profit Line

FEA Driven

Development Conventional

Development

The Ideal Development Path

Develop

Design

Build

Prototype It works!

Idea!

This is the ideal design pathway but it can have inherent costs:

•Greater likelihood that components are over designed.

•Extra cost through unnecessary material use.

•Overdesign may hide fatigue failures from standard test

methods.

In the real world things are rarely this easy!

A More Likely Development Path

Prototype fails.

Why?

This is a

costly

cycle!

Develop

Design

Build

Prototype

Idea!

Test

Eventually

Redesign

Establish source

of failure

A Virtual Design RouteBuild prototype

and test

Develop

design using

CAD tools

Build and test

virtual prototype

Idea!Assess results

This yields a design with the following advantages:

•Overall better design.

•Higher quality and reliability.

•Much more cost effective development.

•Safer when branching into new areas.

Redesign

and optimise

This is a much

more cost

effective route!

The Cost of Design Failure

• Failures in service are often due to

a combination of forces.

• Forces that the prototype testing

was unable to effectively analyse.

• Such failures are very costly in

terms of financial cost but also of

loss of customer faith.

Tacoma Narrows Bridge failureImage courtesy of Bettmann / Corbis

What is finite element analysis, FEA?• The Finite Element Method is a

numerical technique for finding the

solutions to partial differential

equations and integral equations.

• It is simpler to say it divides a system

or component into discrete points,

applies known boundary conditions,

material data, and calculates the

system response.

• It allows the detailed modelling of

complex systems and components

with a greatly reduced need for

prototyping.

Image Courtesy of Siemens Femap

Rocker Component Example

Component

Model development Stress analysisImages courtesy of engineering by design

Courtesy Virginia Military Institute.

Artery after Stent Inflation

Biomedical Areas of Application

Inhaler Airways AnalysisImage Courtesy of Anne de Boer, University of Groningen

Impact analysis

Stress Analysis of Tablet CompactionWu et al 2005

Structural FEA

Above images courtesy of

Paul Nylander

Gasket compression analysis

Nonlinear buckling of a stiffened vesselAbove images courtesy of ANSYS

Compression of a rubber component

Stress analysis of Meshing gears

Thermal

Thermal distribution in a heat sinkImage courtesy of neisoftware

Image courtesy of Mentor Graphics Mechanical AnalysisThermal Distribution in a circuit Board Image courtesy of Vectis

Thermal Distribution in a Cylinder head

Image Courtesy of BorgWarner Turbo & Emission Systems

Thermal Distribution in an manifold

Computational Fluid Dynamics

Images courtesy of ANSYS and Conventor

Fluid flow through a

cardiovascular valve

Air flow in an electronics module

Fluid flow in a

microfluidic device

Mixing of fuel and air

in a engine cylinder

Application Examples

Fatigue Analysis of Pump Housing.

Determining the life cycle of a pump housing using FEA

Pump from a chemical processing plant, designed to run with an internal pressure

range of 2-7 Mpa. This resulted in a stress concentration in a support rib that could

lead to failure in fatigue. Pump is made from 316L stainless steel

Case 01 Pressure 2-7 MPa

Original Design and Estimated Fatigue LifeCase 02 Pressure 1.5-4 MPa

Estimated Fatigue Life for Original and Optimised

Design

In order to increase the service life of the pump without sourcing a new one the system

pressures were reduced leading to a marked increase in service life. Mohammad et al., Fatigue Life for Type 316L Stainless Steel under Cyclic Loading, Advanced Materials Research Vol. 701 (2013) pp 77-81

Conclusions

• Design can be a costly business!

• Finite element analysis is a powerful design tool.

• It facilitates design optimisation at an economic cost.

• It also provides enhanced reliability and quality in products.

Questions?

Flow field around an F1 car. Image courtesy of Voxdale.

South Eastern Applied Materials Research CentreApplied Technology Building

Waterford Institute of Technology

Waterford

Contact

Dr. Ramesh Raghavendra

Centre Manager

Ph: 051-845648

Fax: 051-302452

Email: [email protected]

Website www.SEAM.ie

Eoghan O’Donoghue

Development and Research Engineer

Ph: 051-845649

Email: [email protected]


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