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26 Apr 2019

Adaptive’s Cynde Murphy to Speak at V&V Symposium

V&V Verification and Validation Symposium
Conference May 15-17
Training & Committee Meetings May 13-14
Westgate Resorts, Las Vegas, Nevada

Dynamic Load and Weld Fatigue Calculation for Validation of a Telescoping Boom Chassis presented by:

Adaptive’s Cynde Murphy, Simulation and Services Manager
Bob LeGrande, Engineer Principal III, Terex Corp., AWP Division – Genie Industries
Kyle Roark, Engineer Principal II, Terex Corp, AWP Division – Genie Industries

Analytical simulation is a powerful tool that can allow for understanding the dynamic behavior and fatigue life of any structure. However, one of the most challenging tasks involved with developing a simulation is developing accurate and realistic load cases, which replicate field strains in the structure, so that it may be used for validation. Once a representative finite element model (FEM) of a structure is created, challenges arise when understanding and applying dynamic loads to the FEM so that correlation and validation with physical testing is accurate. One step further in complexity is being able to calculate dynamic stress profiles for the entire structure, and use those results for further investigation, in this case fatigue estimates.

Historically, analysts have had to rely on expensive prototyping and time-consuming full vehicle measurements, even within the iterations of one design concept. Analyze-Build-Test is quickly becoming a thing of the past, as product development companies strive for quick to market designs. Simulation experts at Adaptive Corporation, in conjunction with Terex, were able to circumvent this traditionally laborious process and develop an efficient and accurate validation process. Our team has leveraged the use of ANSA, ABAQUS, Wolf Star Technologies True-Load™ software and Fe-Safe, to develop an FEM, understand the dynamic mechanical loads and develop a duty cycle for the Terex telescoping boom chassis. This body of work can and will be subsequently used for design, simulation, fatigue analysis, validation and engineering development of iterations of the same chassis structure, as well as similar chassis designs.

The general steps of the process are as follows: FEM Creation of Assembly FEM of the chassis structure was created using ANSA pre-processor software. Instrumentation and Data Acquisition To successfully calculate mechanical loads acting on the Terex Telescoping Boom Chassis for the FEM, accurate strain measurements were required. Using the FEM and the Wolf Star Technologies True-Load™ software, optimal strain gages placement was identified and installed on a test chassis. Strain gage time history data for various proving ground events, such as cornering, washboard, curbs and potholes. Load Calculation and Development Using the time history data for the optimal map of strain gages, the FEM and True-Load™ software, equivalent (dynamic) unit loads were calculated. Fatigue Analysis Using dynamic stress results from the FEM, given a duty cycle that included a combination of various proving ground events, fatigue life estimates of the Terex Telescoping Boom Chassis and critical welds were calculated. Calculating the mechanical loads for this project allows Terex the ability to rapidly iterate on designs for this chassis, as well as provide a starting point for other similar chassis designs. This ultimately saves time and money in their product development cycle by reducing the efforts of traditional design-build-test cycle, by means of “virtual validation.”


If you aren’t able to attend the V&V Verification and Validation Symposium tune in to our on demand webinar: Dynamic Load Calculation and Correlation of an Aluminum Truck Body,” also presented by Cynde Murphy.

11 Apr 2017

Training for SIMULIA and CATIA

Need to deepen your knowledge of SIMULIA or CATIA to enhance your job performance? Adaptive provides the training you need to become knowledgeable and experienced with the solutions that advance your organization. Check out our upcoming training below and sign up today.

April:

Introduction to fe-safe with Verity

A 3-day course that covers setting up and running fatigue analysis using fe-safe. The third day is focused solely on using Verity for Weld Fatigue Analysis.

 

May:

CATIA V5 Fundamentals

In this course, you will learn how to build simple parts and assemblies in CATIA, and how to make simple drawings of those parts and assemblies.

You will also learn how to manage parts in the context of an assembly. This is a hands-on course where you will produce simple parts drawings and assemblies.

 

June:

CATIA ICEM Shape Design Fundamentals

This course will teach you how to use the ISD workbench to create good quality curves and Class A surfaces. You will learn how to analyze the wireframe and surface quality and interpret the results in order to correct visual defect

CATIA Composites Design Essentials

This course will teach you how to design simple composites parts using a manual approach. Then you will learn how to use a zone-based approach to complete the preliminary design and then the detailed design. The course will also focus on how the grid approach can be used for wing, fuselage or wind turbine blade design.

You will also learn how to generate plies automatically, use the analysis tools and simulate fiber behavior and how to generate exact solids and create composites drawings.

 

06 Jan 2017

What’s New in the SIMULIA 2017 Portfolio Releases?

There are plenty of new developments in the latest SIMULIA portfolio release (rolled out in November 2016).

New in Abaqus 2017:

  • Enhanced contact and constraints
  • XFEM contact improvements for Abaqus/standard
  • Advances in LCP (linear complementary problem) equation solver for Abaqus/standard
  • CZone Enhancements for Abaqus/explicit
  • Enhanced materials and elements
  • Development for welding and additive manufacturing (AM)
  • Event series
  • Usability

You can view the recording of the new release here (login required).

New in Isight 2017:

  • Updated SIMULIA Execution Engine (SEE)
    • Improved robustness and performance of TomEE
  • Component Enhancements
    • Abaqus component upgrade
    • ANSYS Workbench component upgrade
    • Excel/Word components upgrade
    • MATLAB component upgrade
    • Pointer-II performance improvements

You can view the recording highlighting all that the latest release features here (login required).

What’s New in Tosca Structure and Tosca Fluid 2017:

  • Tosca Structure 2017 enhancements:
    • Improved fe-safe integration
    • New Tosca Python driver integrates Abaqus and Tosca together and offers up to 75% faster runtime performance
    • New custom interpolation schemes
  • Tosca Fluid 2017 enhancements:
    • Tosca Fluid improved interfaces for: StarCCM+ 9.02 – 11.04Tosca Structure

Watch the full recording of the eSeminar featuring the new release here (login required).

New in fe-safe

  • Weld fatigue enhancements
  • PSD improvements
  • Enhancements for Abaqus users
  • ANSYS Workbench component
  • Enhanced NASTRAN interface
  • Vibration fatigue enhancements
  • Improved batch/macro usability.

Watch the full recording of the updates here (login required).

16 Dec 2016

Advanced Composite Design Capabilities with Laser Projection

This technical webinar demonstrates the advanced features of composite design using Laser Projection that is integrated within CATIA V5 and the 3DEXPERIENCE platform.

The design process for composites requires ply placement using hand layups that is repeatable and accurate. Further laser files need to editable and fed to the shop floor.

Kevin will demonstrate new advanced composite design functionality in both versions of CATIA V5-6R2016 and 3DEXPERIENCE including:

  • Assisted composite ply placement in both applications
  • Define target points and plies/cores/cut pieces for export
  • Generate and edit laser files
  • Review of Composites Manufacturing Preparation for those not already familiar with 3DEXPERIENCE.

About Kevin Waugh

kwaugh2016Kevin has 20 years of experience in digital product development across a variety of industry settings, from small businesses to large OEMs.  Most recently he was part of the Systems Engineering team at Sikorsky Aircraft, responsible for supporting the usage of CATIA V5 within the configured PLM and file-based production environments.  While at Sikorsky, he provided support and methodology development to the enterprise user base as well as the collaborative supply chain for multiple aircraft programs. 

His subject matter expertise includes advanced shape styling, model based definition, and composite design for manufacturing.  He is an active volunteer member of COE, the Community of Experts for Dassault Systemes, serving on the product definition and academic committees.  Additionally, he is an adjunct professor teaching Engineering Graphics to graduating seniors at the university level.

16 Dec 2016

See the Future of Pipe Stress Analysis

Watch our Webinar Replay to see the Future of Pipe Stress Analysis

Currently, there are no high-performance FEA packages capable of efficiently generating the analysis model for complex piping systems.

Born out of the frustrations of the ad hoc methods available, the engineers at RMC developed an add-on to quickly generate complex piping systems inside Abaqus/CAE, the preprocessor for Abaqus.

This powerful yet easy to use system provides:

  • Analysts the ability to develop geometry inside the same program where the advanced FEA work will be performed. Transferring geometry from another program can be time intensive and error prone.
  • Design engineers a simplified User Interface to enable them to perform more complex analysis

The Pipe Calculation System (PCS) from RMC includes:

  • Ability to generate pipe routing, bends, supports, hangers, etc.
  • 3rd party file imports from most common piping software programs
  • Post Processing templates for multiple ASME codes
  • Access to go beyond beam models that can miss some of the real world behavior
  • More accurate and efficient pipe modeling and simulation platform

 

Background:

The current framework for piping stress analysis is based on a simplified calculation method directly derived from experimental research performed over 60 years ago in the 1940s and 1950s. This framework was originally intended for hand calculations and, apart from minor changes and amendments, has been successfully employed by piping engineers since its development.

As computational power increases and finite element analysis (FEA) becomes more accessible to piping engineers, it has become clear that this framework is not well suited for complex FEA evaluation of piping systems. Advanced FEA procedures enable engineers to perform in-depth evaluation of piping systems that are extremely difficult or even impossible to evaluate through traditional methods.

Contrasting to traditional methods, a FEA simulation allow engineers to evaluate creep-fatigue interactions, advanced material models, complex loadings, complex geometries, complex support conditions, as well as the inherent evaluation of fatigue stress intensification factors.

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