More and more engineers in Australian and New Zealand companies are performing computer simulations as part of their design process. These simulations are aimed at determining how their product designs will perform in the real world. The most commonly used form of simulation for mechanical engineers is a structural and/or thermal finite element analysis (FEA). Structural FEA software is also one of the most mature technologies in the area of simulation.
What are Australian and New Zealand engineers hoping to achieve with a structural / thermal analysis and what challenges do they face when they use these tools? How can LEAP Australia help you with these problems?
In general the objective of a structural / thermal analysis is to determine if a product design will perform as intended when it experiences real life loads and temperatures and this can be done before building the first physical prototype of the design. How much will the parts of a drilling rig deflect when drilling into a coal rock face? What factor of safety do we have before the parts start to yield? How hot will certain parts and surfaces of a plastic injection mold get when the heating elements are turned on?
In some unfortunate cases these tools are also used to investigate why a product failed. For example, why did a boom on a crane collapse? In other cases these analyses are used to optimise an existing product design. How much will plastic crates deflect (or even buckle) when stacked up if they are now made from a new material? Will it be a stronger, lighter and cheaper design?
All these problems can be solved with the help of a structural or thermal analysis. LEAP Australia has helped our customers with hundreds of these types of problems over the past 15 years (including all the examples above).
Challenges, Solutions and Benefits
- CAD to Mesh
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CAD to Mesh: Challenges
Most product designs are created using a 3D CAD tool. This geometry needs to be meshed before performing FEA. This can present a number of challenges:
- Can your mesher import you 3D CAD geometry easily and cleanly?
- If your geometry changes will your mesh update automatically?
- Do you really need to use all the geometry for a simulation? What can you discard?
- Should you convert some geometry to idealisations like beam elements or shell elements?
- How fine should the mesh be?
- Will your hardware or software limit bthe number of elements you can have in your mesh?
- Contact? How do you detect and treat contacting surfaces between separate parts?
CAD to Mesh: Solutions and Benefits
LEAP Australia can help you address all these challenges. Our team of experienced engineers can provide the right advice for your CAD to mesh issues. The meshing technology from ANSYS is very powerful and robust and ANSYS has an excellent suite of solutions for interfacing with all forms of 3D CAD geometry
- Efficiency v Accuracy
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Efficiency versus Accuracy: Challenges
When performing simulations you will make some assumptions. In some cases assumptions are made to reduce the time taken to reach a solution and the assumption can impact the accuracy of the results. This trade-off is a challenging decision and will depend on a number of factors, including the following:
1.) 1.) Knowledge of the product design and the associated loads
2.) 2.) Time constraints
3.) 3.) Desired level of accuracy
4.) 4.) Experience with structural / thermal analyses
5.) 5.) Understanding of simulation software assumptions
Efficiency versus Accuracy: Solutions and Benefits
LEAP Australia has years of experience with simulation software. We have a team of approximately 40 people and many of the engineers have experience with structural and thermal analyses. Our customers understand points 1 to 3 above and we understand points 4 and 5. We partner with our customers to help them address this challenge of efficiency versus accuracy so they can get a solution as quickly as possible and at the same time have confidence in the results.
- Confidence
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Experience and Confidence and Capabilities: Challenges
Simulation software is very easy to use these days. How can you be sure the answer you get is the right answer? Confidence comes with experience. This is a challenge for companies especially when they first start to use FEA.
Confidence also comes with available capabilities. Does your software have all the features required to solve your type of analysis? Do your engineers have the skills to use these advanced features?
Experience and Confidence and Capabilities: Solutions and Benefits
As mentioned before LEAP works with the engineers at our customers to help them develop the required skill and experience. We transfer our knowledge. The tools we sell have the broadest and deepest range of capabilities. With our experience and these advanced features our customers soon develop confidence in the results from their structural and/or thermal simulations.
- Associated Products
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ANSYS Mechanical
LEAP Australia has a wealth of experience and a suite of leading edge software products to help you address these challenges and get the most benefits out of a structural and/or thermal analysis.