{"id":217,"date":"2014-08-01T14:41:17","date_gmt":"2014-08-01T04:41:17","guid":{"rendered":"https:\/\/www.finiteelementanalysis.com.au\/?p=217"},"modified":"2014-08-01T14:41:17","modified_gmt":"2014-08-01T04:41:17","slug":"simulation-driving-the-transport-industry","status":"publish","type":"post","link":"https:\/\/www.leapaust.com.au\/blog\/fea\/simulation-driving-the-transport-industry\/","title":{"rendered":"Simulation Driving the Transport Industry"},"content":{"rendered":"<div id=\"bsf_rt_marker\"><\/div><p><strong><em>LEAP Australia recently ran a webinar demonstrating some of the processes and factors to consider when embarking on the simulation driven design process. Watch the recording below:<\/em><\/strong><\/p>\n<p><iframe class=\"wistia_embed\" src=\"\/\/fast.wistia.net\/embed\/iframe\/xryasiwp28\" name=\"wistia_embed\" width=\"640\" height=\"360\" frameborder=\"0\" scrolling=\"no\" allowfullscreen=\"allowfullscreen\"><\/iframe><script src=\"\/\/fast.wistia.net\/assets\/external\/E-v1.js\" async><\/script><\/p>\n<p>Earlier this year, Melbourne hosted the 2014 International Truck, Trailer &amp; Equipment Show (ITTES) and &#8211; amidst declining automotive, mining and manufacturing industries in Australia \u2013 the event posted a fourth consecutive attendance record.<\/p>\n<p>The transport industry, like many other Australian industries has not been spared from the global economic downturn. \u00a0However, Australia is a population scattered over an expansive continent that is reliant on the transport industry to convey and deliver the basic living essentials.\u00a0 Australia is also deeply immersed in a growing digital e-commerce lifestyle supported by efficient order-tracking systems, and a road-transport infrastructure that &#8211; until more recent times &#8211; had no real urgency to be innovative.<\/p>\n<figure id=\"attachment_212\" aria-describedby=\"caption-attachment-212\" style=\"width: 300px\" class=\"wp-caption alignleft\"><a href=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/CAD-Semi-Small.png\"><img decoding=\"async\" class=\"size-medium wp-image-212\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/CAD-Semi-Small-300x144.png\" alt=\"3D CAD Model of a semi-trailer\" width=\"300\" height=\"144\" \/><\/a><figcaption id=\"caption-attachment-212\" class=\"wp-caption-text\">3D CAD Model of a semi-trailer<\/figcaption><\/figure>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>The humble semi-trailer \u2013 responsible for the safe transport of your precious ebay items \u2013 is a typical example of a structure that has probably not evolved too much over the decades, with natural progression quickly eliminating the products that failed to meet the old \u2018built to last\u2019 adage.\u00a0 Nowadays, companies understand that \u2018built to last\u2019 generally equates to over-engineered, expensive or uncompetitive.\u00a0 The traditional semi-trailer not only has to meet durability and reliability requirements, but \u2013 in today\u2019s competitive market \u2013 weight-reduction, reduced fuel-consumption, ease-of-manufacture, ease-of-repair\/inspection, and increase in deliverable payload have rapidly become key design considerations.\u00a0 Optimising the traditional semi-trailer design to address all this criteria can be a reasonably trivial task through the use of Finite Element Analysis (FEA).<\/p>\n<p>FEA software tools \u2013 such as ANSYS \u2013 can easily interface with your existing 3D CAD geometry to quickly prepare, set-up, solve and visualise your simulation results. \u00a0An intuitive, easy-to-use graphical user interface and highly-automated workflows result in the rapid uptake by engineers and designers.<\/p>\n<figure id=\"attachment_213\" aria-describedby=\"caption-attachment-213\" style=\"width: 300px\" class=\"wp-caption alignleft\"><a href=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/FEA-Semi-Small.png\"><img fetchpriority=\"high\" decoding=\"async\" class=\"size-medium wp-image-213\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/FEA-Semi-Small-300x173.png\" alt=\"Finite element model of a semi-trailer frameFinite element model of a semi-trailer frame\" width=\"300\" height=\"173\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/FEA-Semi-Small-300x173.png 300w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/FEA-Semi-Small.png 500w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/a><figcaption id=\"caption-attachment-213\" class=\"wp-caption-text\">Finite element model of a semi-trailer frame<\/figcaption><\/figure>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>Simulation products like ANSYS are now widely used in commercial applications \u2013 alongside 3D CAD systems \u2013 as mainstream design tools.\u00a0 ANSYS Inc. continue to pioneer this technology and the ideology of Simulation Driven Product Development (SDPD) that encourages the use of FE simulation to explore concepts at the early stages of the design process.\u00a0 A validated conceptual design can significantly minimise problems downstream during the detail, prototyping, testing and production stages of the product development process.<\/p>\n<p>&nbsp;<\/p>\n<figure id=\"attachment_215\" aria-describedby=\"caption-attachment-215\" style=\"width: 300px\" class=\"wp-caption alignleft\"><a href=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/Results-Semi-Semi.png\"><img decoding=\"async\" class=\"size-medium wp-image-215\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/Results-Semi-Semi-300x151.png\" alt=\"FEA Deformation plot of a semi-trailer frame under load\" width=\"300\" height=\"151\" \/><\/a><figcaption id=\"caption-attachment-215\" class=\"wp-caption-text\">FEA Deformation plot of a semi-trailer frame under load<\/figcaption><\/figure>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>SDPD is only possible when the following key FEA requirements are satisfied:<\/p>\n<p><strong><em>Speed<\/em><\/strong><\/p>\n<p>The conceptual design process is driven by exploring as many different designs as possible to arrive at the best concept \u2013 or eliminate the worst designs \u2013 as quickly as possible.<\/p>\n<p>The FE Solver speed is critical \u2013 faster simulations mean more design iterations.\u00a0 There are a number of different solvers available, such as direct sparse, PCG, JCG, AMG, etc. that can offer computational efficiency gains depending on the application and physics involved. \u00a0Most of the time we won\u2019t have to worry about which one to use as some FEA codes will automatically select the appropriate solver to use.<\/p>\n<p>Advanced computing capabilities such as the ability to <a title=\"High Performance Computing for Simulation\" href=\"http:\/\/www.leapaust.com.au\/ansys-hpc\" target=\"_blank\" rel=\"noopener noreferrer\">distribute the solver across multiple CPUs<\/a> (Central Processing Units) can significantly improve solve times, and in some cases provide a linear increase in speed, that is, solving on 4 CPUs can reduce solve times to \u00bc when compared to solving on 1 CPU.\u00a0 The advancement of GPU technology (Graphics Processing Units), which utilise \u2018000s of cores, are now proving to be the next generation of processing technology architecture.<\/p>\n<p>&nbsp;<\/p>\n<p><strong><em>Parametric Design Optimisation Capability<\/em><\/strong><\/p>\n<p>All mainstream 3D CAD systems are based on parametric technology and workflows, as originally pioneered by PTC Pro-Engineer (Parametric Technology Corporation) and its latest successor in PTC Creo.\u00a0 <a title=\"PTC Creo Parametric\" href=\"http:\/\/www.leapaust.com.au\/creo-parametric\" target=\"_blank\" rel=\"noopener noreferrer\">Parametric technology<\/a> enables engineers and designers to incorporate design-intent into their 3D models and easily modify geometry by changing dimensions.<\/p>\n<p>Some FEA tools, such as ANSYS, are parametric and can even take advantage of the same parameters in CAD, to perform \u2018what-if\u2019 simulations.\u00a0 What if I change the thickness of my RHS section from 6mm to 4mm?\u00a0 How will that impact the stresses in my trailer frame?\u00a0 Will it sag under load?\u00a0 How much life can I expect before fatigue cracking becomes an issue?\u00a0 Parametric functionality is at the core of SDPD.<\/p>\n<p>In fact, parametric technology can actually turn design optimisation into quite a trivial task.\u00a0 The ability to tag both <em>input<\/em> design parameters (e.g. dimensions, material properties, etc.) as well as <em>output<\/em> simulation parameters (e.g. maximum stress, resultant mass, minimum bolt pre-tension, etc) creates the basis for closed-loop simulations.\u00a0 Goal-seeking functionality can be easily performed and the FEA software will automatically do all the hard work for you.\u00a0 Example:\u2013 Reduce the maximum stress in the trailer to 100MPa by varying the RHS thickness range between 2mm to 8mm, and change weld sizes accordingly \u2013 then let the software do the rest.<\/p>\n<p>&nbsp;<\/p>\n<p><strong><em>CAD Integration<\/em><\/strong><\/p>\n<p>3D CAD geometry is the foundation for most FEA simulations.\u00a0 The ability to perform geometry changes and automatically update your FEA setup for consequent design iterations is paramount.<\/p>\n<figure id=\"attachment_216\" aria-describedby=\"caption-attachment-216\" style=\"width: 300px\" class=\"wp-caption alignleft\"><a href=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/Stress-Semi-Small.png\"><img loading=\"lazy\" decoding=\"async\" class=\"size-medium wp-image-216\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/Stress-Semi-Small-300x196.png\" alt=\"FEA stress plot of a welded sub-model section highlighting high stress hot spots\" width=\"300\" height=\"196\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/Stress-Semi-Small-300x196.png 300w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2014\/08\/Stress-Semi-Small.png 500w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/a><figcaption id=\"caption-attachment-216\" class=\"wp-caption-text\">FEA stress plot of a welded sub-model section highlighting high stress hot spots<\/figcaption><\/figure>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>Automotive companies in Australia have been utilising SDPD for decades to push the boundaries of innovation and now it seems the heavy transport industry is catching up. Driven by pressure to reduce weight, increase payload and decrease time to market, trailer manufacturers are discovering the advantages of SDPD. \u00a0Cost savings derived from a reduction in materials and more efficient manufacturing processes (e.g. decreasing the number of welds) is just the beginning. \u00a0When one considers the continuing strength and inherent competition within the Australian heavy transport industry as evidenced by the strong showing at this year\u2019s ITTES, the need to bring to market the strongest, lightest and most efficient products possible becomes increasingly important.<\/p>\n<p>The transport industry in South Africa faces similar challenges to that of Australia \u2013 distances are vast and a strong mining industry demands high payloads and robust vehicles. South African company <a title=\"Alutip Success Story\" href=\"http:\/\/info.leapaust.com.au\/acton\/attachment\/9346\/f-00ae\/1\/-\/-\/-\/-\/Alutip%20Testimonial.pdf\" target=\"_blank\" rel=\"noopener noreferrer\">Alutip utilised SDPD<\/a> early in their design process, managing to shave off a quarter of the material from their original tipper design while retaining the required strength and load capacity. \u00a0This kind of innovation &#8211; achieved through SDPD &#8211; is increasingly being adopted by companies locally as a renaissance of sorts takes place in an industry that is transitioning from a mentality of \u201cif it ain\u2019t broke\u201d to a deep clear understanding of their product\u2019s performance.<\/p>\n<p>For more information on Simulation Driven Product Development, contact <a title=\"Contact LEAP Australia\" href=\"http:\/\/www.leapaust.com.au\/contact-us\" target=\"_blank\" rel=\"noopener noreferrer\">LEAP Australia<\/a>.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>LEAP Australia recently ran a webinar demonstrating some of the processes and factors to consider when embarking on the simulation driven design process. Watch the recording below: Earlier this year, Melbourne hosted the 2014 International Truck, Trailer &amp; Equipment Show (ITTES) and &#8211; amidst declining automotive, mining and manufacturing industries in Australia \u2013 the event&hellip;&nbsp;<a href=\"https:\/\/www.leapaust.com.au\/blog\/fea\/simulation-driving-the-transport-industry\/\" rel=\"bookmark\">Read More &raquo;<span class=\"screen-reader-text\">Simulation Driving the Transport Industry<\/span><\/a><\/p>\n","protected":false},"author":0,"featured_media":235,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"neve_meta_sidebar":"","neve_meta_container":"","neve_meta_enable_content_width":"","neve_meta_content_width":0,"neve_meta_title_alignment":"","neve_meta_author_avatar":"","neve_post_elements_order":"","neve_meta_disable_header":"","neve_meta_disable_footer":"","neve_meta_disable_title":"","neve_meta_reading_time":"","footnotes":""},"categories":[144],"tags":[171,201,220,269,276,286,290,309,311],"class_list":["post-217","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-fea","tag-ansys","tag-design-optimisation","tag-finite-element-analysis","tag-parametric-modelling","tag-ptc-creo","tag-semi-trailer","tag-simulation-driven-product-design","tag-trailer","tag-truck"],"_links":{"self":[{"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/posts\/217","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/types\/post"}],"replies":[{"embeddable":true,"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/comments?post=217"}],"version-history":[{"count":0,"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/posts\/217\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/media\/235"}],"wp:attachment":[{"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/media?parent=217"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/categories?post=217"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/tags?post=217"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}