STEFANO ODORIZZI | Curriculum

Graduated in Civil Engineering in 1973, Stefano Odorizzi started his activity as researcher in 1976 at University of Padova, where he holds the course of Solid Mechanics.
CEO and co-founder of EnginSoft, multinational consultancy company engaged in Simulation Based Engineering Science, he actively promotes numerical simulation for research activity, with particular attention for manufacturing process, metallurgy, multi-disciplinary and multi-objective optimization.

Since 1977, he has been Project leader of a large number of EU co-funded research projects (like COMETT, CRAFT, BRITE-EURAM, MURST, EU-RTD); he is an active member of several associations (ISOPE, ASM Europe, AICAP, AIM, ATA, NAFEMS) and he plays an important role within prestigious European Networks (MACSinet, FENET, INGENET, TECHNET). His commitment in numerical simulation dissemination is witnessed by his many initiatives as General Manager of EnginSoft, in academic research and advanced training and education.

Abstract

The design and implementation of future autonomous vehicles is a complex task that touches a number of diversified topics and requires extended interdisciplinary techniques and knowledge. An autonomous vehicle needs to move in ordinary traffic and master intercultural behaviors, therefore environmental perception together with intelligent decision planning play a role of paramount importance. The training of a perception system can indeed be performed on a simulator first, and then continued on real situations on public roads open to traffic, since the vehicle is manually driven; however, when training a planning system, the quantity of simulation on a synthetic environment is larger than in the previous case and is required in order to ensure safety for all road participants during the tests. The talk will discuss the role of simulation in view of the experience of the VisLab autonomous vehicles.

ALBERTO BROGGI | Curriculum

Prof. Alberto Broggi received the Dr. Ing. degree in Electronic Engineering and the Ph.D. degree in Information Technology both from the Universita` di Parma, Italy. He became Full Professor at the Universita` di Parma and in 2009 he founded VisLab a spinoff of the Univ of Parma focused on technologies for autonomous driving. In 2015 VisLab merged with Ambarella, a silicon valley company working on HD and super HD video. Alberto is now General Manager of VisLab.

As a pioneer in the use of machine vision for automotive applications and on driverless cars, he authored more than 150 publications on international scientific journals. He served as Editor-in-Chief of the IEEE Transactions on Intelligent Transportation Systems for 5 years and served the IEEE Intelligent Transportation Systems Society as President for 2 years. He is recipient of two ERC (European Research Council) prestigious recognitions.
Alberto is an IEEE Fellow.

Abstract

Simulation becomes more and more important in today's engineering work in order to reduce product cost, accelerate entry to market and improve product quality. The talk will focus on the grand challenges in developing and using simulation capabilities from an industrial perspective, and how product simulation and physical testing need to be developed in the future.

AKIN KESKIN | Curriculum

Dr Akin Keskin is a Rolls-Royce Engineering Associate Fellow in Design Systems and Methodologies. Akin has an Aerospace Engineering degree with a focus on Turbomachinery Design from the Berlin University of Technology in Germany and PhD in Mechanical Engineering with a focus on Process Automation and Design Optimisation from the Cottbus University in Germany.

He started his professional career 15 years ago at Rolls-Royce Deutschland and is now based in Derby working for Rolls-Royce plc. Throughout his entire career he has been developing improved simulation methods and integrated design systems to help the Engineering community with better and faster tools.

Abstract

The presentation will show Grundfos journey towards fully Virtual Product Development.
A simulation strategy has been developed for the Mechanical Development area where the use of prototypes will be dramatically reduced. The overall purpose is that Grundfos want to cut development time dramatically. This implies that simulations will be used to much broader extent, competences will to be updated and the trust in simulations has to be established.

A pilot project was carried out and resulted is in a significant cost saving, a shorter development time and a much higher level of quality validation.

CHRISTIAN BRIX JACOBSEN | Curriculum

Director Mechanical Development at Grundfos Management A/S - September 2012 - Present
Visiting Professor at Jiangsu University - October 2011 - Present
I have been apointed as visiting professor at Jiansu University. China national college key displine Jiangsu University Research Center of Pumps and Pumping System Engineering and Technology.
Manager Structural and Fluid Mechanics at Grundfos Management A/S - October 2010 - September 2012
Manager for the new function: Structural and Fluid Mechanics
Head of Structural and Fluid Mechanics at Grundfos Management A/S - October 2000 - October 2010
Head of Motor Engineering at Grundfos Management - May 2007 - September 2008
Project manager at Grundfos Management A/S - May 1997 - October 2000
Development Engineer at Aalborg Industries A/S - September 1992 - August 1993

Abstract

The research focus of the Structural Mechanics and Acoustics Department at the University of Applied Sciences of Ulm is the calculation of the sound radiation of gearboxes. The focus of the presentation is the validation of the noise generation through the tooth engagement inside the gearbox. Using the multibody-simulation the model of the powertrain has been designed to calculate the dynamic bearing force at the bearings outer ring as the vibrations are travelling from the gearwheel section through the shafts and bearings to the gearbox housing causing it to vibrate. The calculation results of the multibody simulation models are appropriate. The tooth meshing frequencies and sidebands caused by the bearing rolling elements are occurring as expected and are proofing the quality of the model.
After determining the bearings outer ring as the intersection between the powertrain and the gearbox housing a bearing force measurement device was designed to validate the calculated dynamic bearing force. The measurement device enables to record the dynamic bearing force between the bearing seat and the bearings outer ring. After setting up the modified powertrain, a gearbox test bench was designed having a rotational speed range from 800 min-1 to 3500 min-1 and a maximum torque of 140 Nm. The test bench and the gearbox concept enables to investigate influences on the noise generation of helical and spur gearwheel sections and variable viscosities of the lubricant.
In conclusion, the designed gearbox test bench combined with the bearing force measurement device to measure the dynamic bearing force is a significant enhancement of the state of the art. Furthermore, the results of the calculation of the dynamic bearing force using the multibody simulation correspond with the measured dynamic bearing force.

STEFAN FALKENBERGER | Curriculum

Mr. Falkenberger started his career as a Certified Technician, in accident Medical Technology, at the Medical Technical Academy Esslingen. After that, he started in 2003 his studies at the Hochschule Ulm, focusing on Automotive Engineering and achieved his diploma in 2008. From 2008 until 2011 Mr. Falkenberger worked at Bosch Engineering as an Application Engineer. Since 2011 up to now, he is an assistant professor (an external doctoral candidate) at the Hochschule Ulm in the Laboratory for Structural Mechanics and Acoustics.
www.hs-ulm.de/falkenberger

Abstract

Metallurgy is a key enabler of a Circular Economy (CE), its digitalization the metallurgical Internet-of-Things (m-IoT). In short: Metallurgy is at the heart of a CE as metals all have strong intrinsic recycling potentials.Process metallurgy as a key enabler for a CE will help much to deliver its goals. The first principles models of process engineering help quantify the Resource Efficiency (RE) of the CE system, connecting all stakeholders via digitalization. This provides well-argued and first principles environmental information to empower tax paying consumer society, policy, legislators and environmentalists. It provides the details to detail Capital and Operational Expenditure (CAPEX & OPEX) estimates. Through this path the opportunities and limits of a CE, recycling and its technology can be estimated. The true boundaries of sustainability can be determined in addition to the techno-economic evaluation of RE.The digital integration of metallurgical reactor technology and systems, not only on one site but linking different sites globally via hardware, is the basis for describing CE systems as dynamic feedback control loops i.e. the metallurgical Internet of Things (m-IoT). It is the linkage of the global carrier metallurgical processing system infrastructure, that maximizes the recovery of all minor and technology elements in its associated refining metallurgical infrastructure. This will be illustrated through:

• System optimization models for multi-metal metallurgical processing. These map large scale m-IoT systems, which link to Computer Aided Design (CAD) tools of the Original Equipment Manufacturers (OEMs), and then establish a recycling index (RI) through the quantification of RE.
• Reactor optimization and industrial system solutions to realize the “CE (within a) Corporation - CEC”; realizing the CE of society.
• Real-time measurement of ore and scrap properties in intelligent plant structures, linked to the modelling, simulation and optimization of industrial extractive process metallurgical reactors and plants for both primary and secondary materials processing.
• Big-data analysis and process control of industrial metallurgical systems, processes and reactors by the application of among others artificial intelligence (AI) techniques and computer aided engineering (CAE).
• Minerals processing and process metallurgical theory, technology, simulation and analytical tools, which are all key enablers of the CE.
• Visualizing the results of all the tools used for estimating the RE of the CE system in a form that the consumer and general public can understand.
• The smart integration of tools and methods that quantify RE and deliver sustainable solutions, named in this paper Circular Economy Engineering (CEE).

MARKUS A. REUTER | Curriculum

Director at Helmholtz Institute Freiberg for Resource Technology (since Sept 2015).
Education: Honorary Doctorate (Dr. h.c.) University of Liège (Belgium); D.Eng. & PhD Stellenbosch University (South Africa); Dr. habil. RWTH Aachen (Germany). Industry: (i) Chief Technologist Ausmelt Australia & Director Technology Management at Outotec Finland 2006-2015 (Ausmelt acquired by Outotec 2010); (ii) Mintek (leading furnace control group) & (iii) Anglo American Corporation (ZA).
Academic: Professor at TU Delft (Netherlands) 1996-2005. Holds honorary & adjunct professorships since 2005 @ (i) Technical University Bergakademie Freiberg (Germany); (ii) Aalto University (Finland); (iii) Central South University (China), and (iv) Melbourne University (Australia).
Publications: Main author - “Metrics of Material and Metal Ecology” (Elsevier); Co-editor & author-“Handbook of Recycling” (Elsevier) (1st Publication Prize 2014 from International Solid Waste Association) & Lead author-United Nations Environmental Protection (UNEP) report (2013): “Metal Recycling: Opportunities, Limits, Infrastructure” (>400,000 downloads since May 2013), Publications in Academic Journals, Conference proceedings, Encyclopedias (see www.researchgate.net/profile/Markus_Reuter3 for details).
Recent awards: 2016 TMS EPD Distinguished Lecture Award (USA) & 2015-2016 SME Henry Krumb Lecturer (USA).

Abstract

The market globalization, the increase of the competitiveness of the emerging economies, the scarcity of natural resources, the growing cost of commodities and energy, together with a difficulty in recruiting skilled human resources, are pressing the manufacturing sector and the services industry in Italy and in Europe.

The emerging and digital technologies probably constitute the opportunity to maintain the necessary competitiveness on the market in relation to a new business model approach, a revised company investment, a reduction of the fixed costs and the risk slitting up.

MARCO TAISCH | Curriculum

Marco Taisch is Full Professor at Politecnico of Milano, where he teaches Advanced and Sustainable Manufacturing and Operations Management. Vice-rector for Placement, he was director of the MBA Executive and of the International MBA of MIP-School of Management of Politecnico of Milano. He was chairman of Working Group on Advances in Production Management Systems (APMS) of the International Federation for Information processing (IFIP), member of the International Federation for Automatic Control (IFAC), senior member of the Institute of Industrial Engineer (IIE) and other IEEE societies. He coordinates the Manufacturing Group of Politecnico of Milano, constituted by 40 people, engaged in topics afferent to design and management of manufacturing systems and operations with a specific focus on sustainability and energy efficiency in the manufacturing sector and the industrial services, product and asset life cycle management, and with a recent focus on Cyber-Physical Systems, IoT, Smart Manufacturing and Industry 4.0.

He has published four books and more than 130 works on international journals and conference proceedings. He has participated in more than 15 European research projects with important research centres (ETHZ, EPFL, TU Darmstadt, TU Braunschweig, Chalmers University) and leading companies (ABB, BMW, Bosch, Comau, FCA, Rolls-Royce, Schneider Electric, Siemens, SKF, Volkswagen, Whirlpool), with an overall financed budget of over 11 million Euros since 2009. Since 2002, he has been particularly engaged in the analysis of technological trend, setting up technological roadmaps and technology foresight on productive systems for the European Commission. In such context he is a member of the PPP board of Factory of the Future. Furthermore he is member of the Management Control committee of the National Cluster of the Intelligent Factory. He is founder and scientific chairman of the World Manufacturing Forum (www.worldmanufacturingforum.org), international event leading the definition of the manufacturing agenda.
He is president of Holonix, a spin-off of Politecnico of Milano, involved in the management of the product life cycle am om the IoT technologies for the manufacturing sector.

Abstract

The twin LIGO detectors have successfully completed the first gravitational wave search after a major upgrade. We will highlight the features of this new generation of detectors and overview the first direct detections of gravitational wave signals by the LIGO Scientific Collaboration and the Virgo Collaboration. These discoveries have started a new era in fundamental science and astrophysics, making gravitational wave astronomy a reality. Upcoming observations by LIGO-Virgo detectors will soon unveil new horizons and pave the way for unprecedented multimessenger observations of astrophysical phenomena.

GIOVANNI ANDREA PRODI | Curriculum

Giovanni Andrea Prodi is associate professor in experimental physics at the University of Trento. He is Coordinator of the Data Analysis activities of the Virgo Collaboration and co-chair of the joint Data Analysis Council with the LIGO Scientific Collaboration. His research group gave a direct contribution to the first detection of gravitational waves. Prodi is contributing to the development of gravitational wave detectors and of related data analysis methodologies since 25 years. His scientific interests include experiments on quantum noise limits to precision measurements and he is currently participating to experimental validations of the Heisenberg Uncertainty Principle against the possible deviations predicted by quantum models of gravity.

Abstract

Numerical simulations have progressively expanded their application scope, deepened the investigation capability and increased in accuracy. Simulations and Computer experiments are used in the design phase of almost any system to verify and validate as early as possible requirements under the entire range of known physical laws and conditions in special way in absence of physical prototypes. This capacity of handling the complexity is typically handled by highly trained analysts, formed through specific academic and professional curricula, by specific software applications. CAE effort typically produces highly focused deliverables which are intended to be integrated into the other documented evidences highlighted during the development and re-used during the overall system life-cycle.

Virtual and physical simulations need to underlie on standards which foster a flaw-less iterative information exchange, mutual validation and continuous improvement. The uncertainty treatment of these two conjunct approaches needs however careful evaluations for each application. One of the key success factors to extract the required amount of value for successful systems is to integrate the CAE analysts in the Systems Engineering community. Their models and virtual experiments will so be designed within the common ontology, methodologies and planning of the project team and stakeholders. This effort is driven by Model Based Systems Engineering. The communication will so get KISS. The delivered information, instead of remaining isolated engineering application gems in a flat "everything as usual" verification and validation approach, will be nestled into a successful system for the overall community.

CARLO LEADRI | Curriculum

Dott. Ing. Carlo Leardi graduated 1989 in electronic engineering in Genova Italy. His professional background starts with quality assurance responsibility evolving in the last years to full verification, validation and testing commitment within complex systems development deployment projects in the following areas: automotive, freight railways and packaging industry. As a passion before and today as a full job, he is dealing with Quantitative Systems Engineering on a day-to-day application and coaching of a full range of statistical and simulation methodologies supporting the decisional process. He published several articles in Engineering and Systems Engineering journals. He is one of the founders and past President of the INCOSE Italian Chapter and of AISE. He teaches in the Systems Engineering Masters in Tor Vergata and ForteMare in La Spezia.

Abstract

Cyber-physical Systems of Systems (CPSoS) are large physical systems with many interacting elements that are managed, controlled and monitored by distributed interconnected computer systems. These systems, from railway systems to large production sites, are vital for the welfare of the European citizens. They are characterized by distributed control, supervision and management, partial autonomy of the subsystems, dynamic reconfiguration of the overall system on different time-scales, continuous evolution of the overall system during its operation and the possibility of emerging behaviours. The CPSoS Project (www.cpsos.eu) has performed extensive consultations with industrial and academic experts and has identified three core research and innovation areas for Cyber-physical Systems of Systems: Distributed, reliable and efficient management of CPSoS, Engineering support for the design-operation continuum of CPSoS, and Cognitive CPSoS.

In the presentation, we will focus on the distributed management of CPSoS and explain the challenges in this domain for the examples of electric vehicle charging and coordination of petrochemical production sites. Distributed management methods that do not employ a centralized optimization instance will be presented: population control and market-based coordination of systems that have to balance production/consumption networks. For the validation of such management and control strategies, new flexible modular simulation and validation framework for cyber-physical systems of systems has been developed within the EU project DYMASOS (www.dymasos.eu).

SEBASTIAN ENGELL | Curriculum

Sebastian Engell obtained the Dipl.-Ing. degree in Electrical Engineering from Ruhruniversität Bochum in 1978 and a Dr.-Ing. degree and the Habilitation in control from the University of Duisburg, Germany, in 1981 and 1987.
After working for the Fraunhofer Institute IITB in Karlsruhe, Germany as a group leader in process control and production scheduling from 1986 to 1990, he joined Dortmund University in 1990 as a Full Professor for Process Dynamics and Operations in the Department of Biochemical and Chemical Engineering at TU Dortmund.
2002-2006 he was Vice-Rector for Research of TU Dortmund and in 2005 he was appointed Fellow of the International Federation of Automatic Control.
2012 he received an ERC Advanced Investigator Grant for the project MOBOCON: Model-based optimizing control - from a vision to industrial reality.
He is leading the European project DYMASOS on distributed management and optimization of physically coupled systems of systems as well as the Support Action CPSoS which defined a research agenda for cyber-physical systems of systems. He currently is the President of the European Control Association EUCA.

Abstract

Flow control is an important subject from both the scientific and the engineering points of view. In the recent literature, a growing number of research papers have been dedicated to applying the techniques of linear stability and sensitivity analysis, usually employed for the characterization of flow instabilities, to the design of flow controls. In particular, sensitivity analysis is the key ingredient for the control design and it is carried out efficiently using adjoint-based methods. The same methods are typically used in gradient-based constrained optimization problems as they allow an efficient evaluation of the gradient of a cost function when the number of optimization parameters is large. Thus, the tools needed for sensitivity analysis are often already available in existing open-source and proprietary codes even if they are mainly used for optimization.

Stability and sensitivity analysis can be rigorously applied to relatively simple flow regimes, usually observed at low values of the flow Reynolds number, and for this reason they have been developed and typically applied to problems of pure academic interest. However, in recent years an intense research activity is being aimed at extending the same tools to complex flow cases in which large-scale flow instabilities are observed. This happens in several flows of engineering interest. To cite two examples which will be discussed in some detail here, we can mention the instabilities in the turbulent wakes of bluff bodies and wind turbines. The interest for complex flows has also pushed the researchers to extend in a simple way the numerical methods related to these techniques to open-source or commercial complex codes. As stated above, similar methods have already been implemented in certain codes. In cases in which an adjoint solver is not available, techniques for using existing codes as black-boxes are also proposed, thus avoiding ad-hoc implementations.
Although the methods considered here can be applied in different fields and not only in fluid dynamics, the subject of this presentation may seem to be very specific since it focuses on particular techniques which can be applied to a sub-class of flow controls. However, this is also a paradigmatic example of how a specific know-how, which has been developed in decades of academic base research, starts to migrate to engineering applications.

SIMONE CAMARRI | Curriculum

Simone Camarri is Associate Professor in Fluid Dynamics at the University of Pisa, where he teaches Gasdynamics and Computational Fluid Dynamics. He graduated in Aerospace Engineering in 1999 and he completed his PhD in 2003 at University of Pisa with a thesis on numerical methods and mathematical models for fluid dynamics.
His main research interests are in turbulence modeling, reduced-order models for fluid dynamics, bluff-body aerodynamics, hydrodynamic stability, flow control, numerical methods and high-performance computing for fluid dynamics. He received the “young scientist award” Euromech prize in 2006 and the Junior AIMETA Award in 2009. He has led several HPC projects dedicated to massively parallel simulations, including a Prace project in 2013. He is author of several publications on leading international journals in fluid dynamics.

Abstract

The 26th of June 2016 have been inaugurated the New Canal of Panama. This 5.2 billions dollars work permits the transit of the Post-Panamax ships between Atlantic and Pacific Ocean, allowing the countries of the South Eastern America, rich of raw materials, to be fully connected to the Far-East impetuous economies. The winning consortium for the construction, GUPC (Sacyr Vallehermoso S.A., Salini Impregilo, Jan De Nul n.v., Constructora Urbana, S.A.) had entrusted to CIMOLAI SPA the fabrication, the sea and ocean transports, the overland transports, the lifting operations for site assembly, the testing and commissioning of the sixteen gates, eight on the Atlantic side and eight on the Pacific side, for an overall weight of 52000t. Due to structural quality requirements, among the others fatigue and water proof weldings, each of the 2500t to 4000t gate was completely constructed in Italy and carried in groups of four to Panama, with Heavy Transport Vessels crossing the Atlantic Ocean with nominal design waves of 7.67m. This and other challenges had engaged Cimolai design teams in front of the world in this spectacular once on one hundred year event.

Abstract

With proven expertise on the design and provisioning of highly vertical IT solutions, E4’s comprehensive range of hardware, software and services allow for significant performances increase at a fraction of the time in a number of Manufacturing workloads.

This overview will highlight the main benefits deriving from the implementation of hardware commodity running on specific codes for simulation and high performance computing. From Shared-memory computing to Storage for HPC, to more standard clusters and workstations, the outline will illustrate the codes’ best-practice when running CAE applications , as well as describe some real case scenarios.

Abstract

Industry-academia partnership is crucial for the training of postgraduate students. This is particularly true in the highly demanding sector of ceramic production, where barriers to intersectoral mobility have to be overcome for the enhancement in the quality of education for graduate students involved in doctoral programmes.

An important target in this industral field is the achievement of nearly-constant density and residual-stress fields throughout the a ceramic green body. This is necessary for producing high­quality and high-performance ceramics. The use of computational tools for virtual prototyping of molds and processes helps to accelerate development and to decrease costs. Possible design improvements are particularly advantageous for the production of large green bodies with complex geometries.
Through a novel industry/academia partnership funded by the Euroean Community, post graduate students have developed a novel constitutive models for ceramic powder compaction, which include: a new formulation for elastic behavior of the powder phase, a modelling of the compaction law, and of elastic stiffening. This new computational model has been calibrated on uniaxial compaction experiments and triaxial compression data for Martoxid KMS 96 alumina powder. Once the model has been calibrated, the parameterization has been succesfully used to predict the compaction behavior of the alumina powder in the formation of green bodies.

Acknowledgement:
The research leading to these results has received funding from the People Programme (Marie Curie Actions) of the European Union’s Seventh Framework Programme FP7/2007-2013/ under REA grant agreement n? PITN-GA-2013-606878-CERMAT2.

DAVIDE BIGONI | Curriculum

Professor Davide Bigoni is a mechanician working in material modeling (nonlinear elasticity, damage, elastoplasticity, visco- and thermo- plasticity, with applications to ceramic materials, granular media, composites, metals, and biomaterials), wave propagation in solids (with applications to metamaterials), fracture mechanics (with applications to porous media, and rock–like materials) and structural mechanics (with an emphasis on bifurcation and instability). He has been awarded an ERC advanced grant in 2013.
Currently Davide Bigoni holds a full professor position at the University of Trento (Italy), where he is leading a very active group in the field of Solid ad Structural Mechanics. He has authored or co-authored more than 100 journal papers and has published a book from Cambridge University Press. He was elected in 2009 Euromech Fellow (of the European Mechanics Society), has received in 2012 the Ceramic Technology Transfer Day Award (of the ACIMAC and ISTEC-CNR), and in 2014 he has received the Doctor Honoris Causa degree at the Ovidius University of Constanta. He is co-editor of the Journal of Mechanics of Materials and Structures, is associate Editor of Mechanics Research Communications and member of the editorial boards of: Archives of Mechanics, International Journal for Computational Methods in Engineering Science and Mechanics, Journal of Elasticity, Journal of the Mechanical Behavior of Materials, Acta Mechanica Sinica, and International Journal of Solids and Structures. He is reviewer for more than 100 international journals. He is vice chair of the panel PE8 for the European Research Council Starting Grants, panel member: for the Swiss National Science Foundation Starting Grants, for the Excellence Initiative funded by the Government of Spain, and for the Romanian National Council for Development and Innovation. He is reviewer for the Deutsche Forschungsgemeinschaft, for the EPSRC Research Grants (UK), for the Irish Research Council, for the Research Council of Norway, for the Technology Foundation STW of Netherlands, and for the Israel Science Foundation.
More details can be found at www.ing.unitn.it/~bigoni

Abstract

With the increasing concentration of large storage and HPC facilities, either in Public or Private Clouds, moving data to and from the user’s desktop is getting more and more challenging. The availability of powerful graphics cards in the (private or public) Clouds enable moving the engineers' workstation seamlessly into the Cloud realizing the Virtual Workstation. The virtual workstations together with storage and HPC enable the full support for post-/pre-processing with the full performance. In this talk we’ll discuss why more and more often, companies move interactive jobs, including analysis, design and visualization tools, near the HPC resources.

We’ll show how NICE DCV enables this remote mode of operation, moving pixels in place of large files, thanks to the GPU resources now increasingly available in different kinds of virtualized environments.

Abstract

The topic of the lecture is devoted to the ecological consequences of the rocket and space human activity at the environment of his habitation. Attention is focused on infestation of near-Earth space by debris and infection of the Earth's surface rocket fuel at emergency launches of the rockets.
As a tool for assessment and prediction of the effects these processes proposed to simulate their by the software based on the finite element method. The analysis of the dynamics of the interaction of high-speed space debris with the shell of spacecraft allows us to set the optimum combination its layers, providing crushing particle to safe fragments.

Simulation of fracture the tank with fuel for rocket-carrier allows us to determine the zones of spreading its toxic components along the earth surface. The great complexity in analysis of processes such kind requires the using of cluster computing systems.

VIKTOR I. POGORELOV | Curriculum

Education:
On leaving school with honours in 1957 entered Leningrad Institute of Mechanics, Faculty of Mechanical Engineering by specialty aircraft. Received MS with honours in 1963. In 1964-67 worked on a doctoral dissertation in Leningrad Institute of Mechanics and in 1968 received Ph.D in Fluid Mechanics. The theme was devoted to the application of numerical methods for the calculation of supersonic jets.
During graduate studies took a refresher course in mathematics for engineers at the Leningrad State University in the Mathematics and Mechanics Faculty (1963-1966). In 1998 received Doctor of Science Degree in Mechanical Engineering at the St.Petersburg State Technical University (BSTU). The subject of the doctoral dissertation was Simulation modeling of coupled problems of gas dynamics.
Experience:
1996- to present: Full Professor at Rocket Science Department in BSTU, Faculty of Rocket and Space technology.
1998-to present: part time Full Professor at Saint Petersburg National Research University of Information Technologies, Mechanics and Optics, Department Computer Design.
1994 to 1999: Head of the Department of Information and Computer Mathematics, Professor, Leningrad State Regional University (LSRU).
1968 to 1994: Junior Researcher, Lecturer, Senior Lecturer, Associate Professor.
Research area:
1. Finite Element Method.
2. Multidisciplinary Analysis.
3. Thin-walled structure.

Abstract

The RBF4AERO project is properly conceived to tackle all the aspects related to aircraft numerical design and optimization by making the CFD model parametric through an innovative shape optimization tool based on a high-performance meshless morphing technique. This technique is founded on Radial Basis Functions (RBFs) theoretical approach which offers a number of distinct advantages over the more traditional optimization approaches. This new optimization methodology will guarantee very fast and highly detailed CFD optimization analyses such to significantly reduce costs of optimization of aircraft aerodynamics without losing accuracy or domain extent. The final goal of the Project is the development of the RBF4AERO Benchmark Technology, namely a dedicated numerical platform and strategy capable to allow aeronautical design engineers to build up the novel optimization environment by using their own numerical models and computing platforms, and achieve the results of multi-objective and multi-disciplinary optimization studies in a dramatically shorter time with respect to current practices, and with no need to face with typical limiting trade-off constraints. Besides, the RBF4AERO numerical platform enables to solve other relevant aircraft design studies such as FSI and icing growth in an original fashion, and proposes a challenging CFD optimization technique that foresees the adjoint-morphing coupling.

Relevant impact is then expected in the ever-growing technological demand posed by aeronautical manufacturers in relation to the performance and reliability of aircrafts constituting components. The RBF4AERO Project is funded by the EU Seventh Framework Programme (FP7/2007-2013) under GA n° 605396.

EMILIANO COSTA | Curriculum

Dr. Emiliano Costa is the coordinator of the EU FP7 project RBF4AERO. He graduated in Mechanical Engineering (thesis title: “Aero-acoustic analysis in the automotive field”) and gained PhD in Energy and Environment Engineering (thesis title: “Advanced FSI analysis within parallel ANSYS Fluent by means of an UDF programmed explicit large displacement FEM solver”) at the University of Rome Tor Vergata.
He worked as a researcher in the HPC center CASPUR (today CINECA), as a CFD designer in the university spin-off SCIRE and as a CAE expert consultant for different private firms. Since October 2007 he has been working for D’Appolonia SpA and he is currently member of the “Industrial design & CAE” team as Senior Project Engineer. He has a considerable industrial experience in simulation driven modeling and optimization, and numerical methods design particularly in CFD and structural FEM. Moreover, he has a longstanding experience in European Commission and Italian Defense research projects participation as proposal writer, CAE-based analyses responsible as well as project coordinator.
He is active in the scientific community as author of papers and reviewer for specialized journals. The main topics which he has worked in the last years are blast, FSI (Fluid-Structure Interaction) and the application of mesh morphing techniques in simulation-based design and optimization.

Nicola Cauda, FCA Italy
Fausto Di Sciullo FCA Italy

Abstract

Compared to the past, automotive engine cooling systems are reqired to extend their capabilities, supporting fuel economy improvement and reducing vehicle ecological footprint. This task can be accomplished introducing new components or innovative subsystems design, whose purpose is tailoring engine cooling system performances according vehicle demand.

Most new parts have to be programmed to be effective, therefore thermal engineers need a quick investigation method to avoid mutual controls interference and set up appropriate specifications during early vehicle development. This paper describes a possible approach to fulfill this goal, relying on simplified 1d thermohydraulic simulation.

Andrea Bedogni – VM Motori
Francesco Franchini – EnginSoft
Marco Serafini - EnginSoft

Abstract

The purpose of this project is the study of the influence of several engine design parameters on engine performance in terms of Time to Torque, Brake Specific Fuel Consumption (BSFC), Torque and Air/Fluel ratio, for different operating conditions: full load, emissions area, transient condition. The integrated work of the two software, GT-SUITE and modeFRONTIER, allowed to manage, in an automated way, a really challenging project, both for the high number of parameters involved and for the strong conflict of optimization objectives. Exploiting the Multi-Criteria Decision Making tool available in modeFRONTIER it has been possible to choose the final engine configuration amongst all optimal solution identified by the optimization software (Pareto frontier)

Compared to baseline, the optimized engine ensures a significant improvement of performance in transient condition and, at the same time, a reduction of fuel consumption and emissions.

Brian C. Watson, Vanderplaats Research and Development, Inc.

Abstract

This paper describes the integration of topology optimization with shape, sizing and other types of optimization. Traditionally engineers use topology for preliminary design whereas sizing and shape optimization is used later on to further refine the design. So it is common to have topology as a separate type of optimization while sizing and shape is used together. In recent years more advanced types of sizing and shape such as topometry, topography and freeform have being used like topology optimization for preliminary design.

Therefore users of these types of optimizations have started to have a need of a merged topology with the rest of types of optimization. In response to this need, we have integrated topology with other types of optimization. The paper describes the use of the approximation concepts approach to efficiently solve the mixed topology, shape and sizing optimization problem. This work has already been implemented in the structural optimization program GENESIS. Several examples that show the benefits of the integration are presented. One example will demonstrate the integration of topology and shape optimization. Another example will demonstrate the integration of topology and sizing optimization. In addition, applications for the automobile industry will be shown.

Ivan Flaminio Cozza, General Motors - Global Propulsion Systems

Abstract

One of the most critical systems for a Diesel Engine is the Cooling System: the hottest components durability and the engine performance are related to the capability to reject the heat from combustion chamber. The Cooling system main component is Cooling Jacket: a fluid core dug inside the Engine Head and Block surrounding the hottest parts of the engine, preventing hot shocks.

An important process during Coolant Jacket design for automotive applications is the Gasket Tuning: it is possible to improve Coolant Jacket performances, just scaling gasket holes size. In this way, it is possible to locally increase flow velocity in order to assure the best cooling in hottest regions and to avoid boiling risk. Thanks to the small geometry modifications and the easy calculation and representation of the outputs, it is possible to perform a parametric automatic optimization: it uses gasket holes percentage of scale as parameters and permits to optimize every Coolant Jacket performance. Different commercial softwares were tested.

Mehdi Mehrgou, Mario Brunner, Achim Hepberger, Hemant Bansal - AVL List GmbH

Abstract

Gear whine and rattle are the two key-aspects of NVH in automotive gearboxes. A reliable simulative prediction requires a comprehensive workflow starting from the gear contact, further covering structure borne noise transfer and finally ending at the sound radiated from the gearbox housing. The paper aims to explain the physics behind gear rattle and whine, and the building up of physical simulation models utilizing multi-body dynamics for the structural domain as well as the wave based technique (WBT) for the air born noise domain. At the end results are presented by means of sound samples obtained via experiment as well as simulation.

Abstract

Real life production and the use of products of higher complexity – such as Autonomous driving or related processes to Industry 4.0 – put a higher interlectual pressure onto development resources. Multibody could cover historical mechanical and mechatronic requirements – Multiphysics - including taking into account programming algorithms- plus vice/versa optimization and statistics is the only strategy to support upcoming product development requirements. Parasitic effects, that cause defects in proper / unproper use, can be identified and eliminated; Effects of use and wearout can be forecasted and included into an advance maintenance strategy. Driving objective is to specify the key to Zero Defect!

Subramanian G, Mercedes Benz Research and Development India Private Limited

Abstract

Automotive trim is an aesthetic cover which conceals the structural features from view of the human vision. Since it offers negligible structural function it is essential that its weight should be as minimum as possible. However at the same time it should be stiff enough to withstand accidental blows from the user. Given a vast design variables and constraints along with the shortening product lead time there is a need for coming up with a simplified optimization procedure where in a product engineer can quickly come up with a design solution which can offer a direction towards an optimized structure.

In optimization the most time consuming activity is to build a separate design volume (solid) based on the packaging and other assembly constraints. An investigation carried out to reduce this time is presented in this paper. OptiStruct is the tool used for optimization. With the method presented in this paper, structural optimization can be carried out quickly and easily to arrive at the initial first cut concept.

Abstract

Global drivers, such as the need to save primary energy sources or to reduce green house gas emissions have resulted in many new challenges for the automotive industry, one of them being the increased demand for electrified vehicles. In order to meet these new demands and customers’ expectations, performance of electric vehicles must be enhanced and development times shortened. This paper presents an advanced simulation environment that allows to consider the influence of different driving cycles on the energy consumption of electrified drivetrains in the early development phases and thus increases efficiency, flexibility and development speed.

As framework, a co-simulation platform efficiently integrates various sub-models (vehicle, driveline, cooling system, controls) from different tool suppliers and for different analysis tasks. A detailed vehicle model for energetic analysis of the powertrain system is built; including a high-voltage battery pack, a high-performance electric machine and a control program with features of the actual VCU (= vehicle control unit).Thermal models of battery, electric machine, inverter, and cooling system estimate the power request of coolant electric pumps. This vehicle model also facilitates investigations on balancing efficiency and drivability by optimizing the e-machine size and the transmission ratio. In a further step the vehicle dynamic model and the environment are included in the co-simulation environment to enable the evaluation of electric powertrain comfort. This paper also gives an outlook on how this model can be further extended to a driving simulator with a driver interface and can be used for testing purposes of ADAS functionalities.

Abstract

The increasing focus in the use of alternative fuels for automotive application, that allows an improvement of the environmental sustainability and the strictest international standards, require high performance for the system and its components in different operating condition. In the LPG gaseous injection systems the fuel that comes from the tank is a mixture liquid-vapor and it must be completely vaporized before reach the injectors. In the installed on-board system, the evaporator-pressure regulator shall ensure the completely vaporization of the fuel and the correct pressure of injection in the different engine operating condition. The evaporator developed by Landi Renzo S.p.A., worldwide leader company in the sector, is a heat exchanger of a liquid-bi-phase mixture that uses the engine cooling water as the heat source to provide the necessary heat flux to vaporization of the LPG. In order to study and optimize the heat exchange, increasing the heat transfer to the LPG, a conjugate heat transfer analysis has been performed to simulate the different operating conditions of the component in terms of water flow, water temperature, LPG flow rate and LPG composition.

The CFD simulations have allowed realizing an optimized geometry ensuring the excellent performances even in the presence of very low environmental temperature. Finally, the CFD simulations have proved to be an excellent tool to define the characteristic curve of the evaporator performances.

Mariapia Marchi, ESTECO

Abstract

Automotive industry has significantly improved vehicles in terms of safety, fuel economy and emissions by using many networked electronic control units at the price of an increased software complexity, managed in the design phase by resorting to Model Based Development. Physical processes or mechanical systems are described with hybrid models combining discrete and continuous dynamics. The main challenge is to verify whether the model satisfies some requirements previously specified. Simulation alone, however, cannot ensure a rigorous fulfilment of all requirements.

Thus a growing interest has recently arisen in formal methods which can guarantee that. In this work we analyze the validation process of a vehicle control software using an optimization strategy capable of identifying those designs which violate the requirements expressed in terms of temporal logic formulae. The novelty of this approach consists in combining design optimization, metamodels and formal methods.

Abstract

One of important quality aspect during the design process of a vehicle is the provided occupant comfort. Comfort in a vehicle is achieved, among others, through a quiet and durable interior, and through the elimination of Squeak and Rattle noises. A huge amount of different tests take place in laboratories in order to produce interior and exterior components that eliminate the occurrence of such undesirable phenomena. As a result the need for developing numerical models that explain and predict the behavior of a vehicle in Squeak and Rattle is inevitable.

A simulation method that is used for the Squeak and Rattle numerical analysis is the E-LINE method which focuses on calculating and evaluating the relative displacement between two components in time domain. The current paper dives deep in E-LINE method and presents the BETA CAE Systems automated tools that offer a complete and efficient solution in Squeak and Rattle analysis, minimizing the simulation time and human interaction.

Angelo Tonelli, Rina Services

Abstract

Noise and vibration numerical analyses on a pleasure vessel design were carried out to analyze its dynamic behaviour and to identify the overall vibration characteristics, so that components sensitive to induced vibration forces may be identified and assessed in accordance with the high standard of acoustic comfort requested by this kind of ships. The analyzed pleasure vessel has a total length of 54.6 m and a maximum beam length of 10.2 m. All structural components are made of aluminium. Shell and beam elements were adopted to model structural parts.

Free vibration analysis allowed identifying natural frequencies and mode shapes, while forced vibration analysis were carried out to investigate the dynamic behaviour in different operating conditions and resonances of local structures with excitation forces. Results obtained, in form of structural vibration velocity versus frequency graphs, allowed identifying critical components and suggesting necessary modifications to vessel design. Finally the case study was checked by sea trial measurements to develop even more reliable predictive models.

Sthéphane Dyen, Hydros Innovation
Alaric Lukowski, Hydros Innovation (CH)

Abstract

In this work we present the complete optimization loop of an industrial yacht hull on an HPC platform coupling Caeses and OpenFOAM as performed by a scientific collaboration between CINECA and Hysdros. Hydros is an Engineering & Research Swiss company founded in 2007 with several patented designs in the field of marine and sailing yachting. In recent years Hydros is facing new market segments such as yachts and super-yachts hull design. In this perspective the usage of HPC resources and open-source softwares can be a valuable tool for massive design optimization, nevertheless the feasibility of automatic optimal hull design on HPC infrastructure is to be proved.

A complex multi-hull yacht hull has been selected to perform shape optimization coupling two state-of-the-art software: CAESES for CAD parametric design and optimization driving algorithm and OpenFOAM for 3D Navier-Stokes equation solving including dynamic mesh motion (free sink and trim). CINECA, the Italian node of the HPC European infrastructure (PRACE), provided the computational platform and the technological expertise to enrol in an automatic workflow the design procedures developed by Hydros.

Mauro Giaffreda, MICAD

Abstract

In last years the trend in marine industry is produce even large and mega yachts, up to 40 m, using composite materials, commonly fiber glass in place of aluminium or steel. Usually, the approach to the construction of a small or medium yacht can be divided into three phases: firstly, the realization of the hull included all the structures, secondly the structural bulkheads are inserted and connected to the structures and finally, the hull is closed from above placing the main deck. Over the deck, if present, are normally connected the superstructures.

Hull and main deck are two pieces that can weigh many tons and reach important dimensions. From the structural side, when parts reach big dimensions there come out several problems especially about handling and transportation. In this paper we describe the structural simulations arranged to study the behavior of a hull and its support tool during their movements. The aim is to define a better configuration.

Hasan Avsar, EnginSoft Turkey
Nasser Ghassembaglou, EnginSoft Turkey
Bulvarı, Sanayi Mahallesi, Pendik, Istanbul, Turkey
Levent Kavurmacioglu, Istanbul Technical University, İnonü
Caddesi, Gümüşsuyu, Beyoğlu, Istanbul, Turkey

Abstract

In this study, the design of exhaust system belonging to a diesel engine has been realized. During the study of the exhaust system design; 3-dimensional model of the system has been constructed and, the Computational Fluid Dynamics (CFD) analyses covered flow mechanism of back pressure. For design of silencer belonging to the exhaust system, acoustic characteristics have been determined by applying an empirical methodology.

The design of the exhaust system has been finalized regarding the design criteria of a diesel engine given by producer company and outfitting of the engine compartment in which the diesel engine was used. Besides that, producing of the silencers has been realized according to the silencer design driven from this study. The dimensions and internal structure of the silencers which are the main components of the exhaust system and physical properties of insulation material have been determined based on acoustics, back pressure and the layout of the diesel engine in engine room. From results of the back pressure analyses, it is seen that total back pressure in the whole exhaust system is within the limits of the given diesel engine. It is determined that the noise which is produced from the diesel engine exhaust can be considerably lowered as shown by acoustic analyses. Designed silencers have been produced and the whole exhaust system has been outfitted to the engine room compatibly. It has been validated the back pressure and acoustic characteristics resulted from the analyses; via the tests by measuring these values. A methodology for optimizing the acoustics and back pressure at the same time has been derived finally by using optimization platform modeFrontier.

Giovanni Esposito - Argo Tractors
Sebastian Colleoni - EnginSoft

Abstract

In the design of a new tractor model, one of the major issues to face is the cooling of the engine and of all the heat exchangers located in the underhood. Lately, tractors are being designed having larger dimensions, increasing the engine power and thus the need for greater air mass intakes. Due to the vehicle low speed, the air intake is mainly induced by a fan.

Argo Tractors, in collaboration with EnginSoft, studied the air distribution in the underhood in one of their 230 kW models by means of CFD analyses. The study was carried out investigating the cooling of the tractor in the underhood region. The CFD analyses allowed to assess the air flow rate split entering and exiting the underhood, and also allowed the evaluation of the performance of the heat exchangers. During the study, two different fans were compared and the external shell was re-designed. The choice of the more efficient fan, together with the redesign of the shell, allowed a boost in the cooling performance of the vehicle.

Pietro Bianchi, Leonardo Engineers for Integration

Abstract

Piston are a key component of high performance motorcycle engines, last decade’s requirements in gaseous emissions have pushed most of OEM to adopt exclusively four stroke engines with a potential loss in power density. The path to the recovery and eventual increase of specific performance pass through a mechanically painful increase of cycle maximum pressure and turbocharging of motorcycle engine is a matter for the present research and discussion. The contact between piston bore and gudgeon pin is a key feature in the design of a piston and the micro-geometry of the bore is often defined in a non-perfectly cylindrical fashion in order to ensure a uniform contact pressure among the two mating surfaces. Duraldur and Leonardo Engineers for Integration have developed an automatic optimization procedure capable, with the time of a working day in a normal work station, to generate a correction of the cylindrical shape, which reduces to minimum the variability of the contact pressure in that area. The results were validated by the use of the latest features of Ricardo SW program for the secondary motion and durability analysis, PISDYN, which enables the Elasto-HydroDynamic (EHD) simulation of pin-bore contact. Following such validation, Duraldur has introduced such procedure within its process of design release for new applications.

Cristiana Delprete, Politecnico di Torino - DIMAS

Abstract

The last decade’s technical evolution of high performance gasoline engines has posed, at least, two major design challenges to piston suppliers: increase of peak cylinder pressure, as a consequence of increased power density, in particular the widespread use of turbocharging, and increased thermal loading due to a soot-rich GDI combustion. Moreover, the requirement for an improvement of fuel economy for environmental reasons pushes the design to search new areas of thermodynamic optimization, aiming both at higher pressure and temperature and lower heat exchanges to the cooling systems. Such challenges have been brilliantly solved in heavy duty diesel engines by the widespread introduction of monolithic steel pistons, which can be considered the standard of the industry at this time. Such an evolution finds, however, unavoidable hustles when it comes to its application to high speed gasoline engines because of the increased mass of the piston, which would significantly reduce the maximum allowable engine speed. It is an opinion of the authors, therefore, that titanium may become a suitable material, at least for a portion of the entire market, for such engines. Even though currently limited by the cost of the base material, it can be shown that such a barrier is less significant, when analyzed against the total cost of production of such parts and the overall benefits that its adoption may lead to. This paper describes the potential market analysis for such a piston, identifying a penetration dynamic into a suitable niche and the identification of a conceptual design for such a component and its virtual validation by the use of Ricardo SW product, namely FEARCE and PISDYN. The impact on engine performance, efficiency and knock limits were also assessed by the use of WAVE, the cycle simulation product of the same suite.

Michael Ehlen, qpunkt Deutschland GmbH

Abstract

Simulation of large-scale water interacting with dynamic objects is essential in virtual reality, with wide applications in Automotive and Civil industries, etc. As it involves much physical computation, how to achieve fast and reliable simulation is still a challenge. This paper proposes a physically-based simulation framework which is developed to simulate free-surface flows as fast and accurate as possible for rapid simulation of water interacting with moving objects.

The interactions between dynamic objects and the surrounding environment were realized with a specially designed simulation grid. The paper explains new techniques to simulate a deformed tire rolling through water channel and rigid body wiper motion. It provides an accurate solution which includes the effects and interaction of water particles on the deformed profiles.

Abstract

Polimi Motorcycle Factory designed and developed a motorcycle prototype to participate to the MotoStudent Competition. This work focuses on the optimization of the chassis stiffness. The combination of the classical tubular structure with a honeycomb core and a carbon fiber cover, turns into a single resisting sandwich structure. This technology increases the mechanical stiffness without altering the global structural behavior of the frame. The result is a thinner and lighter swing arm with added mechanical strength.

The innovative design permits to get both an improvement of the performances of the vehicle, guaranteeing the necessary torsional, flexional and lateral stiffness, and the simplification of manufacturing process. Iterative procedures of structural analysis and optimization, that exploited a set of commercial CAD and FE software, such as Creo, Abaqus and ANSYS, lead to a versatile structure, whose performances stand out the other solutions available on the market, that is now ready for further developments. The advantages of the research activity can be appreciated also from the financial point of view.

Alberto Clarich, ESTECO

Abstract

Racing engines are experiencing a continuous evolution that brought them to extraordinary levels of performance and complexity. At the same time racing regulations are restricting considerably development of the engine constraining its main design parameters. As a consequence, improving performances of racing engines has become an increasingly hard task where traditional design methods have become less effective and a significant and ever-increasing contribution of CAE is required. In this paper a method to perform fluid dynamics optimization of intake valves and intake ports of the Aprilia RS-GP motorbike is presented. The purpose is to develop a procedure in which parametric geometry design, automatic mesh generation and three-dimensional CFD analysis are coupled with various optimization techniques (modeFRONTIER) in order to improve fluid dynamic efficiency of valve and port while guaranteeing their feasibility.

As a result the discharge coefficient, at maximum valve lift, of both valve and port has been improved, respectively of 1.5% and 2%. These results have been validated experimentally showing a good agreement, with measured improvements of 1.2 % and 1.6 % respectively.

Abstract

Connecting rod is one of the most important components in powertrain systems, therefore, a particular attention is required for stiffness and strength of this part. In this paper, a CAE analysis was carried out in order to evaluate the structural performance of a con rod that Piaggio & C. spa is developing for a new twin engine. The project was designed as follows:

- The multibody model was implemented in order to estimate the dynamic load condition.
- The FE model was used to estimate static and dynamic stiffness, buckling, and stress field for the fatigue analysis.
The evaluations have allowed to predict the safe design of the part.

V. Santarcangelo - BCS Div. FERRARI
C. Martin, G. Bolla - EnginSoft

Abstract

The Roll Over Protection Structure (ROPS) are key safety features in agricultural and forestry tractors in order to avoid or limit risks to the driver in case of roll over during normal use. The Organization for Economic Co-operation and Development (OECD) in an effort to improve operator’s safety in Agricultural and Forestry Tractors has set up harmonized testing procedures for ROPS systems. The current OECD Codes for tractors relate to several features of performance. In particular, Code 7 is related to the strength of protective structure in case of roll over. On the one hand, Code 7 foresees a sequence of loadings that the protection system has to withstand until the prescribed energy or force is satisfied. In addition to successfully resist the loading sequence, the ROPS has to guarantee a clearance zone during any part of the tests. By fulfilling all these conditions, the structure is classed as a roll-over protective structure in accordance with the OECD Code 7. In light of the complex testing scenarios, numerical simulations with LS-DYNA® were carried out to virtually assess the performance of a ROPS system designed by the BCS Ferrari manufacturer. As a matter of fact, ROPS simulations turned out to be very useful to understand the behavior of the protection system subjected to complex loading and get valuable insights into performance. The main goal of the simulations was to virtually test the tractor according to the Code 7 prior to official test approval and, if necessary, introduce the necessary structural changes in order to successfully pass the ROPS tests.

Abstract

Wear out and vibratory phenomena related to sliding of mating components represent one of the main failure modes of gas turbine combustion systems. Sliding configurations are often used in such kind of systems in order to avoid the over constraining of the combustor which, in turn, can cause low cycle fatigue (LCF) issues. This study aims at:

• designing a hyperstatic constrained (over-constrained) configuration of an annular combustor (therefore eliminating most sliding contacts),
• evaluating the structural response of the system under static and dynamic loads,
• optimizing the configurations on the basis of both static (LCF) and dynamic parameters (HCF),

Fundamental has been setting up the study on the basis of a virtual prototyping approach where Finite Element Analyses, properly linked to an optimization tool, allowed the selection of the most feasible hyperstatic combustor configurations.

Michele Raciti, Ansaldo Energia

Abstract

The rotor body of a turbogenerators is normally made as a single heat-treated forging with high mechanical strength and high magnetic permeability. Considering only the electromagnetic phenomena, the rotor provides the excitation field source of the machine by means of the excitation winding located into the rotor slots, thus creating the rotating magnetic field source. In addition, one or more special windings are normally inserted in the rotor body by an appropriate electrical connection of the copper wedges located at the top of each rotor slot.
The main aim of these additional rotor windings is to create a strong electromagnetic shielding of the rotor iron giving rise both to a greater machine stability and to a significant reduction of the eddy currents induced in the rotor steel under the worst conditions of faults and supplying unbalanced loads. In particular, the supplying of unbalanced loads produces negative effects in terms of hot spots induced in the rotor, phenomena that must be accurately predicted by calculations in order to avoid an excessive overheating of the rotor surface which can lead the rotor at risk of dramatic damage.
In this paper, the analytical and numerical calculation methodologies developed in Ansys Maxwell to optimize the turbogenerator damper windings design will be presented besides to an innovative way to transfer via Workbench the electromagnetic analysis results into Ansys Fluent in order to calculate the temperature reached in the rotor hot spots by means of the standard CFD analysis technique. The work here presented has been carried out in collaboration with the Enginsoft technical training team.

Leonid Korelshteyn, Piping System Research & Engineering Co (NTP Truboprovod)

Abstract

TUFFP Unified model, developed by Tulsa University Fluid Flow Project research group, is one of the most advanced modern mechanistic models for gas-liquid piping flow analysis and allows to determine flow pattern and calculate liquid holdup and pressure losses with appropriate accuracy. However to apply this model to specific flow case, an engineer needs to define a number of settings (select closure relations) which best suit specific flow parameters of the pipeline. This usually demands expert knowledge. The authors developed a methodology which allows to automate closure relations selection on the base of preliminary processing of available databases of experimental results and embed into the software correspondent knowledge of best closure relations for different regions of parameters.

The methodology was successfully implemented in Hydrosystem software and made TUFFP Unified model to be available for practical usage by non-experts.

Manolo Venturin, EnginSoft
Mariarosaria Ferrara University “La Sapienza” of Rome / ENEA Italy

Abstract

Solar-powered thermo-chemical and hybrid cycles are capable of transforming concentrated sunlight into chemical energy by a series of chemical and electrochemical reactions. The net result of such processes is water splitting, i.e. the decomposition of water into oxygen and hydrogen, which can be used as a carbon-free fuel. SOL2HY2 (Solar To Hydrogen Hybrid Cycles) is a European project focused on hydrogen production by water splitting through the so-called hybrid-sulfur process powered with solar energy. Besides investigating key materials and process solutions, the project analyzes the whole production chain and process flowsheet and connects them with multi-objective design and optimization algorithms.

The ultimate aim is to ease the commercialization of hydrogen plants based on this “green” technology. This presentation is focused on the optimization process, which also exploits metamodeling techniques. Different plant locations and production scenarios are considered, with the aim of minimizing hydrogen production costs and maximizing the share of renewables in the energy used in the process.

Marco Rottoli, Brembana & Rolle
Thomas Odry, Brembana & Rolle - Italy

Abstract

Shell&tube heat exchangers are widely used in many industries (Oil&Gas, Chemical, Power). Their robustness and affordability make them the preferred choice for several applications. Some services require the processing of large fluid flowrates. If a large flowrate is located at the shell-side, the inlet region of the exchanger could be prone to erosion and vibration due to the high velocity of the fluid entering the tube bundle. The use of an annular distributor allows for a gentle entrance of the fluid in the inlet region.

It reduces the vibration potential, lowering the velocity of the fluid approaching the tube bundle, and provides an impingement protection to the first tubes, preventing them from erosion issues. The present work describes a numerical analysis of this device. The analysis was performed using ANSYS Workbench: Using the geometry of a gas-gas heat exchanger a model was created and meshed. The solver CFX was used to run the simulation. A number of cases were analyzed, varying some geometrical parameters in order to characterize the flow in the distributor and compare different configurations.

Abstract

Zeco is an Italian SME in the renewable energy sector. It specialises in the production of different types of water turbine: Pelton, Francis, Kaplan, and others. Nowadays, the renewable energy sector is one of the most competitive and promising markets, as efficiency and pollution constraints are becoming more and more strict every year. SMEs like Zeco must develop and innovate their products to keep and to gain market share. Hence high-fidelity simulation has become an essential tool for turbine designers because it is faster and cheaper than physical experiments. The Fortissimo SuRE_HPC project has the goal to set up an HPC-cloud-based service to simulate and customize power plants, using Kaplan turbines, under different operating conditions. As physical tests are very expensive in terms of time and costs, CFD analysis can be a very powerful tool in the design process for new turbines, resulting in better designs for less effort and lower cost. For Zeco, and in general for SMEs, the main obstacle for the full exploitation of CFD tools is the required computing power, which can be considerable in a optimization process, and which requires the use of HPC. Hence, CINECA, a supercomputer centre, is involved as the HPC cloud infrastructure provider, while EnginSoft, the domain expert, provides technical know-how and support for the development of the virtual tool, together with the CFD software license.

Abstract

The methods of analysis of real gas and two phase gas-liquid flow in safety valve and discharge piping of pressure relieve systems with possible multiple choking are discussed. The role of 2 independent isentropic exponents which define fluid thermodynamic behavior is shown. General differential equations (matrix of influences) for real gas and two phase flow in the pipe for general thermodynamic conditions (including heat exchange with environment) are formulated. The equations are regular and can be effectively solved numerically using standard methods. For special cases of vapor-liquid flow of one-component fluid, and for non-flashing gas-liquid flow exact and appropriate equations for two phase mixture isentropic exponents are proposed, which take into account real properties of vapor/gas and compressibility of liquid. New simplified equations for valve sizing and piping analysis are proposed for a number of important cases.

Agate G., Ricerca sul Sistema Energetico - RSE
Guandalini R., Moia F., Ricerca sul Sistema Energetico - RSE

Abstract

A software suite, called GeoSIAM (Integrated System for GeoModelling Analyses), has been developed in order to realize numerical simulations of all the energy production aspects involving geological reservoirs, such as CO2 and gas storage, oil&gas production, geothermal field exploitation and compressed air energy storage, mainly with the goal of verifying the feasibility and safety of the processes.

In order to point out the main methodology aspects, a demo study referred to a gas field located in Lombardia (Italy) is shown, which analysis includes the creation of the 3D static geological model and the related 3D fluid dynamic model, the search of the equilibrium steady state of the geological reservoir corresponding to the discovery condition and finally the transient simulation of a typical natural gas production and storage scenario, with the goal of verifying the sustainability of the whole process from the safety point of view. The results prove that GeoSIAM allows to perform geological reservoir characterizations with an high level of accuracy and reliability.

Håvar Sørtveit, WellPartner AS

Abstract

WellPartner, a supplier of products and services for the international Oil and Gas market, uses numerical modelling as part of the technology qualification process for their WellSafe Explorer product. WellSafe Explorer, a passive heave compensator, provides a near instantaneous emergency back-up for the main and active heave compensator of a floating unit. This way WellSafe Explorer protects the riser and other assets of the operator, and provide an additional safe guard against severe consequences including fatalities and environmental spills. A proper selection and system design for the release valve defines one of the main challenge of the WellSafe Explorer. Previously a series of testing on the valve itself confirmed that the valve behaved satisfactory. However, the qualification process demanded the valve performance to be confirmed in a full scale release test of the WellSafe Explorer. In July 2016 WellPartner performed these tests. The use of Flowmaster, and its mechanical-fluid dynamics, models was instrumental during planning but also for post-processing of results and subsequent technology qualification. This CAE contribution focuses on the benefits of combining physical testing and numerical modelling, and the role of CAE in technology qualification processes. Results both from tests and numerical modeling, and the comparison between the two, will be presented.

Sergio Bondi, Nuovo Pignone Tecnologie
Luca Fioravanti, Simone Amidei, Giovanni Gennari, Nuovo Pignone Tecnologie
John V. Panikulam, S.A.T.E. Systems and Advanced Technologies Engineering

Abstract

ORegen™ is an Organic Rankine Cycle (ORC) based thermodynamic superheat cycle that recovers waste heat from gas turbine exhaust and converts it into electric energy. Heat from the turbine exhaust is transferred to a closed diathermic oil loop, which is used to heat an organic fluid loop. This lower temperature heat is converted into useful work and electricity, like in a conventional steam bottoming cycle. The diathermic oil and the organic fluid allow low temperature heat sources to be exploited efficiently to produce electricity over a power range from a few MW up to 16 MW per unit.

The ORegen simulator is a large scale model, based on COMPSYS-MCwI™ application for SIMULINK®, useful to analyse transients plant dynamics, such as in start-up and shut down. It describes several interacting phenomena and subsystems with about 2000 states. It implements two phase fluid thermodynamics, with working fluid near the critical point mixed with inert gas, entering the circuit through rotary gas barrier seals and during depressurized shut downs. Valves and turbomachinery performances are modelled by gas thermo-fluid dynamics components, based on performance curve and maps.

M. Bolla, SIMIC
M. Spagnolo, G. Falcitelli, EnginSoft

Abstract

The magnet system of ITER consists of 48 superconducting coils of different sizes, shapes and performance and is subdivided into 4 sub-systems, i.e. the Toroidal Field Coil system, the Poloidal Field Coil system, a Central Solenoid and the Correction Coil System. The Toroidal Field Coil system consists of eighteen "D"-shaped toroidal field magnets placed around the vacuum vessel in order to produce a magnetic field whose primary function is to confine the plasma particles. The toroidal field coils are designed to produce a total magnetic energy of 41 gigajoules and a maximum magnetic field of 11.8 tesla; weighing 310 tonnes each, and measuring 9 x 17 m, they are among the largest components of the ITER machine. Toroidal field coils are wound in "double pancakes"—layers of spiralled conductor embedded in radial plates and encased in large stainless steel structures (https://www.iter.org/mach/magnets). With such numbers, the "superstructure" of toroidal field coils pushes the limits of manufacturability; SIMIC, by means of state-of-the-art welding techniques, accepted the challenge to manufacture 10 of the 18 TF coils as well as to design and to manufacture all the special tools necessary for performing the job. FEA calculations were mandatory; a procedure for the welding simulation of TFC cases was set up and validated on the basis of welding trials on portions of the system (mock-up); the results of welding simulations on the whole TFC FE model are currently available.

Abstract

Vestas Wind Systems A/S, the world’s largest producer and manufacturer of wind turbines, used Excel to run tolerance analyses combined with some trial and error on the prototypes for a new design. During one final test before shipping the first unit to the field they realized that the spinner at the center of the blades was colliding with the fixed nacelle. The required gap in the design wasn’t there in the actual assembly.

What would they do? What would be most effective in terms of cost and time? Would they change the design - an engineering change could cost 5000€ for just the paperwork? Before understanding the cause of the problem one consideration was making adjustments at the time of final assembly in the field. Before changing anything, though, they used CETOL integrated within PTC® Creo® to understand the true cause of the problem and explore better alternatives for resolution. Attendees will learn how Vestas explored both manufacturing and design alternatives to enable them to solve their hub and nacelle issue. They will learn how to apply the same methodology in their design process by incorporating tolerance analysis tools, such as CETOL 6σ.

Ivan Di Piazza, ENEA FSN-ING, C.R. Brasimone
Vincent Moreau (CRS4, Environment and Imaging Science), Italy
Federico Piscaglia, Andrea Montorfano (POLITECNICO DI MILANO - Dipartimento di Energia), Italy
Walter Borreani (University of Genova, DIME-Thermal Division), Italy
Ranieri Marinari (University of Pisa-DICI), Italy

Abstract

In the context of GEN-IV heavy liquid metal-cooled reactors safety studies, the flow in the Fuel Assembly (FA) is critical for ensuring the proper removal of the fission heat; the blockage of a sub-channel of the FA is considered one of the most important and realistic accident condition. The temperature of the coolant leaving the FA is an important indicator of the health of the FA (i.e. the effective heat removal) and is usually monitored via a dedicated, safety-related system (e.g. thermocouple). The blockage of a sub-channel in the FA impairs the correct cooling of the fuel pins, may be the root cause of anomalous heating of the cladding and of the wrapper and potentially impact other fuel pins not directly located in the proximity of the blocked area. This paper presents the results for the flow field as predicted by different turbulence models (LES, DES, RANS-based) using commercial codes (ANSYS Fluent, ANSYS CFX, CD-adapco STAR-CCM+) as well as open source code (OpenFOAM).

In 2017 the new facility Blocked Fuel Pin bundle Simulator (BFPS) will be installed within the NACIE-UP (NAtural CIrculation Experiment-UPgrade) facility located at the ENEA Brasimone Research Center (Italy) to perform an experimental campaign whose results will provide the validation of the numerical investigations.

Marco Evangelos Biancolini, University of Tor Vergata
Andrea Chiappa, University of Rome Tor Vergata, Italy
Francois Nunio, CEA (Commissariat à l'énergie atomique et aux énergies) Saclay, France

Abstract

DEMOnstration fusion reactor (DEMO) represents the second step in the EU fusion roadmap that has the objective to demonstrate the feasibility, from an economic point of view, to produce electric power using fusion reaction. The structural analyses of such a large machine represent a crucial issue for the design assessment. In fact a full detailed 3D model would require a huge mesh. In this work a novel procedure is presented, based on Radial Basis Functions interpolation, that allows to recover the stress state in a generic 3D section with low computational effort and significant time saving. This tool uses a mixed approach that allows to adjust the boundary shape and applies the magnetic loads to the local 3D model. To prove the Stress Recovery Tool (SRT) validity the results, obtained in a portion of the whole structure, have been compared to those of a high fidelity model. Once validated the SRT has been applied to a 2015 reference geometry.

Erik Mazzoleni, EnginSoft

Abstract

This paper describes the results of the installation in two industrial facilities of the innovative SnamprogettiTM SuperCups technology. The design of the SuperCups was supported by a comprehensive CFD performance assessment carried out by Saipem and EnginSoft, that allowed to study the physical phenomena taking place into the reactor, in order to select the best SuperCups configuration and to confidently move to the test phase on field.

The improvements in mixing performances and residence time predicted by the CFD simulations were confirmed by the field data in terms of increased performance of the reactor. The collaboration between Saipem and EnginSoft for the development of the SuperCups has been a continuous process of theoretical studies, CFD simulations and field testing that started in 2011 and culminated in 2014 with the first industrial application.

Alberto Deponti, EnginSoft

Abstract

The physical modeling of uranium isotopes (235U, 238U) separation process by centrifugation is a key aspect for predicting the nuclear fuel enrichment plant performances under surveillance by the International Nuclear Safeguards Authorities. Enriched uranium may be diverted and used for building nuclear weapons. Rigorous safeguard activities are needed to avoid any possible misuse of the enrichment plants and the consequence thread of nuclear weapon proliferation. In this framework numerical models can support the activities of inspectors and help in the detection of possible misuses. The first step is to have a fast, reliable and validated model capable to simulate gas centrifuge plants. The proposed 1D CFD numerical model of a centrifuges enrichment cascade was implemented using the Flowmaster tool and validated with literature data. Different enriched U diversion scenarios were simulated and analyzed and the results are presented. The first results demonstrate the capability of the code to reproduce the enrichment plant operation in Normal and Off-Normal condition putting the ground for regular use of the simulation tool in the frame of Nuclear Safeguards activities.

Philipp Good, ETH Zurich
Andrea Pedretti, Airlight Energy Manufacturing, Switzerland

Abstract

The CSP parabolic collectors developed by the Swiss company Airlight Energy SA exploit air as HTF with operating temperatures up to 600°C. In a CSP plant adopting this kind of technology, the piping network optimization is pivotal to minimize plant infrastructure and operation costs. The plant piping model, including collectors, straight pipes insulated with radiation shields and junctions, was developed in Simscape adopting a custom physical domain. The CSP plant model was exploited to simulate several operating conditions taking into account the yearly solar power variation, which depends on the site geographical coordinates. The model includes a single tank thermal energy storage based on the rocks packed bed technology, designed to daily store part of the sun energy, so to ensure a constant feeding for the bottom steam power cycle also during the night. ModeFrontier, coupled with the Simscape model, was used to establish the most promising piping layout in the domain of interest (which includes pipes diameter, solid insulation thickness and thermal shields arrangement) investigating different optimization functions and criteria.

Abstract

In order to assure a diagnostics services for reciprocating compressors experimental measurements of pressure are necessary. The comparison between the pressure cycle indicated and the cycle of theoretical pressure is currently used to check the conditions of reciprocating compressors and prevent failures or design errors. The indicated pressures of transducers mounted in the passage cylinder and along the tubes can estimate losses, check for the movements of the valves and depend on the number of revolutions, from the cooling system, the size of the ducts, valves and the wear of the compressor. Theoretical cycle can be determined by knowing the geometric dimensions of the compressor elements, the suction and delivery pressures, the pumped gas, the clearance volumes, polytrophic index of compression and expansion.

Theoretic cycles are more realistic when calculated by means of experimental measurements. Simulation programs are also able to estimate the pressures in the ducts and in the cylinders of a reciprocating compressor.

Giuseppina Montante, CHIMIND - University of Bologna
Alessandro Paglianti, DICAM - University of Bologna

Abstract

Several industrial equipment, such as stirred tanks, fluidized beds, slurry bubble columns, are adopted for tackling multiphase systems at high dispersed phase loadings and turbulent flow regime, either for physical operations and for (bio-)chemical reactions. The development of experimental and modelling methods for their characterization has experienced significant advancements so far, but several aspects of the complex interactions governing the liquid-particle and the particle-particle interactions still require extensive investigation. In this work, a solid-liquid stirred tank equipped a Pitched Blade Turbine is investigated by Electrical Resistance Tomography (ERT) and Computational Fluid Dynamics (CFD) The analysis concerns dense solid suspensions, that are of interest for several chemical and biochemical processes. The main goal of the contribution is to present a benchmark for RANS-based CFD simulations based on the Eulerian treatment for each phase and suitable multiphase turbulence models, whose scant validation out of dilute conditions is often due to limited experimental information on the local dispersion features.

Nicola Aldi, Fluid-A
Carlo Buratto, Fluid-A
Alessandro Carandina, Fluid-A
Nicola Casari, Fluid-A

Abstract

In this work a reverse engineering (RE) procedure and a comparative CFD analysis using different software are presented. The three-dimensional flow in the semi-open impeller and volute of a centrifugal pump has been numerically simulated. This kind of impeller is less likely to clog with solid bodies (this is an important aspect in the case of slurry-processing) and for this reason is suitable for food, chemical and Oil&Gas industries. It is well known that the performance of a centrifugal pump drops when handling viscous fluids. Even so the pump behavior during the pumping of non-Newtonian fluids has not been investigated so far.

The RE procedure has been applied to a commercially available pump and the solid models of the impeller and volute have been reconstructed by means of a laser scanner. The simulations have been carried out using both open-source and proprietary software (OpenFOAM® and STAR-CCM+®). The performance of the machine handling both Newtonian and non-Newtonian fluids have been investigated. The slurries which are usually processed show a behavior which can be modeled according to a power law. Internal flow field, pressure distribution and pump performance have been obtained for both Newtonian and non-Newtonian fluids. Particular attention has been put on the apparent viscosity that drives the non-Newtonian model.

Manolo Venturin, EnginSoft

Abstract

Extracting and recognizing objects in satellite images is an important tool that enables exploitation of geographical data. Example of information that can be provided by these systems are land use, plant species, presence of water, safety, etc.

In this talk an efficient classification image system is presented and the possibilities that it provides are described. The developed method is based on a supervised data mining system (properly trained) with an automatic system of image features extraction. The images classification process consists in the extraction of classes of information from a raster image composed of several bands . The resulting raster can be used to create thematic maps.

Abstract

The present paper concerns the coupling between a commercial software package and the in-house tool GUNWave3D to determine the stress levels in the structures loaded by the blast wave emitted in ambient at the fire of a cannon-type weapon system. In fact, during combat systems firing the structures adjacent to a gun are typically subjected to the blast load due to the impingement and propagation of the shock waves expanding from the weapon muzzle. The first stage of the coupled approach foresees that the gun blast data are calculated by means of GUNWave3D. That tool is an empirical-analytical model based on scaling relationships that provides a fast and reasonable estimate of the main gun blast parameters upon structures in function of weapon characteristics and launch conditions taking also into account the asymmetric shape characterizing the gun blast wave. Successively, the calculated blast data are processed and passed to the LS-DYNA® software as input load in order to finally compute the structural response of the components of interest.

The application of the coupled approach is showcased through the development of a test case concerning a 30-mm gun whose muzzle blast quantities have been already validated in a previous published work. The proposed approach can thus be effectively employed in the design, optimization and retrofit of surface warship, aircraft and ground combat systems

Abstract

Physical tests are performed at various stages of the development cycle of a product — from prototype validation to product qualification. Although costly, there are growing demands for qualification tests like endurance vibration testing to be more representative of the real world. At the same time there are growing demands to assess the durability of these items based on FEA simulation. In this presentation we will explain how to set up a CAE-based test and how to correlate the results with some physical measurements. Specific assumptions will be explained and some advantages of using virtual tests will be highlighted:

• Reduce the number of prototypes needed
• Investigate why a physical test fails and propose an optimal solution
• Perform sensitivity analysis
• Find out what the margins are at the end of a successful test

This presentation will therefore focus on explaining and showing how virtual tests can enrich the exploitation of physical tests.

Abstract

Electromagnetic environments such as those produced by lightning can cause failures on aircraft safe operation and even catastrophic effects if precautions are not taken. The risk is elevated for modern aircraft having an increased number of flight control, communication and guidance systems, and incorporating structures made of carbon-fiber composite (CFC).

Aircraft certification by testing with respect to different electromagnetic environments is both costly and time consuming. Today, electromagnetic (EM) field simulation offers the possibility to predict vulnerabilities to electromagnetic environments early in the design process and reduce the number of tests required for certification. Simulation may be used to assess the impact of changing a component at a later time in the product life cycle. As such EM simulation is ideally suited to complement testing. In this talk the application of CST STUDIO SUITE® to simulate aircraft exposed to various electromagnetic environments will be presented. We will discuss the use of CST EM STUDIO® for lightning attachment zoning characterization and CST CABLE STUDIO® for indirect lightning effect analysis including coupling into cable harnesses systems.

Abstract

Real life production and the use of products of higher complexity – such as Autonomous driving or related processes to Industry 4.0 – put a higher interlectual pressure onto development resources. Multibody could cover historical mechanical and mechatronic requirements – Multiphysics - including taking into account programming algorithms- plus vice/versa optimization and statistics is the only strategy to support upcoming product development requirements. Parasitic effects, that cause defects in proper / unproper use, can be identified and eliminated; Effects of use and wearout can be forecasted and included into an advance maintenance strategy. Driving objective is to specify the key to Zero Defect!

Abstract

The plant of Avio Aero in Brindisi carries out activities of MRO on aircraft engines. In this context, it is necessary to use an efficient system of identification and tracking, within the same plant, of the parts constituting the engine under revision and the equipment in use. A methodology, under investigation, takes into account the use of a “smart tag” of identification based on RFID or similar technologies, enabling a multiple reading and an automated identification of the parties with respect to the access gaps or portable players. The activity described in this work is focused on the numerical study of the electromagnetic interaction between RFID systems placed on parts to be tracked and the antennas mounted on the access gates. The study has been carried out is through FEM numerical analysis by means of the ANSYS HFSS software. The whole system has been designed, including the footboards, parts to be traced and the multi-antenna system installed on the gate. The objective of the analysis is the study of the electric field distribution on the planes of the footboards, in the real operating conditions of the reading system, as effect of the radio frequency propagation mechanism, introduced by the presence of the parts to be traced. The results of the activity, expressed as contour plots of the electric field distributions, as a function of the its phase, have allowed to identify the shadow zones in which it could be difficult to read the tags associated with the parts to be traced. The whole activity has therefore allowed to carry out a preliminary assessment of the performance of the RFID technology with respect to this application.

Gabriele Bombaci, Aviospace

Abstract

Active removal of large space debris, such as the upper stages of elderly launch vehicles or the decommissioned satellites, constitutes a technological challenge which is so far well-known and recognized by all the main players of space business, both at institutional and at industrial level, as a required step to achieve significant progress towards a safer and cleaner space environment. To accomplish such objective, a non-collaborative rendez-vous and capture procedure, to be performed by a robotic spacecraft (namely “chaser”), is required.

The present activity is focus on a belts-based capture mechanism develop in the frame of CADET program. Dyna supports all phases of design, at the beginning for the flight systems and than for the ground system. In fact the activity ended with the construction of a laboratory where a scaled ground demonstrator was used to validate the performance of the capture mechanism and Dyna models. In particular LS-DYNA has been adopted in the following areas: study of the maneuvers of proximity between chaser (active spacecraft) and target (non-cooperative object), mechanical interaction between the two objects (exchange of forces, energy, accelerations, contact pressure), the development and optimization of mechanisms to perform the capture, assessment and verification of the dynamic behaviour during the deployment of extensible parts (arms, solar panels, deployable structures), design test environment on the ground, prediction and correlation of test data.

Elena Campagnoli, Politecnico di Torino

Abstract

In order to correctly simulate the fluid and thermal behavior of different aircraft components, the choice of the suitable numerical tools alone isn’t sufficient and so it must be combined with a good tuning procedure that, starting from the available experimental data, allows obtaining high accuracy numerical models.

In the past the authors, to accomplish the tuning, have identified a procedure that has been applied, with fairly good results, to the numerical model representing the Test Article of an experimental rig built to simulate, properly scaled, one stage of a LPT (Low Pressure Turbine). The aim of the present work is to definitely validate the pointed up procedure verifying, at the same time, how its use can be extended to others engine components. For this reason the tuning procedure has been applied to a different engine element, a rotating blade, having in common with the previous one only the need to be cooled during the operation, but with completely different geometrical features and, in addition, numerically simulated by using others software.

L. Bucchieri, E. Mazzoleni | EnginSoft
M. Bamsey , D. Schubert, V. Vrakking, P. Zabel, C. Zeidler | German Aerospace Center (DLR)
G. Bonzano | AeroSekur

Abstract

The development of plant cultivation technologies for safe food production in space is a research field which intends to increase the possibilities of human future long-term space missions.

Abstract

The MU90 torpedo is a high performance underwater vehicle whose structure is mainly dimensioned on buckling stresses. Its success as well as its high acquisition cost makes customers require a prolongation of the operational life up to more than 40 years. The life prolongation is subjected to the assessment of the residual performances of the aged torpedoes. Normal life affects the torpedo structure creating defects (scratches, abrasions, corrosions, …) that appear to be on all torpedoes in the same areas. These defects can reduce the structure performance. The assessment of the residual capability of the torpedo structure has been achieved applying a methodology based on the verification and measurement of the effects of normal life on the torpedo shell, creation and validation of a FEM detailed ideal torpedo model, application of shell defects on the FEM model and measurement of the residual margin on structure performances.

Gabriele Bombaci, Aviospace

Abstract

The present activity is focused on a safety assessment performed on CubeSat satellites, in the frame of an ESA-funded study. The simulation of blast waves is maintaining and maybe increasing its role in fluid dynamics, due to the many important applications primarily in the aerospace, defense and the oil&gas sectors. A Multi-Material Arbitrary Lagrange Eulerian (MM-ALE) solver is generally used, together with FSI (Fluid-Structure Interaction) algorithms. The structures are modeled as Lagrangian, and FSI is used for coupling with the MMALE domains. This computational approach is able to predict accurately the relevant aspects of the blast-structure interaction problem, including the blast wave propagation in the medium for pressurized loading cases and the response of the structure to loads induced by the blast.

Here, this methodology is applied to evaluate the effects of the thermal runaway phenomena originating inside a battery, to be subjected to external vacuum (zero pressure). The study is finalized mainly to verify the interaction between the blast of battery and the structure of cubesat, and assess the derived space debris production. A finite element model of the ignition is built to simulate wave and pressure development, battery structural failure and solid / fluid parts ejection from the assembly. The goal is to evaluate permanent deformations and / or the fracturing pattern of the assembly and each part. LS-Dyna is the software used to model the phenomenon. The approach can be applied fruitfully to assess the accomplishment of the structural design of the device, which can be subjected to dangerous environment conditions leading to an explosive thermal runaway, so that a suitable containing structure can be easily integrated, if necessary.

Marco Evangelos Biancolini, University of Tor Vergata
Ubaldo Cella, University of Tor Vergata
Francesco Giorgetti, University of Tor Vergata
Corrado Groth, University of Tor Vergata

Abstract

A common issue of loose coupling of multi-physics simulations arises from the necessity to analyse the same structure relying on different meshes, each one suited for a different field of physics. Output data from a simulation must be transferred as input to another model to run a new analysis. It is strongly desirable for such information transfer to be conservative in terms of load balance.

A novel method for pressure mapping between dissimilar meshes is presented. Transfer procedure consists of two steps: pressure interpolation by means of Radial Basis Functions and Fuzzy Subsets correction. The first is a pointwise interpolation using a series of basis functions. The second phase applies to the outcome of the first one to restore balance between the two models by introducing a smooth correction field. Practical test cases from the aeronautical field are presented to validate the proposed method.

Annalisa Cassinelli, CETMA - Engineering, Design & Materials Technologies Centre
Danilo Bardaro, D’Appolonia
Antonio Caruso, Leonardo Helicopters

Abstract

This paper describes a numerical tool for the prediction of draping process with the aim to increase the production and quality of composite parts. The drapabilty of a dry textile fabric into a mould is analyzed and predicted by explicit simulation. The developed tool provides a considerable simplification of the pre-processing, in particular, the f.e. model of the fabric is generated automatically. Starting from the contour line of the fabric (i.e. fabric.dxf) the customized Matlab subroutine allows to obtain the preliminary discretized f.e. model (i.e. fabric.k). The creation of the final input file is obtained with a second customized script in Hypermesh. The materials properties and meshing of the mould are assigned by the script on the basis of a pre-defined database; only the positioning of parts is decided manually.

The f.e. input file is ready for the simulations of draping process with LS-DYNA. Finally, the results can be analyzed easily by means of the developed tool that allows to plot the drapabilty response on fabric. An analytical model is proposed for relating the fabric parameter (E, ε, τ) to the locking angle in order to predict the arise of wrinkling.

Abstract

One of the main challenges of modern aircraft’s design deals with their increasing complexity. Aircraft manufacturers are striving to find means to accurately assess the interactions among systems and sub-systems since the beginning of their design, with the goal to produce better integrated products and reduce their time-to-market. To support these needs, methodologies and processes based on Model Based System Engineering, Modeling and Simulations, Verification and Validation procedure are more and more used. The virtual integration of aircraft systems is the outcome of the modeling process, starting with the creation of models and their assembly. As such, it depends on how this process is managed in the context of the extended enterprise. In order to answer to these needs a set of methodologies called Virtual Integrated Aircraft (VIA) is proposed and described in this paper. As a result of VIA methodologies, the modeling process is harmonized, and the know-how is capitalized.

Ulrich Heck, DHCAE Tools
Tamas Kiss, University of Westminster, England
Gabor Terstyanszky, University of Westminster, England
Nicola Fantini, CloudBroker GmbH, Switzerland
Andreas Oldenburg, CloudSME UG, Germany

Abstract

The employment of CAE processes for the development and optimisation of high quality products has become widespread. Depending on the optimisation strategy, a large number of simulations must be performed to cover wide parameter ranges. For SMEs, it is often unfeasible to provide the required capacities for complex flow simulations. A solution would be the usage of open source technology in a HPC cloud.

The aim of CloudSME project ( www.cloudsme.eu ), funded by EU Commission, is the creation of HPC-based approaches to the rapid and effective deployment of CAE software in the cloud (HPC-as-a-service) in order to enable in particular SMEs companies to make use of both at affordable conditions (pay-on-demand basis). In order to achieve this goal, 29 project partners have been working on the implementation of different use cases (MSaaS). The software developer DHCAE Tools provides access from within their modelling environment CastNet to open-source solver technology (OpenFOAM for CFD, CalculiX of structural analysis) in the cloudSME HPC environment, which has been used for the simulation and the technical design of model helicopter rotors and their blades.

Andrea Rapisarda, Politecnico di Torino
Elena Campagnoli, Politecnico di Torino, Italy

Abstract

The present work focuses on non-rotating honeycomb labyrinth seals, devices utilized to improve the efficiency by reducing the leakage flow, in modern Low Pressure Turbines (LPT) on aircraft engines. This research provides an effective comparison among different designs, pointing out how the most influencing geometrical parameters affect the labyrinth seal leakage flow behavior.

The first step consists in the validation of a numerical model, based on the literature data, by using the CFD approach. Then, a geometrical sensitivity is carried out, where the effects of combined variations of the seal clearance, the fin tip thickness and the honeycomb cell diameter are evaluated. The CFD analysis provides the detailed flow pattern and leakage flow information. These results are utilized to develop a 1D analytical model, allowing the prediction of the labyrinth seal leakage behavior simply referring on the geometrical data and consequently reducing the computational time and costs.

Abstract

The structure has two storeys above ground. The ground floor, entirely reinforced concrete, is de facto a rigid base support to the first floor, entirely structural steelwork, which features a cantilever whose size is significant compared to the volume of the whole building.

The building’s roof, also a steel structure, acts as a rigid diaphragm and is pitched to allow drainage of rainwater to the sides of the building. From a seismic point of view, taking into account the low seismicity of the site, the structure is designed to remain elastic, so that its horizontal deformations are so small as to fit with the rigidity of the stone cladding.

Abstract

The Khalifa International Stadium is one of the symbolic buildings of Doha and is part of the biggest sports complex in Qatar: the Aspire Zone. The stadium has been chosen as one of the stadiums for the World Football Championship 2022.

The stadium will host games during the qualification phase, quarter and semi final. Built in 1976, Khalifa Stadium was renovated during 2006 for the Asian Games and in order to host the World Football Championship a further renovation will be performed by the end of 2016. The Capacity of the stadium will be doubled from 20.000 to 40.000 seats ant the roof will be modified to cover all the bleachers with two big arches spanning over 400 meters, supporting the cable net and fabric cover. During the presentation the most important items of the design of the roof structure will be highlighted: innovative engineering approach was required to solve extraordinary challenges for the renovation of the existing structure as well as the integrated dependency of steel, cables and fabric elements.

Abstract

During the 19th Century the town of Rimini acquired an international reputation for the seaside, and a new theatre which was designed by Luigi Poletti succeeded in translating into Neoclassical form the ambitions of the ruling classes. The theatre was completely destroyed during II World War.

In the following decades, many proposals were developed for the new theatre. In 2003, the final design was accepted, following the rule “where it was, how it was”. The new structural design involves various fields of structural engineering, from geotechnical design to prefabricated and cast in place reinforced concrete structures, steel and wood structures.

Enrica Riva, Department of Industrial Engineering - University of Parma
Andrea Spagnoli – University of Parma, Italy

Abstract

Industrial installations, such as food storage and handling systems, might be characterized by pendulum oscillating masses. When such installations are placed on an elevated story of a building, its seismic response is influenced by dynamic coupling effects of the building vibrations and the pendulum mass oscillations. In the present paper, with reference to RC framed buildings, such an interaction is investigated through geometrically non-linear dynamic transient analyses in which the earthquake excitation is inputted as artificial accelerograms compatible with design response spectra for damage limit state. The dynamic response is compared with that obtained for a model of the building where the pendulum masses are assumed to be attached to the building structures. The final aim of the present study is to highlight possible beneficial effects on the seismic response of the building of the oscillating masses belonging to the industrial installation, which might act as a pendulum mass damper.

A first model of the entire building has been carried out using Abaqus code, therefore the structure has been modelled as a cantilever beam using Straus 7 software.

Abstract

The paper illustrates the design process and the load testing of a steel-reinforced laminated glass beam built for a 6 m span glass footbridge. This specific glass footbridge has been designed and tested to join two existing floors of the main room of a refurbished masonry building of the 19th century public slaughterhouse of Pisa. To meet the needs for transparency asked by the Municipality of Pisa the beams, the running surface and the balustrades, were made of laminated glass. The project started with a design of a 5790 mm length beam which has been designed and checked using analytical and numerical modelling.

Previously a series of 4-point bending experimental tests had been performed on 6 specimens of 2000 mm steel-reinforced glass beams at the University of Pisa in order to validate the accuracy of both the numerical and the analytical modelling. A final load testing has been done on the footbridge and the results have been compared with the numerical findings.

Antonello Gasperi, C.Eng, Consulting Engineer, Modena, Italy
Beatrice Belletti, Roberto Valentino - DICATeA – University of Parma, Italy

Abstract

Soil-structure interaction in the structural modelling can be fundamental to predict the actual response of structures subjected to seismic actions. In the present paper, soil-structure inertial interaction is analysed with reference to a single-story precast frame concrete structure (typical of industrial buildings) founded on isolated footings.

The analysis is carried out within the framework of dynamic impedance method using Straus7 software.

Abstract

During the seismic improvement works executed on the secondary school Jacopo Zannoni situated in Montecchio Emilia (RE) it has been carried out the load test on the framed Reinforced Concrete structures during the final inspection period. In order to check the allowable test load to be applied on the structure it has been developed a non linear analysis of the concrete section in the test configuration, the theoretical results obtained from this study have been compared with the results obtained from the load test. Afterwards the test data have been compared to the data obtained from the software to redefine the model using a back analysis to validate the results.

The below images show the structural model using the software Straus7 and the behaviour of the element sections in therms of bending curve starting from the data set for the scope, evaluating at the same time the influence of the ultimate resistance value of the materials on the analysis results.

Samuele Sassi, FSC Engineering
Setti Paolo, Politecnico di Milano

Abstract

After a fire took place in construction phase of a new elliptic roof of a shopping centre in Doha (Oasis Skylight - Mall of Qatar), which has a great span dimensions (112 x 68 m), a series of studies and analyses are performed to ensure the structural safety of the roof. The fire proofing previously applied on the roof structure limited the possible damage and the passive fire protection is renewed after the fire.

The preliminary fire investigation is useful to understand the dynamics of the fire took place in the roof and the results are utilized to rebuild fluid dynamics models (two zones models by B-Risk software and CFD models by FDS software) in order to obtain thermal effects generated on structure. Assessment of post-fire damages of roof structure became possible by FEM analyses (Straus7 software) once the fluid dynamics models are performed. Welded connections and the highly loaded structural elements, which are critical, are investigated according to obtained results. In the end, the structural analyses are redone (Straus7 software) by taking into account the post fire effects (permanent deformations, etc.) and local reinforcements in order to guarantee structural safety with cost and time optimization.

Abstract

Digital Project is the name given by SWS Engineering to the digitalization of civil infrastructures design processes. Digitalization of design processes is a relatively new and revolutionary concept for civil infrastructure engineering, and clears the air to computer aided design approaches traditionally belonging to the mechanical engineering disciplines: multi-objective optimizations, sensitivity analyses, statistical analysis, process optimization.
BIM and GIS technologies are the key technological tools that, combined with robust procedures, allow to digitalize conventional civil engineering design, i.e. convert design input and output in 3D geo-referenced parametric geometries and store non-geometric information in databases. Furthermore, IT technologies are nowadays accessible at a civil engineering design company level and boost conventional design processes and approaches.

The presentation will illustrate the latest application of SWS Digital Project to large underground works where BIM, GIS and IT technologies have been leveraged to optimize Tunnel Boring Machine performance and minimize risk during construction.

An important target in this industral field is the achievement of nearly-constant density and residual-stress fields throughout the a ceramic green body. This is necessary for producing high­quality and high-performance ceramics. The use of computational tools for virtual prototyping of molds and processes helps to accelerate development and to decrease costs. Possible design improvements are particularly advantageous for the production of large green bodies with complex geometries.
Through a novel industry/academia partnership funded by the Euroean Community, post graduate students have developed a novel constitutive models for ceramic powder compaction, which include: a new formulation for elastic behavior of the powder phase, a modelling of the compaction law, and of elastic stiffening. This new computational model has been calibrated on uniaxial compaction experiments and triaxial compression data for Martoxid KMS 96 alumina powder. Once the model has been calibrated, the parameterization has been succesfully used to predict the compaction behavior of the alumina powder in the formation of green bodies.

Acknowledgement:
The research leading to these results has received funding from the People Programme (Marie Curie Actions) of the European Union’s Seventh Framework Programme FP7/2007-2013/ under REA grant agreement n? PITN-GA-2013-606878-CERMAT2.

GABRIELE ECCHER | Curriculum

SWS is an engineering company active in infrastructure construction, offering specialist engineering, project management and risk management services. For over thirty years, SWS has been helping clients build works which form the infrastructural backbone of local communities. We are committed to designing and building works with a sustainable economic, environmental and social footprint. As a leader in tunnelling, SWS prides itself for working on the world's most important projects where we were able to offer the same level of technical expertise and efficiency for projects constructed in geologically complex or congested urban areas. SWS has offices in Trento, Torino, Roma (Italy), Ankara (Turkey), London (UK) and Toronto (Canada).

Gabriele Eccher graduated as a structural engineer from University of Trento, Italy and completed post graduate studies with PhD in computational mechanics for coupled instability of thin-walled steel structures at the University of Sydney, NSW, Australia. He joined SWS Engineering in 2010 and since then has specialized in tunnelling and underground technology, research and development. Since 2014 Gabriele has managed the Research and Development department at SWS’s headquarter in Trento, Italy. His main areas of interest are related to data collection and analysis, integration of design processes, BIM technologies and coordination of IT projects supporting underground engineering.

Abstract

In the context of civil construction, like building and infrastructures, is increasingly common the use of “in site” diagnostic tests in order to characterize the real structural behaviour. The definition of the structural limits of whatever thing to be investigated, both reinforced concrete or metallic structures, requires a preliminary careful study both to check out test’s reference values (displacement or ultimate strength rather than the interesting frequencies range) both to be able to operate safely. The numerical models, with FEM modeling, allows to pre-qualify tests and also to operate an useful “back analysis”. In this paper will be presented the comparison between numerical models and experimental activities of interest cases listed below:

• An example of application of prestressed technique in metal tie rod on historical buildings;
• An analysis to define the limit load of an aluminium cast industrial component;
• A reinforcing technique by coaction of existing hollow-core concrete floors;
• Vibrational analysis of suspended walkway;
• A transient dynamic analysis with evaluation of maximum acceleration levels on vibrating screen.

Rusne Sileryte, Delft University of Technology, The Nederlands
Antonio D'Aquilio, Delft University of Technology, The Nederlands
Michela Turrin, Delft University of Technology, The Nederlands
Yimin Sun, University of Technology, Guangzhou, China

Abstract

Parametric modelling allows quick generation of a large number of design alternatives. Ultimately, it can be combined with optimization algorithms for obtaining optimal performance-driven design. However, setup of design space for optimization is a very complex task requiring designer’s a priori knowledge and experience.

Therefore, this paper focuses on the process, which happens before the optimization.

It proposes to use multivariate analysis algorithms for exploring and understanding the relations between various design parameters, after sampling the design space. Additionally, portrayal of geometry is introduced as an extension of conventional visualization methods, which accounts for evaluation of ill-defined design criteria by using designer’s expertise. The proposed method is computationally efficient and integrated into an environment familiar to architects. It relies on multivariate analysis capabilities and an interactive dashboard developed for geometry portrayal.

Alessandro Contin, E2B

Abstract

The hydraulic devices are an efficient solution for the control of seismic stresses induced by continuous viaducts on substructures. The paper discusses the analysis of the dynamic behavior of the retrofit of a multi-span steel-concrete viaduct adopting velocity dependent anti-seismic devices. The bridge features a total length of 1,360m and a continuous deck on 18 spans with variable clearance from 52 to 92m; the piers have a variable height ranging from 7.90m to 38.80m.. Given the remarkable irregularity of the height of the piers and of the road alignment, it was necessary to couple the oscillation of the deck and the oscillation of the piers. Such coupling has been induced by the introduction of shock transmitter and viscous-type devices able to control the forces conveyed to the underlying piers which can form plastic hinges. The analysis of the viaduct takes into account the dissipative behavior of the structural elements, (material and geometric non-linearity). The assessment of the actions has been carried out by means of a non-linear dynamic analysis with step-by-step integration of equation of motion.

Matteo Cova, SACMI IMOLA S.C., ITALY
Giacomo Bertuzzi, SACMI IMOLA S.C., ITALY

Abstract

Shape optimization is a way to improve the structural performance of components and tools based on parametric geometries are becoming standard for fine-tuning optimization in industry. Direct update of nodal positions of finite element models by mesh morphing is a meaningful alternative to re-meshing a parametric geometry, helping the designer in what-if studies, optimization and robust design development without geometry coherence problems. There are some cases where FE loads depend on the geometric features on which they are applied or, on the other side, the analyst could want to strictly control the geometric features of the component.

Geometry features can be controlled with mesh morphing, but in general, it is much easier and intuitive to direct control them with parametric geometries. On the other side geometry coherence can be a too strong limitation that inhibits any optimization of it. A different approach to mix the goods of both the techniques and overtake their limitations is proposed together with its application. The proposed methodology is based on the main idea that the optimization is a mesh-based optimization driven by a parametric geometry. ModeFrontier potentialities are exploited to manage the optimization loop while RBF Morph is used to perform mesh morphing. Thanks to the proposed methodology different shapes can be obtained and analyzed according to internal procedures in order to speed up the design selection process.

Marco Ricci, Bonfiglioli Riduttori
Andrea Torcelli, Bonfiglioli Riduttori

Abstract

The optimization of a planetary gear train arrangement or even single gear pair, included in a complex transmission system can be fairly complicated mainly because it involves a high number of input variables as well as multiple objectives which are often in contrast with each other. This paper describes the implementation of a process which would allow to optimize the design of a helical gears pairs using a multi-objective optimization platform coupled with a calculation software for design of rotating machinery and gears.

With the specific focus to reduce the noise related to the gear meshing, a combined objective function which maximizes the transverse contact ratio and the overlap ratio, and minimizes the transmission error has been considered in this model, always imposing acceptable stress values on the teeth. The model has been validated by means of experimental measurement on the actual machine where the results have been compared with those related to the actual solution, in which the pair of the first stage gears are designed with traditional methods.

Abstract

Open impellers are the main rotating components in centrifugal compressors and their structural integrity and safety are crucial characteristics in the operative success and safety of the machine itself. Stress and modal analyses are the basis for a good structural design of impellers. While a static structural analysis guarantees the assessment within mechanical material limits in steady-state condition, particular attention has to be paid in the pre-stressed modal analysis that permits to identify the harmonic frequencies of the bladed disk and consequently to evaluate the possible resonant excitation to avoid vibration-related failure, due to the dynamic stresses.

The Singh’s Advanced Frequency Evaluation (SAFE) Interference Diagram is an important tool that allows to combine the impeller natural frequencies, the disk mode shapes, the operative speed range and the excitation frequencies in the same graph, providing a complete overview of the system behavior. The aim of this paper is to describe the SAFE Interference Diagram and its parameters and to illustrate the results of a pre-stressed modal analysis performed on an impeller with ANSYS Workbench.

Antonio Lettini, Casappa

Abstract

Today any kind of hydraulic subsystem has to guarantee high performances and reliability in order to match customer challenging requests. Furthermore, it is required to reduce price and time-to-market of new products. During the last years optimizations through simulation tools have become the standard to be competitive and fast enough. In this context it is not unreal to think that reducing the optimization time and increasing the optimization quality will become more and more important in the nearest future. This paper will show an example of how a new external gear pump can be optimized to achieve best performances in terms of efficiency, pressure pulsations and noise emission.

Since the expected performances are always higher in respect to previous versions, while complying production needs, this kind of problem becomes highly constrained. A comparison between optimization results obtained with two different modeFRONTIER algorithms will be shown: it will be pointed out how much important is to choose the algorithm that best suits to the specific application in order to find the lowest Pareto frontier in the lowest computational time.

Marcello Colledani, Politecnico di Milano, Dipartimento di Meccanica
Andrea Ratti, Politecnico di Milano, Dipartimento di Meccanica
Anna Bassi, Francesco Micchetti, Giovanni Borzi, EnginSoft
Simone Belardinelli, COMAU Spa

Abstract

The design of automotive manufacturing systems is a core competence of COMAU, and represents a complex task that relies heavily on knowledge and experience. COMAU is continuously improving its manufacturing systems design processes in order to reduce the design lead times, shorten the time to market and increase the “first time right” designs. Results presented in this work are grounded on a novel approach to the preliminary design of production systems, capable of taking into account engineering and throughput constraints, equipment and lifecycle costs, and including region-dependent parameters such as local energy and personnel costs.

This approach enables the system designer to automatically generate and evaluate hundreds of different alternative manufacturing system designs, obtain the Pareto frontier, and subsequently select and validate the optimal ones. Acknowledgment: the ProRegio - Customer-driven design of product-services and production networks to adapt to regional market requirements - project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 636966.

Abstract

To improve the efficiency of geared transmissions, prediction models are required. Literature provides only simplified models that often do not take into account the influence of many parameters on the power losses. Recently some works based on CFD simulations have been presented. The drawback of this technique is the time demand needed for the computation. In this work a less time-consuming numerical calculation method based on some specific mesh-handling techniques was extensively applied. With this approach the windage and the churning phenomena were simulated and compared with experimental data in terms of power loss and lubricant fluxes.

The comparison shows the capability of the numerical approach to capture the phenomena that can be observed experimentally. The powerful capabilities of this approach in terms of both prediction accuracy and computational effort efficiency make it a potential tool for an advanced design of gearboxes as well as a powerful tool for further comprehension of the physics behind the gearbox lubrication.

Abstract

This presentation will show how Maplesoft’s Engineering Solutions team provided a platform for examining the dynamic behavior of a Lifted Radial Stacker, a complex machine used for material handling in mines.

As stability and weight distribution are key considerations in the design of such machines, engineers at FLSmidth required a multi-domain dynamic model of the Lifted Radial Stacker. Maplesoft’s Engineering Solutions team developed a model of the complex machine in MapleSim, providing engineers with a virtual environment to apply multiple approaches to evaluate dynamic response of the system.

Ragnar Skoglund, EnginSoft Nordic
Massimo Galbiati, EnginSoft

Abstract

A two speed reduction gear box has been used in a case study to evaluate if the MPS method can replace expensive and time consuming lab tests. The gear box is a part of the rotor drive transmission chain of a forage harvester machine and works in a very wide range of rotational speed and torque. A good lubrication for all rotating component is mandatory to avoid failures and overheating issues.

The goal has been to calibrate the MPS model parameters in order to fit the oil physics in the experimental lab tests of the same gear box. After the calibration phase, geometry changes are made and a new oil level is defined to see the effect on lubrication and on churning losses. The MPS method proved to be successful in predicting performance of a tailored gear box and in reducing lab tests. The physics of free surface flow and splashing phenomena of the oil are accurately captured with the MPS method. Moreover the modelling and simulation time is low compared to traditional CFD methods, so that the MPS simulations fit in the product development process.

Hiroyuki Kase, Prometech Software Inc.

Abstract

In the manufacturing processes such as glass and ceramic processing, precision casting processing and blast polishing, various sludge gets mixed into working fluid. If sludge is not filtered out from the working fluid sufficiently, it may cause many troubles, e.g., scratch on the surface of products, deficiency in forming precision, lifetime shortening of grinder and so on. As the result, production cost increases. In these precision machining processes, it is crucial to decontaminate working fluid using high performance filters. For this purpose, improvement of decontamination efficiency of a cylinder shape filter was investigated using simulation. Dirty water flows into the filter system from the inlet placed at the bottom of the case and it flows through the cylinder shape filter.

At this moment sludge is absorbed on the surface of the filter and the purified water flows out from the filter system through the outlet at the top of the case. The purpose of this study is the optimization of the efficiency of the filter system. Shape optimization of the filter system was performed using MPS particle method based CFD software Particleworks and filtering performance was improved dramatically.

Abstract

The study of the development of Consumer Price Index and Producers Price Index in OECD countries, it demonstrates that there is an imbalance between price and cost development. This situation has created a productivity gap that presents a challenge for many companies. One key opportunity to close this productivity gap is during the purchasing of machines or tools ecc. In this paper we’re going to review the process and row material and to show what Sandvik can do to close this negative productivity gap. Productivity is a chain where the rings are: Material ,Machine tool, Tools Methods ,Knowledge , CNC. We will analize the influence of the material to improve productivity and reducing costs We’ll start with the presentation of the stainless steel material duplex , superduplex hyperduplex, from mechanical and chemical characteristics of bars and hollow bars manufactured by Sandvik. The analysis of the process of manufacturing Sandvik Material Technology will lead us to define the various passages from the casting and melting through rolling forging extrusion to the heat treatment. We will focus in particular on the methodology of production of steels SANMAC (high machinability). Following the illustration of the characteristics of steels SANMAC defining the advantages and disadvantages of these products. The central part of the presentation will report the results obtained from tests performed on our material superduplex 1.4410 compared with an equivalent of a competitor. In the test are considered the tool life of the cutting edge at different cutting speeds (60-125m/min), the chip control with different parameters, the surface finishing and power consumption The tests were carried out in turning, drilling, tapping and parting off. Following the results it is assumed the realization of a piece whereas the two starting materials. We will calculate the cost of production and will allow us to quantify the savings achievable by a material with the best machinability. We will also consider the use of hollow bar for the realization of the same piece. Again we are going to compare the cycles and the analysis of the times and costs will lead us to draw conclusions about the possibility of using this solution. The conclusion will be a pratical and interesting reduction of the final cost and improving the productivity

Andrei Voitsik, Irion LLC

Abstract

Object of Optimization:The centrifugal pump of the mining dump. This pump is using in the engine cooling system. Goal of Optimization: It is necessary to find the optimal geometry of blades and the optimal quantity of blades to increase the pump efficiency. Parameters of Optimization: Geometrical structure of blade.

In total 12 parameters!

Nicola Parolini, MOX, Politecnico di Milano
Alessandro Mola, Stara Glass

Abstract

Reacting combustion, turbulent flows and thermal exchange mechanisms are only few of the coupled physics governing the glass melting process in industrial furnaces. The comprehension of such complex phenomena is mandatory to design furnaces respecting the high standard quality required by the glass market, keeping energy consumption at bay and fulfilling the strict EU NOx pollutant regulations. Numerical simulations based on advanced models accounting for the coupled physics are an ideal tool to achieve these goals.

In this work, Moxoff presents a multiphysics CFD simulation framework modelling the combustion process in glass furnaces developed for StaraGlass, an Italian SME producer. The advanced coupled numerical model is implemented in a standard and automated simulation workflow based on open-source software. This provides engineers, even if not experts in simulations, with an accurate and flexible tool to support furnaces optimal design and operating scenarios.

Valerio Caputo, EnginSoft

Abstract

Autec Safety Remote Control is an Italian company leader in the design and manufacturing of wireless radio remote controls for industrial/construction cranes and mobile machinery for off-highway applications. Autec improving processes are guided by 3S principle, i.e. excellence in Safety, Solutions and Service EnginSoft helps Autec on each ‘S’ using LS-DYNA.
Safety: LS-DYNA has been used to simulate drop tests and falling object tests to help engineers to choose the best solution to guarantee a good resistance of the Remote Control that can operate amid challenging circumstances on highly demanding environments Solutions: simulations, introduced in the early phase of the concept design, help Autec to choose the most efficient design and the best material for specific customer needs. A well correlated FEM avoid to build up many prototypes and to do many physical tests reducing R&D costs and time development product.
Service: Autec believes that customers are the lifeblood of any business, so it is important to place an emphasis on the customer experience both before and after a sale is made. The simulations is one of the tools used to reach this objective and it helps Autec to create “Customers for Life” by the design of reliable products

Michael Ehlen, qpunkt GmbH
Hua Liu, M.Sc., Gear Research Centre (FZG), Technical University of Munich
Dipl.-Ing. Thomas Jurkschat, Gear Research Centre (FZG), Technical University of Munich
Thomas Lohner, M.Sc., Gear Research Centre (FZG), Technical University of Munich
Prof. Dr. Karsten Stahl, Gear Research Centre (FZG), Technical University of Munich

Abstract

The demand for further efficiency enhancements of current transmission systems and gearboxes makes it inevitable to investigate no-load power losses that can contribute a considerable portion to the overall losses of gear drives. Especially, current developments of ultra-high-speed drive systems require the optimization of windage and churning losses, which can have significant impact on the performance of lubricated systems. Unfortunately, current analytical and empirical approaches for no load gear losses often provide poor results with high deviation compared to measurements, particularly for operating conditions beyond the validity of the approaches.

CFD methods offer a high potential to investigate the no load power losses with a much higher quality than current empirical equations. However, few works have been able to successfully validate their approaches for multiphase models with experimental results yet. In a first step, this study employs a Volume-of-Fluid-based approach to model the churning losses of a dip-lubricated spur gear pair in the gearbox of the FZG back-to-back gear test rig. The rotation of the gear pair is realized through overset meshes, which allow a realistic representation of the meshing of the gear pair. In a second step, we investigate the possibility to model the churning losses with a state-of-the-art particle-based method (ISPH), which promises a significant reduction in preparation and computation time. Both simulation methods were compared to experimental data measured with a standardized FZG-back-to-back gear test rig at the Gear Research Centre (FZG) of the Technical University of Munich. Finally, a summary of the results and an outlook to future developments and the potential applicability of the methods are given.

Pierluigi Mollicone, University of Malta
Ivan Grech, University of Malta
Bertram Mallia, University of Malta
Nicholas Sammut, University of Malta

Abstract

Microelectromechanical systems (MEMS) have established themselves in various science and engineering domains. MEMS-based microgrippers provide several advantages in terms of compact size and low cost, and play vital roles in microassembly and micromanipulation fields within both micromanufacturing and biological sectors. Microactuators based on different actuation principles have been devised to drive MEMS-based microgrippers.

This paper presents a finite element model of a MEMS-based electrothermally actuated microgripper performed using CoventorWare®. The microgripper design follows standard micromachining processes that make use of reactive ion etching (RIE) where polysilicon acts as the main structural material while a gold layer is deposited on the structure for thermal actuation. The simulations are used to assess the performance of the microgripper and to optimize its operating parameters.

Abstract

One of the key issues in CAE world is the storage of the large amount of data that are being generated. As models are progressively increasing in size and the calculation time decreases rapidly due to solver improvements and higher processing power, the amount of derived data is proliferated and thus, storage becomes an important concern that must be confronted. On the users side, big result files are always related to longer idle times since transferring these files over a network and load them on a post-processor can take considerable time. On top of that, in most of the cases, the actual data that need to be stored represent just a small percentage of the total content of a result file thus minimising, if not removing at all, any possible benefit from keeping the total amount of data. In order to address this issue in an efficient way, BETA CAE Systems initiated the development of several techniques that have been embedded in μETA, the cross-discipline post-processor of the BETA CAE Systems suite for FEA and CFD analysis. Selected results can be saved in a native binary format either uncompressed or compressed. Compression can be either lossless or lossy, the latter offering the biggest advantage since it can achieve compression ratios of up to 90% or more. However, in that case, the provided full control on the accuracy level per type of results as well as per part or group, allows for exploiting the maximum benefit from the compression without compromising the accuracy in model areas of interest. Compression for large CFD models can be further augmented through the simplification of solids for non-important areas. In parallel to minimising the storage needs through jointly applying the above compression techniques, a significantly higher reading performance is realised.

This paper presents in detail these compression techniques and the results from comparative studies conducted for different models.

Alessandro Tasora, University of Parma

Abstract

Nowadays, a wide choice of finite element formulations is available, not only within the academia, but also in ready-to-use commercial software, covering very different case scenarios. Many of these are suited to capture high-order behaviors or to fit complex shapes (e.g. isogeometric elements) but, because of their complexity, are not always the best choice for large-scale simulations or for entangled non-uniform shapes. For these latter cases, a finer mesh of less computational demanding elements is often a better choice.

In this context, the Basic Shell Triangle, a rotation-free triangular element based on Kirchhoff–Love theory, has been implemented in the multibody simulation software Chrono::Engine, taking into account different approaches already proposed in literature [1][2][3][4]. Lacking of rotational degrees of freedom, the curvature of this element cannot be directly inferred from the (linear) displacement field, giving rise to a more code-involved implementation that has to consider also the state of neighboring elements.

Luca Catellani, Asotech
Giovan Battista Trinca, Asotech
Pietro Ghillani, Asotech

Abstract

Asotech is proud to present some of the solutions that it has developed for the world of Amusement Rides. For many years, Asotech has devoted particular attention to ROLLER COASTERS with passion and competence applied to the calculation, to the structural verifications, and to their design. Starting from the structural verifications carried out in the ANSYS environment and Straus7, Asotech has developed specific software tools for the kinematic and dynamic verification of the chosen trajectory given by CAD or NO LIMITS software. The program has been validated against the most advanced multibody software available on the market. Asotech will demonstrate its working procedure, placing particular emphasis on the dynamic and kinematic verifications that support the design and sizing of, what is, one of the most complex feats of engineering.

The structural verification of the space frame of the ride is carried out within Straus7 and ANSYS Workbench environment: a fatigue verification of the main welding joints following Eurocode 3, and an optimization of the beam sections in order to minimize material wastage, are included.

Bogdan Ene-Iordache, IRCCS - Istituto di Ricerche Farmacologiche “Mario Negri”
Andrea Remuzzi, IRCCS - Istituto di Ricerche Farmacologiche “Mario Negri”, Italy

Abstract

Arteriovenous fistula (AVF) is the vascular access of choice for hemodialysis patients. The AVFs have high failure rates, primarily due to development of neointimal hyperplasia (NH) in the juxta-anastomotic vein (JAV). The aim of this study was to investigate the blood flow in patient-specific AVF, in order to characterize local wall shear stress (WSS) acting on the AVF walls. We reconstructed the 3D model of AVF from contrast-free magnetic resonance images and then performed high-resolution CFD simulations, using a mesh of 1,278,000 cells. We also used patient-specific blood rheology and flow boundary conditions. We then characterized the flow field and categorized disturbed flow areas using established hemodynamic wall parameters.

We observed transitional laminar to turbulent flow developing in the JAV and damping towards the venous outflow. High-frequency fluctuations of velocity result in eddies that induce similar oscillations and rotations of the WSS vector. This condition may impair the physiological response of endothelial cells and trigger NH formation.

Abstract

The focus of the study is to reproduce real stress and deformation fields into a polymeric membrane that works inside complex industrial filling valve. In the first part a CFD model has been developed in order to estimate loads distribution that acts over membrane during the closure procedure of valve its lf: strong and hard unsteady phenomena are generated during this phase (water hammer effect).

Following the first step, loads calculated from CFD analysis are directly shared and applied into structural solver. Structural FEM of membrane is created using real characterization data and loads from CFD: generated model allows to reproduce 1 way fluid structure interaction analysis. Finally, after identification of critical issues, an optimization of the geometry has been developed in order to reach desired performances.

Marco Fanciulli, Università Milano Bicocca, Italy
Giacomo Indiveri, INI Zurich, Switzerland
Christian Mayr, University of Dresden, Germany
Themis Prodromakis, University of Southampton, United Kingdom
Sabina Spiga, MDM-CNR, Italy
Grazia Tallarida, MDM-CNR, Italy
Ralf Zeitler, Venneos GmbH, Germany

Abstract

Information processing in classical ‘von Neumann’ architectures is less efficient compared to biological counterparts when dealing with ill-posed problems and noisy data. The reason is that the biological brain is configured differently and the key is its evolving structure, where connectivity elements between individual neurons, the synapses, undergo ‘birth’ and ‘death’ as well as strengthening and weakening through a selection process, reconfiguring neuronal connectivity in a self-organizing manner and allowing the networked population of neuronal processors to adapt motor and behavioural responses to the ever changing environment. Artificial neural networks in the form of software run on conventional ‘von Neumann’ computers appear incomparable to the biological systems in terms of speed, energy efficiency, adaptability and robustness. The challenge is to propose a ‘physical’ neural network where elements overcome this deficiency by merging data storage and processing into single electronic devices and by self-organizing and reconfiguring connectivity. Along this route, we report on a new biohybrid architecture of natural and artificial neurons. Communication between artificial and natural worlds is established through new nano- and microtransducers allowing direct electrical interfacing of a network of neurons in culture to an artificial CMOS-based counterpart. Furthermore, preliminary results show how adaptation properties of the artificial network can rely on memristive nanoelectronic devices with synaptic-like plasticity. As such, the biohybrid system will provide new and unique adaptive, self-organizing and evolving properties deriving from the fusion of natural and artificial neuronal elements into a new plastic entity and will represent a fundamental step towards the development of novel brain-inspired computing architectures as well as ‘intelligent’ autonomous systems and prostheses

Abstract

The use of numerical simulation is becoming increasingly important in the product development cycle. From early concept design, through detailed design, industrialization and production, every industrial phase can take benefit from CAE. Nevertheless there are some pitfalls to avoid and good practises to follow. Here some structural analysis examples are presented from the bike components industry.

F. Lampitelli, Electrolux

Abstract

Numerical simulations were used to investigate the impact behavior of complex products such as home appliances. LS-DYNA® is a powerful tool for performing repeated analysis of large assembled parts of the final product, including the packaging. The main goals of the project were to support designers in choosing the best configuration both in the oven structure and in the packaging shape. The studies were carried out to guarantee the integrity of the product from factory to customer and therefore to reduce customers service calls.
In particular, impact simulations on an oven and its packaging were performed using LS-DYNA®. The FE model reproduced the testing conditions defined by internal Electrolux regulations. Edge drop tests and inclined planes were studied and results used to improve overall performances.
The paper will present the current methodology developed to speed up the product development and to reduce the time to market (TTM). Experimental and numerical results will be compared.

Nasser Ghassembaglou, EnginSoft Turkey
Hasan Avşar, EnginSoft Turkey, Turkey
Uğur Kan, Arçelik/R&D/Ankara, Turkey
Levent Kavurmacıoğlu, Istanbul Technical University, Turkey

Abstract

In this study, evaporation and condensation processes have been analyzed and investigated in a domestic dish-washer through different CFD methods. At first the dish-washer contains 4 liters of 58oC water which will be heated to 65oC by an 1800 Watt/m2 heat-flux source at the bottom-center of water volume.

The heating surface has an area of 0.03 m2 and automatically shuts down when the water reaches to 65oC. The analyze goes through natural cooling process for about 15 minutes to see the condensation procedure in different sections of dish washer. The whole volume of dish-washer, including felts, inner and outer cabinets have been considered in these analyses which have been run for both cases either with dishes or without dishes conditions. There are two holes with the names of water pocket and condensation shells at the left and right sides of inner cabinet which lets the water vapor to reach outside of it. Condensation occurs on different surfaces of dish-washer such as outer cabinet, inner cabinet, dishes, etc. which has been taken into account in all analyses. Also there is a very narrow gap at the front of dish-washer with a width of 0.002 m to allow the condensed or evaporated water to leak out of dish-washer. Finally, the amount of liquid and vapor which infiltrates out of dish-washer has been calculated and considered as a parameter showing the design success. 256 cores of a High Performance Computing (HPC) cluster have been used in the sake of calculation for 2 months. The results were written and post-processed as videos and images of evaporation and condensation processes for either with dish or without dish analyses which are presented in this research study.

Ramon De Pascalis, University of Salento
Claudio Pascarelli, University of Salento, Italy
Angelo Corallo, University of Salento, Italy
Francesco Micchetti, EnginSoft, Italy

Abstract

In manufacturing companies, technologists use CAD/CAM tools for NC programming. For faster programming, feature based approaches have been developed; they allow to automatically generate toolpath recognizing both standard and custom machining features, and defining for each of them the best or preferred machining process based on predefined rules. The definition of FBM (Feature Based Machining) rules requires advanced competences, even programming skills, not usually owned by expert CAM technologists. Moreover, the standardization required by these instruments is too rigorous for real machining practices. It is therefore necessary a data and manufacturing rules management environment, in which knowledge engineer can define rules based on industrial best practice and CAM technologists can customize them for production requirements. A possible solution is to extend the FBM software module with an easy-to-use system that simplify feature based rules management and deployment.

A new methodology and a Java tool are proposed.

Alessio Desando, Politecnico di Torino
Elena Campagnoli, Politecnico di Torino

Abstract

The high requirements in terms of thermal and structural stresses for the modern technological applications pointed out the need for a detailed knowledge of the manufacturing processes utilized to produce more durable materials. The quenching process is one of these treatments, a rapid cooling utilized to obtain harder metal components. In the last years, research efforts about this process have developed methods to predict the heat transfer coefficients.

The first part of the present work consists into the application of literature correlations with water and oil as quenching mediums, on different geometries. The objective is to estimate the heat transfer behavior during the thermal process. Then, a numerical model with these thermal transient features has been implemented to simulate the quenching process in oil for a cylinder made of INCONEL 600. Finally, mesh sensitivity has been carried out, in order to evaluate how cell thickness influences the accuracy of the cooling rate curves.

Nicolò Spiezia, M3E

Abstract

In the last decade all the OEMs in automotive industry have been spent a lot of efforts in reducing as much as possible project lead time increasing at same time the quality of final product. This trend, empowered by new technologies, has a strong effect on company organization and project workflow but probably the main impact is on operations and manufacturing area. The complete supply chain has been pulled in order to cut design and manufacturing time and speed up decision processes. The wider area involved in this trend is that one of plastic component suppliers which has to cut the delivery time of tools, machines and equipment.

Operating in the injection moulding field as hot runner system supplier, HRS develops a simulation software in order to predict in the most correct way the performances of hot runners and to provide an automatic sizing of systems in order to respect specific customer’s requests and ensuring at same time the best control of the injection moulding process and polymers transformation.

Peter Tibaut, Ugo Sorge, Cristiano Pecollo
AVL Italia

Abstract

Immersion quenching cooling process is a key step in traditional heat treatment process to produce supersaturated solid solution for subsequent aging hardening of the material. The efficient quenching process leads in reducing the possibilities on distortion and cracking of the cast parts, due to residual stresses, and consequently has an important influence on power and torque requirements. Computational fluid dynamics (CFD) allows to understand the complex behavior of this process. In this work, an FCA Diesel engine has been considered for the numerical investigation during the quenching cooling process using the commercial CFD code AVL FIRE(r). By the mean of CFD analysis, the evolution of Temperature and heat flux during the cooling phase is calculated. These data is then used for structural analysis to get the residual stress without imposing fixed HTC Two different dipping directions have been taken into account, where in both cases aluminum alloy was placed on a steel rack and together submerged within the water.

Abstract

Additive Layer Manufacturing (ALM), also known as 3D Printing, is the forthcoming advanced manufacturing technique. In this fabrication process multiple materials can be combined and the shape complexity is free.

The enormous potential of light weight designs makes ALM a preferred manufacturing technique for components in defense applications such as drones, guided projectiles, etc. One of the current barriers of commercialization of ALM is the absence of best practices, design processes and guidelines. A work flow that utilizes topology optimization, sub divisional surface modeling and lattice structure features will be presented. The Design Optimization Workflow will be demonstrated by an example of a component with heavy launch loads.

Enzo Morosini Frazzon, University of Santa Catarina Campus, Florianópolis
Ruben Foresti, Department of Industrial Engineering, University of Parma
Marco Silvestri, Department of Industrial Engineering, University of Parma, University of Applied Sciences of Southern Switzerland (SUPSI)

Abstract

Due to increasing complexity of manufacturing systems, there is a need for proper approaches supporting fast and reliable preliminary evaluation, before effective system installation. In this direction, this paper presents a simulation-based operational and economic analysis of a Flexible Manufacturing System (FMS). The evaluation, performed by means of a simulation model, considers Industry 4.0 concepts for supporting the integration of innovative technologies, such as additive manufacturing (i.e. 3D-prinitng), a scara robot, a pick-and-place robot, a 3D scanner and an automated warehouse as well as an automated transport conveyor belt between each station.

More in details, a discrete-event simulation model was developed and employed for the analysis. The simulated pilot case refers to a particular automated production line carried out in an academic context. The first objective was to verify if simulation can faithfully reproduce the 3D-printing process and hence demonstrate the suitability of involved technologies for the application in industrial scale. Second, this research aimed to fill the gap regarding structured approaches for the analysis of FMS. Finally, the last objective was to provide a simulation-based tool for enhancing decisions concerning set up changes in 3D-printing production systems.

Abstract

The definition of the acceptability criteria for defects present within industrial components is often a complicated matter, since the specific application of each specimen is always to be taken into account. During the quality control, in order to avoid the risk of critical failures, high safety factors are commonly adopted, thus leading to the rejection of specimens whose defects could, in point of fact, be acceptable. In this context, it would be very useful to simulate whether a specific defect is actually critical or not.

The aim of this work is to highlight the synergy between Industrial Computed Tomography (CT) and Finite Element Analysis (FEA): by means of tomography it is possible to reconstruct the whole 3D volume of the specimen, detecting its actual dimensions and reproducing the material’s defects; by means of FEA this virtualization can be exploited to simulate the real specimen itself, inclusive of the defects detected by tomography, rather than the ideal CAD geometry. Tomographic volumes of some benchmark components are here presented, together with the results of FEA simulation in ANSYS Workbench environment. Simulation results are moreover compared with resistance values obtained by experimental mechanical tests. This allows to demonstrate the reliability of the method and, as a consequence, whether linear flaws and porosities present within the component are actually critical or not, with the final purpose of determining if the component is acceptable or should actually be rejected.

Abstract

Optical 3D metrology is nowadays widely used for the verification and optimization of numerical simulations. Numerical simulations require input parameters, such as surface geometry data and material parameters, as well as boundary conditions, like the test stand behavior and stability under load. 3D measurement systems are today utilized for the determination of material parameters, the evaluation of test rigs and stands, the measurement of components or test specimens and the subsequent validation of the corresponding simulation results.

This paper will discuss the use of optical 3D metrology systems for the generation of input parameters, boundary conditions and the validation of numerical simulation results at different applications examples from the automotive and aerospace industry.

Abstract

FDM, or Fused Deposition Modeling, is a well known technology in the field of Additive Layer Manufacturing disciplines. Specific technical characteristics of the FDM process and new high-performance plastic materials enable the production of functional prototypes as well as end use parts.

Design principles as well as mechanical properties that can be obtained with the FDM process will be discussed during the presentation.

Abstract

Chaos theory is the field of study in mathematics that studies the behavior and condition of dynamical systems that are highly sensitive to initial conditions - a response popularly referred to as the butterfly effect. CFD is one of the field where boundary conditions have big effect on stability of calculations, as Robert Shaw (a physics grad student in the 1970s) discovered studying a simple phenomena, the faucet’s flow.

When the water flow is low, the result is a steady dripping that increases its rate as the faucet is open. As the system is driven harder by increasing the flow, the constant interval between drops gives way to two alternating intervals, similar to mathematical description of animal populations. Then, at higher flow rates, each of the two different intervals itself subdivides; a still higher rate provokes chaotic behavior, with no discernable pattern. This is why in CFD analysis the right choice of boundary condition is the best way to avoid chaos...

Abstract

Modern steel industry aims at producing steels with higher and higher quality standard and low cost, this means steel ingots with low defect, both in terms of segregations that inclusions, and high yield. A virtual approach can be very helpful to achieve this purpose but the virtual model has to describe consistently the experimental reality. Through the software MAGMA5 we create a consistent model and then, on the basis of it, we use the software optimizer to find best process parameters to decrease the segregation of the elements.

Abstract

The global competition is pushing the designers to reduce components mass and cost, still maintaining an high safety and quality target. This is all the more if very large items are considered, since weight reduction has not only an impact in the direct cost of the item, but also in indirect costs like machining, handling, assembly and transportation. Nowadays some companies are tacking on the weight reduction challenge using simulation tools referred as "Structural Optimization Techniques". These aim to the most efficient shape and thus are very well coupled with the casting process, which allows large freedom in terms of geometry complexity. What is often missing when the designers deal with heavy section castings is that the microstructure and mechanical properties change inside the castings due to segregation and different solidification times. In this work we analysed and compared three different design scenarios based on three different optimization workflows applied to a ductile iron casting. In the first scenario we performed a structural optimization without considering local mechanical properties. In the second one the local mechanical properties are introduced in the optimization loop and used to calculate the component reliability. The local mechanical properties are estimated using casting simulation and the component is optimized by taking them into account. In the third scenario the structural and process optimization are fully coupled: the casting process is optimized in the "virtual foundry" to reach and improve the structural target. The more integrated approach does not only reduce the total cost and increase the quality level of the component, but, implementing casting optimization, the manufacturing process cost are reduced as well since it's focused on the designer's needs. A complete automation of the proposed coupled optimization approach is still missing due to data transfer limitations and hence a more open attitude of the software is advisable.

Abstract

Hot-chamber zinc die casting is a process which realizes products through high pressure injection of fluid metal into the mould. Analyzing and predicting the behavior of the metal during filling and solidification is a fundamental help in mould design.

We present three case study examples describing products affected by typical defects of this process (shrinkage porosity, cavitation and turbulent flow) and how CFD simulation by MagmaSoft has been used to analyze the problem and find suitable solutions.

Abstract

The integration between numerical simulation and sampling in the die casting tool standard production process” Nowadays, in the automotive sector, the fuel consumption decrease is quite fundamental, as strongly requested by the global market. Therefore, over the years many components have been converted into light alloys production (aluminum and magnesium above all) and moreover they are produced through die casting technology. Foundries and final customers (car producers among them), look for a tool maker as a partner who is able to provide them not only with “turnkey” die casting equipment, but also valid technological support for the development of pieces characterized by more and more variable and complex geometries and thicknesses. In the standard production process, during the mold design, from the simplest to the most complex, SAEN systematically uses the process simulation MAGMA5 software, thus reducing the casting problems, usually appearing during the first samplings and the production, as much as possible. Thanks to the experience gained through its foundry laboratory, SAEN is able to analyze and constantly compare the results of the numerical simulations and those of the samplings, modifying and optimizing the gating systems and the HPDC machine parameters used during production. Sometimes, it is possible to achieve a standardization of gating and overflow system design, for components which are different among them but belong to the same “family”. Through the experience built up in 45 years of company history, the know-how of its staff and a continuous effort in the process improvement, SAEN is able to realize even small production series (500-1000 pieces) during the first samplings of the die, thus strongly reducing the production time of first series in order to quickly answer the final customer’s needs.

Abstract

Components are getting more and more complex in shape, with high performance demands, and at the same time less defects and an narrow margin of error; in other words, the design of the components requires a combination of acceptable cost, low weight, performance and easy production. In such a context, the product-process design and optimization assumes an extremely important role, since it’s a very delicate phase in which the most effective solutions are evaluated in order to produce the equipment and to optimize the proper process parameters.
The development and optimization of a casting process means to identify the variables that mainly impact on the product features, evaluating the effects with the support of advanced tools for process simulation.
CAE tools, like MAGMA and its Optimisation tool, are evolving to support the design during the research of the best engineering solution. The virtual prototype approach is interesting in particular in case of component with high performance requirements.

Abstract

Ceratizit Italia S.p.A. is the Italian branch of Ceratizit S.A., the biggest producer of hard metal components for wear protection applications. Hard metal is a powder metallurgy material made of Tungsten Carbide and a binding element (f.i. Cobalt). Among many applications, hard metal is widely used for the production of tools for cold metal forming such as stamping dies, punches, knives, rolls and hammers.

Ceratizit Italia produces customized tools for cold metal forming applications in synergy with its customers. The Engineering department at Ceratizit Italia analyses application issues and customer needs in order to provide advices on the best tool design or configuration. The FEM simulator Trasvalor ColdForm has become during the last years a fundamental tool in the design and optimization of special tools. The software is employed to study solutions from all business segments and not only in the stamping industry. Examples of these varied applications will be presented and discussed.

Abstract

The goal of this presentation is to describe how to use different major improvements of the FORGE® NxT 1.1 version. Several developments were implemented or upgraded in the NxT 1.1 version in order to ease the use of our software:

• Multi-project capability
• Thickness computation
• Mesh merging and export options
• Thermal steady state analysis
• Store manager for client/server environments

This best practice aims at providing useful recommendations and advices on these topics in order to help our customers in their everyday industrial applications.

Abstract

MCE Italy has used Forge FEM forming simulation for many years. The user friendliness and flexibility of this software have allowed to make different uses of the simulation, from the simplest study of optimized forging sequences to more advanced simulation of processes that didn't exist. Some examples of successful experiences are shown here:

- Optimization of a forging sequence to improve the grain flow
- Investigation of the origin of a defect, through a reverse simulation of the forging sequence.
- Evaluation of achievable strain levels in a cold ring-rolling operation, in order to design a correct range of real-scale experiments.
- Evaluation of the relationship between linear scale factor and forming loads, in order to use the results from scaled-down ring rolling tests to evaluate the requirements for a real-scale new machine.
- Simulation of cold-rolling a totally new hollow component. The preliminary evaluation of loads on the tools allowed to design, test and patent a new cold-rolling tooling.
- Simulation of a new process with combined impact forming and hydroforming.

Abstract

Due to the increasing demand of higher and higher mechanical properties and geometrical complexity of metallic parts for many industrial sectors, the interest for forging processes and their optimization remains remarkable. In this scenario, Finite Element Methods (FEM) based software actually represent the best solution to obtain fast and reliable results, but there are still significant limitations in the modelling complex material behaviours, especially when complex phase transformations take place.

The aim of the present study is the development and the implementation of an efficient and effective methodology based on the sue of FEM analyses to reduce the hot tearing during the forging of austenitic stainless steel. After a literature survey to identify the metallurgic behaviour of the material taken as case study, a FEM analysis of the forging process was carried out in order to simulate the phenomena and identify the main problems. In the second part of the work, the response surfaces method was used to evaluate the influence of the most relevant process variables.

Abstract

This presentation aims at announcing the upcoming major release FORGE® NxT 2.0 featuring the latest enhancements related to the solver as well as to the graphical user interface. Key-functionalities are highlighted in the field of induction heating, open die forging with real manipulators, flat rolling, mandrel forging, gas/lub trapping with deformable dies. Later, focus is given to the graphical user interface and the ease of the software introducing new features such as loading tooling assembly, new marking grid patterns, add field by distribution and improved animation settings.

Stefano Baù, F.O.C. Ciscato SpA

Abstract

FOC Ciscato SpA provides a wide range of forging and drop forging products. With more than a hundred years of hystory the Company is to be considered a steady point on these market. Reference markets are Transport (Railways and Marine), Oil & Gas and Energy, which demand shaft, rings, bushes, valve bodies, wheels, pipes, connecting rods, hooks, gears and planet carriers. The implementation of numerical simulation on the daily manufacturing process design has allowed interesting achievements about material usage and quality prediction. Furthermore, it allowed an easier process development for brand-new parts, where the company had limited knowledge and which would have required several real tests.

Abstract

The goal of this presentation is to illustrate varied examples of FORGE® NxT 1.1 capabilities in order to have a better knowledge of the software. Therefore the analysis of your results becomes easier and you can get more benefits from its use. The main covered topics are the following: Use of reverse marking grid to optimize preform, Automation of repetitive result analysis, Damage modeling & analysis.

Abstract

Felb Srl has been established since 2006 from a demand of the market for medium weight forgings up to 10 tons, with high production flexibility due to the small batch size. This presentation introduces the experience of a SME during the introduction of Forge FEM forming simulation tool for the development of a new shaped ring rolling processes. The technical and economical benefits achieved by the new approach will be highlighted.

Abstract

This presentation introduces FORGE® product roadmap together with the main guidelines on Transvalor strategic axis of development. Thus, the forthcoming evolutions on the graphical user interface are detailed and the updates related to the ongoing developments upon heat treatment and microstructure are presented as well. A special focus is also given to the recent industrial key-partnerships such as the ones upon induction heating. Finally, the mid and long term research activities will be exposed confirming the deep-rootedness of Transvalor software in R&D.