FEA Projects

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Mechanical engineering analysis on a broad range of clamps and hooks used in the auto body repair industry. These clamps often involve multiple parts with contact behavior between highly stressed components. Stress analysis results are used to guide product development and optimize the tool design for weight and biometrics. Not only must the tool have a high strength to weight ratio, it must also fit comfortably in the hand of the user. All stress results are verified on production prototypes. Outstanding correlation between FEA results and tool load carrying capability has been demonstrated over seven years of product development. Modeling notes: FEA models are routinely created from complex sculpted Pro/E geometry files.

A plastic throttle pedal assembly structurally analyzed using the finite element analysis method. A free body diagram was developed to map the force transfer between the pedal arm and the body components. FEA was then performed on each separate part. By performing this analysis as a piece-part job, it was not necessary to implement a nonlinear contact algorithm allowing the analyses to run efficiently and quickly. Modeling notes: FEA models were imported from SDRC I-DEAS iges geometry.

Research program into the application of fracture mechanics toward the fatigue crack growth prediction of cast components. Leveraging experimental fatigue crack growth data provided by the company, fracture mechanics principles were applied in the analytical and FEA calculation of stress intensity factors (Kic). These stress intensity factors were then used to predict fatigue crack growth based on a modified Paris Law crack growth model in experimental castings. A three-dimensional (3-D) crack growth FEA model was also developed to extract full-field crack growth information. The final report showed good correlation between analytical and experimental life-cycle predictions.

Structural analysis to optimize the world 
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xs first 100% plastic house and foundation. Finite element analysis was performed on the roof, walls, and foundation structural components. Analysis challenges were found in accurately capturing the large deflection, stress-stiffening behavior of the roof structure and in developing an accurate foundation model. The foundation was particularly tricky due to the non-linear contact between the simulated floor joist and ground connections. Analysis results are being used to drive the design process toward more structurally optimized shapes utilizing less plastic while achieving higher strengths. Insights gained during this modeling effort show that extrusions will work as well as pultrusions for most continuous shapes.

fMulti-component FEA model of a ultrasonic transducer head for a medical equipment start up company. The model included the PZT ceramic transducer, foam backing, brass support structure and a polyethylene cap. Stress and deflection results were obtained based on pressure loading across the face of the transducer head. Based on material property data for the PZT ceramic, the transducer head was certified for manufacturing.

fModal frequency analysis performed on an optical thermal imaging pod used by major aircraft and helicopter manufacturers. The assembly included a mixture of aluminum castings, forgings, and electric sub-assemblies. The analysis model was then excited through a sinusoidal sweep under a prescribed acceleration loading. Harmonics were identified within the structure and compared to experimental shaker table results. Good correlation was shown between the FEA and shaker table results. The final report substantiated that the internal electrical components of the pod would be relatively unaffected by external harmonic excitation.

A broad range of analyses techniques used to virtually engineer stoker grates and their sub-assemblies for the world 
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xs largest manufacturer of these critical components within power generation furnace boilers. Stoker grates sit underneath almost every power generation boiler in the world. Their purpose is to support the fuel load (coal, wood chips, food processing waste, etc.), to provide a combustion air stream, and finally, to remove the burnt residue (ash). Vibrating the ash transport mechanism is the massive stoker bed via an oscillating drive. Structural issues arise due to vibration harmonics and temperature induced stresses. Direct transient finite element analysis was used to investigate piping stresses within the stoker grate. Models were built for the complete range of stoker grates using a complex medley of plates, beams, and spring elements. All of these models were subjected to direct transient, direct frequency and modal frequency dynamic analyses. Results from this work were used to optimize the stoker designs and to ensure extended service life. Additionally, thermally induced stresses in large castings were also investigated. Residual stresses arising from thermally induced plastic deformation were found to significantly affect the structural performance, and design changes were implemented in these castings.

Physics based kinematics model of impact hammer used to pulverize coal. Dynamic derived forces were then used to structurally optimize a wear-resistant impact hammer. The goal was to lower the stresses in the hammer allowing the use of a more abrasion-resistant cast iron. Design optimization through the use of finite element analysis facilitated the development of a novel impact hammer using an A-R cast iron that was hitherto unthinkable. A fracture mechanics assessment was also included as part of this investigation.

Forensic FEA work performed for a major supplier of after market auto parts. A complete suspension module was idealized into a finite element model to allow the correct application of torsional boundary conditions to the sway bar component under investigation. Plate elements were used to model the rear sway arms while solid elements were used to allow the construction of a detailed model of the welded sway bar structure. The two FEA structures were connected together using rigid links and spring elements to simulate the coupling affects of bolts and rubber bushings. FEA results were used to validate new designs and to optimize the final design candidate. Field testing validated the modeling results and the part is now in production.

FEA services provided to the world 
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xs market leader in the manufacturing of large, complex, high-quality structural investment castings for the aerospace market. A very large complex investment casting model was analyzed for structural integrity. The wax pattern was modeled using tetrahedral elements with the investment shell modeled via a surface skin of shell elements. The assembly was then supported through risers and stiffeners attached to a steel platform. This complex assembly was then evaluated under multiple loading conditions. Stress results allowed greater confidence in the integrity of the final production casting.

FEA modeling and optimization work to develop the next generation of Stekel mill coiling drums. Stekel mills are gaining in popularity as a cost-effective alternative to multi-stand steel mills for the production of high-grade plate and sheet steels. A coiling drum is subjected to high stresses and high temperatures as it coils thick plate during the reversing Stekel mill operation. This project work was performed for a large industrial casting operation and it end user steel mill client. Several designs were virtually evaluated for high temperature deflection and strength characteristics. At the end of many design iterations, a new interior rib design was developed that provided 2x greater stiffness and lowered notch stresses at the slot opening. This coiling drum is now in service and performing as designed.

Aircraft landing gear slider. Finite element analysis was performed on a landing gear structure for a major aircraft landing gear manufacturer.? Aerospace analysis work requires extreme attention to model construction, mesh quality, and analysis documentation procedure. The engineering idealization of the landing gear part was not trivial. To correctly account for contact behavior between the parts, gap elements were extensively used. With the employment of gap elements, the analysis procedure becomes nonlinear. Typically this is not a hindrance but due to the models large size (approximately 600,000 DOF) run time was a significant factor in the model 
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xs construction.