George Laird's blog

Cooling Analysis of Composite Mandrel using STAR-CCM+

STAR-CCM cooling analysisModern jet engines are getting bigger and also lighter. For example, years ago it was common to use titanium or stainless steel as blade-out containment materials. These large diameter and thick rings can now be replaced by modern carbon fiber composites; however, manufacturing large diameter composites with tight tolerances is difficult. One of the key challenges is maintaining tight tolerance during heating (curing) and cooling (mandrel removal) process. In a recent CFD project for a Tier 1 aerospace manufacturer, we used STAR CCM+ to simulate the thermal-flow process of cooling the composite mandrel down to room temperature. STAR was particularly suited for this project given its advanced polyhedral meshing technology coupled with a fast MPP thermal-flow solver (High Performance Computing (HPC)). Results in this CFD consulting project were verified against prior experience and hand calculations.
 

A Roadmap to Linear and Nonlinear Implicit Analysis in LS-DYNA

Below is a condensed presentation of our paper "A Roadmap to Linear and Nonlinear Implicit Analysis in LS-DYNA" that we presented at the 11th International LS-DYNA User's Conference in Salzburg, Austria on May 9-11, 2017.

Here's the Abstract: The default LS-DYNA settings are tailored for running large explicit analyses. For new and even experienced users, it can be challenging setting up an implicit LS-DYNA analysis to match analytical solutions or other standard implicit FEA codes. For example, the default element formulations are based on single-point integration whereas implicit analyses benefits from full-integration. A series of example problems are provided that will allow the simulation engineer to exactly match industry standard implicit codes (complete keyword decks can be found at DYNAsupport.com). Along with these example decks, CPU-scaling results will be presented for each implicit analysis type from linear to nonlinear.

We hope you enjoy it as well as our soundtrack selection.

Coupled CFD and FEA Project Work

CFD and FEA services are our core business and have been for more than 20 years. We are broad generalists in the consulting services business and our differentiator is experience.

Recently we just completed a coupled computational fluid dynamics (CFD) and finite element analysis (FEA) project on a "Power Augmentation" device that fits onto an existing 60kW gas turbine. The energy physics of this device is to spray water droplets into the inlet of the compressor side of the turbine, thereby increasing the mass density of the already 100% saturated air. This air-water mixture is then combusted with increased gas flow, yielding a 10 to 15% boost in energy output from the turbine. In other words, one can take a 60kW turbine and turbocharge it to ~70kW at no more than 1% of the original turbine cost.

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