Structural Mechanics Simulation with FEM

The static structural analysis of the plastic clips considers four load cases: Case Assembly/Case, Clip Pull-out, Case Assembly/Seat, and Case/Seat Pull-out. By applying a static, linear, and nonlinear simulation, the stresses and deformations during use were evaluated. The deformation and Von Mises stress fields, as well as the forces and moments to be determined, along with the Force-Displacement and Stress-Displacement curves, were provided to the client.

The analysis aimed to determine the structural dynamic response of the “Battery Pack” to a frequency-variable base acceleration. The FEM model provided the natural frequencies of vibration, maximum displacements and stresses for each axis, as well as the force response adapted to fixed boundary conditions. Modal, spectral response, and random vibration analyses revealed that the maximum displacement occurred in the Z-direction, particularly with dampers.

The simulation aims to predict fatigue life and validate the numerical model (without and with a cap) through static physical tests, including bending tests in open and closed positions. The modeling includes the cap fixation, study with shell elements, and modeling of welds and their effects. The validation of the numerical model was also conducted from a fatigue perspective using the Dang Van method as an acceptance criterion. Additionally, the “submodeling” technique is introduced for detailed and in-depth studies.

The objective of the simulation is to verify the mechanical strength of the steel bogie design by finite element analysis (FEM), following UIC 510-3, EN 12663 standards, and allowable fatigue stresses. The studied situations are exceptional loads, dynamic forces, and a fatigue test. The bogie frame in P265GH meets the strength criteria and shows a lifetime exceeding 1e7 cycles.

The goal of this simulation is to determine the structural stability of the DVD. The Ansys model was verified and recalculated without noticing any manipulation in terms of FEM discretization, material properties, boundary conditions, and post-processing results. Furthermore, based on the results of the structural analysis, it was concluded that the DVD operates within a slightly safe mechanical stress margin.

This analysis aims to determine the stability of a component subjected to dynamic loading. The numerical model was used to assess the vibrational responses at different frequencies and amplitudes. The results showed critical areas in terms of maximum stresses, requiring adjustments to improve the component’s performance and safety under real-world conditions.

In the automotive painting process, the body-in-white with the e-coat applied passes through an oven to dry the paint, cure the aluminium alloys, dry the adhesives and spread the foam. Strict standards ensure a uniform temperature to prevent defects or distortion. However, excessively high temperatures or steep gradients can damage the paint and cause thermal stresses, especially in aluminium-steel composites. These stresses are likely to exceed the material’s limits and cause permanent deformation, all within the limited time available to ensure efficient, high quality production.

Large photovoltaic systems on flat roofs have to meet strict criteria, not least wind load. No screws are used to ensure watertightness, and structures with horizontal bracing compensate for lateral forces. Vertical lifting forces are balanced by the system’s own weight, without exceeding the capacity of the roof structure. By eliminating the addition of excessive mass to avoid overloading, the system must be designed to withstand the wind at a competitive cost, ensuring efficient and economical power generation.

Richard AG develops and manufactures circuit breakers, contactors, insulators and fittings for railway power supply worldwide and provides service and support for the railway industry and transport. One of Richard AG’s main objectives is to respond flexibly to individual customer requirements. Avoiding damage due to corona discharges and electrical failures is essential to ensure robust operation in vacuum circuit breakers. A numerical simulation using ANSYS Workbench was carried out to validate the design of the operating conditions according to the customer’s specific requirements.

The Kopter Group was founded to develop, build and support a new generation of composite turbine-powered helicopters. With this industrial vision, Kopter Group has developed the SH09, guaranteeing the operator superior operational performance, safety and durability. A modern helicopter requires a large number of high frequency (HF) systems for communication and other applications. Malfunctions caused by electromagnetic interference (EMI) from the various HF systems must be avoided.

In the development of home appliances, the Internet of Things (IoT) is essential for BSH Hausgeräte GmbH to maintain a competitive edge. Versatile, compact communication modules are designed to operate reliably in a variety of locations. Dual-band WLAN antennas integrated on the PCB require wide impedance matching to ensure acceptable performance in a variety of environments. As processing requirements increase, so do clock frequencies and digital data rates, affecting power distribution networks and the integrity of high-speed bus signals on the PCB.

Hearing aids with integrated transducers offer hearing-impaired people greater comfort in public places such as theaters and churches. An electromagnetic signal generated by a loop in the floor (hearing loop) is picked up by a telecoil. The hearing aid itself usually also emits electromagnetic fields. These superimposed fields pose a challenge in terms of integrating the telecoil into the device, which must be electromagnetically robust. The main aim of the study – in addition to validating the model – was to characterize the influence of the shape of the battery springs and PCB tracks on the telecoil’s output signal through virtual electromagnetic experiments.