| IDAC Consulting Case Studies |
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Hayward Tyler
CFD and Structural FEA Analyses on a Pump Case
Hayward Tyler was required by their client to provide a pump casing which was able to withstand a temperature increase of 56ºC in 3 seconds. The casing was for a 500MW double discharge pump used to circulate water into a boiler, being used in the power generation industry.
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Cathelco Ltd
Dynamic Lift Analysis
Cathelco is the world leader in Seawater Pipework Anti Fouling (AF) and Impressed Current Cathodic Protection Systems (ICCP). Cathelco required IDAC to carry out a dynamic analysis of an enclosure containing a Transformer Rectifier (TR) Unit. All equipment being lifted must have design calculations carried out which take into account a Dynamic Amplification Factor (DAF) to cover all global dynamic load effects.(More)
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IDAC conducts a 3D Design Optimisation
of a Wind Turbine Blade using ANSYS CFX and DesignXplorer
IDAC carried out CFD analyses to optimize a blade design, in order to increase the torque being applied on the blade at a specific rotation speed, hence increasing the power output of the wind turbine. (More)
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AMEC
Buckling Analysis of a Condensate Storage Tank
IDAC carried out structural FE analyses, using ANSYS, of a condensate storage tank design incorporating the frangible roof joints. The objective of the analysis was to evaluate whether, or not, the roof/curb joint would fail before the floor/wall joint. (More)
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Piper Test and Measurement Ltd & Siemens AG
Optimised Design of IPP Drive Support Structure
Piper Test and Measurement manufactures engine test systems incorporating its own range of dynamometers for specialist industries. Their instrumentation is comprehensive & ranges from simple analogue to full computer based data acquisition systems. This case study describes the design and analysis of a support structure for a braking system that was used for a huge flywheel generator. The flywheel generator was designed as a motor generator unit used by the Max-Planck-Institut für Plasmaphysik (IPP) in Garching, Germany, to provide a considerable amount of power for their experiments. (More)
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D J Goode
Blast Vent Panel Explicit Dynamics Analysis
D J Goode & Associates Ltd (DGA) is a leading firm of consulting engineers, specialising in Blast and Ballistic effects on buildings and other structures. In recent times the need to protect ourselves from the hazards of explosive or ballistic attacks, either as a result of an accident or terrorist activity, has increased. This has led to the development of a number of products to help resist blast pressures, which often require analysis using advanced finite element modelling techniques. IDAC were required to demonstrate how an explicit dynamic analysis could be carried out on a model of a steel vent panel made using pressed steel sections, and being subjected to an internal blast load. (More)
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Whittaker Engineering
Static and Impact Structural Analysis of a Deployment Skid
A Deployment Skid is a frame which is used to lift equipment from a vessel onto a rig. The Deployment Skid analysed in this project was required to lift Subsea Control Modules (SCM) and Module Running Tools (MRT). Both the SCM and MRT contain electronics, instrumentation and hydraulics, so it is imperative that they are transported safely with minimum displacement . (More)
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Nova Design
Linear & Nonlinear Static Analyses
The work supplied by NOVA, often at short notice, presented IDAC with many challenges in terms of logistics and flexibility due to the quantity of work. Simon Parry of Nova Design says "IDAC have been able to provide NOVA with a consistently high quality service providing a quick turnaround for the analyses they have carried out. Our satisfaction with the results and service provided by IDAC has ensured our return custom time and time again". (More)
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Atkins Process Limited
Induction Heating of Steel Pipe
As one of the world’s leading engineering and design consultancies, Atkins applies and delivers technical excellence across the lifecycle of oil and gas facilities. Its proven experience allows the company to serve a diverse range of industries, including oil and gas, chemical and pharmaceuticals, semi conductors, steel, iron and cement. (More)
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Laminated Rotor Design Optimisation
IDAC were required by their client to carry out a prototype design investigation of a laminated rotor to be used in an automotive hydraulic steering system in a car. A series of analyses were carried out on various rotor designs. The client was provided with results of analyses carried out on many design and loading combinations (More)
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Conrod
Automated Optimisation of Connecting Rod
IDAC were required by their client to develop automated macros to carry out design optimisation of connecting rods using the ANSYS program. Due to market competitiveness it was important for the client to be able to produce an optimised preliminary design (with a minimum weight in as short a time as possible). The objective of the work was to develop a customised procedure for the client to carry out rapid optimisation of preliminary connecting rod designs. The optimisation procedure was performed in three phases (More)
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AB Electronic
Structural Analysis of Clip Assembly
IDAC were required by AB Electronic to carry out an FE analysis on a new design of a clip to be used in the automotive industry. The reliability of the new design and the flexibility of the components within the clip assembly were to be determined. In order to check the reliability of the clip the assembly load had to be established. An assembly load in the region of 50N was required for optimum usability. (More)
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Nexus
Escalator Step Analysis
Nexus’s plans include a £600m project to modernise the Metro, to create a network of Superoutes with modern accessible buses running on the main traffic corridors, and speeding journey times into the urban centres of Newcastle and Sunderland.
IDAC were required by Nexus to carry out an FE analysis to determine the stress levels and fatigue life of 2 step designs, in accordance with BS EN 115: 1995. Finite element analyses were performed to test the escalator steps under a range of working loads, including passenger and torsional loading. Fatigue assessments were then carried out. (More)
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Noel Village (Steel Founder) Ltd
Stress & Fatigue Analysis of a Rope Thimble
Noel Village required an evaluation of the structural integrity of a new Thimble design and as such commissioned IDAC to conduct some non-linear structural analyses of the Thimble design. The thimble was subjected to the minimum breaking load (MBL), a fatigue load case and a Stern Roller load case via a synthetic fibre rope. The analyses were conducted as structural static analyses with nonlinear contact behaviour. (More) |
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Glenfield Valves
Valve Vibration Analysis
Established in 1852 Glenfield Valves is one of the most experienced valve manufacturers in the world. Major investments into Glenfield Valves Ltd during 2005 and 2006 have ensured that they are able to meet ever increasing requirements from the Global Water Industry. Upon review of the analysis, it was agreed that the valve itself was not to blame for the vibrations experienced while in operations. The advantage of using FEA simulation showed that by removing human handling and operational/installation errors, the valve would perform as required. (More)
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Quintas and Quintas Offshore
Structural Analysis of a Rope Spool Assembly
The objective of the finite element analysis was to investigate the structural response of the assembly under the minimum breaking load (MBL) of the rope. This allowed the most critical locations, stresses and strains in the spool to be identified for the structural and fatigue assessments. (More)
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Stannah Lifts Ltd
Structural Analysis of a Shaft Lift Structure
Stannah Lifts Ltd required a lift shaft structure originally designed for hydraulic lift to be reused in a traction lift.
IDAC were required to investigate the structural response of the assembly subjected to these new loading conditions.(More)
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ERIKS
Structural Analysis of a Temporary Access Platform
ERIKS provide engineering solutions for a diverse range of industries such as Aerospace, Quarrying, Pharmaceuticals and Railways.
IDAC were required to carry out a linear structural analysis of the access platform and check the safety factors. IDAC created two 3D models of the platform in AutoDesk Inventor CAD system to represent two configurations of the platform; legs forward and legs back. The geometry was simplified to remove any small features that were ...(More)
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Nuvia Ltd
Dynamic Analysis of Irradiated Fuel Containers
The aim of this analysis was to determine whether an accidental drop of the assembly would cause a loss of containment of the payload from the system. As the analysis shows, the design is safe such that there would be no leakage in a real world situation similar to the boundary conditions. In conducting a Drop Test analysis using FEM, Nuvia were able to validate their new design which should be going into production by the end of the year. Using ANSYS allowed Nuvia to create an iterative design that could be tested and yield results within a week itself.(More)
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First Subsea
Indentation Vs Torque Investigation
IDAC has carried out several analyses for First Subsea on various tools that have been designed by them. The analyses provide the design engineers at First Subsea with confidence and insight into the performance of new designs. This research has enabled First Subsea to be able to more precisely specify loading capability of special tools that are require to perform outside normal operating conditions, making First Subsea more responsive to its customers needs, maintaining its place as a world leader in ball and taper lifting technology...(More) |
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South Midlands Communications Ltd
Macro Development for a Structural Analysis of a Telescopic Mast
Established in 1958, South Midlands Communications Ltd (SMC) initially specialised in antenna support masts, towers and HF antennas. SMC is now recognised globally as a specialist communications enabling company.
IDAC have created an ANSYS application for SMC enabling their Engineers and Project Managers to run full and rapid three-dimensional nonlinear structural analyses, by.. (More)
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Whittaker Engineering
CFD Design and Analysis of a Gas Damper
Founded in 1983, Whittaker Engineering provides in-house manufacturing, engineering design and analysis for the offshore oil and gas industry.
IDAC were contracted to verify and modify the design of the outlet nozzles by using CFD techniques. The work was carried out in two parts as follows... (More) |
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Cussons Technology Ltd
Sway Carriage Analysis
Established in the late 1800's, Cussons Technology Ltd is today one of the leading manufacturers and suppliers of industrial and educational test equipment spanning Marine Hydrodynamics Research, Automotive Research and Development sectors and Engineering Training & Education.
Cussons Technology required IDAC to evaluate the design of the sway carriage assembly using finite element analysis (FEA). The analyses were carried out using the FEA software suite ANSYS Workbench. (More)
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Hussey Seatway Ltd
Deflection and Vibration Analysis of Auditorium Seating
Hussey Seatway Ltd. is a British company producing telescopic and fixed seating for auditoria, stadia, arenas and lecture theatres.
Their expertise in fixed and telescopic bleachers and retractable seating solutions has enabled them to provide a range of seating products to accommodate various audience seating requirements conforming to various worldwide standards including British Standards, and Fire Retardancy specifications.
IDAC were required to analyse the structural integrity of the seating system in accordance with the deflections and vibrations criteria as specified by the National Building Code of Canada 1985.
The 3D geometry of the seating system, comprising of the units (More)
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Whittaker Engineering
Design and Analysis of a North Sea FPSO Turret Rail Repair Scheme
Founded in 1983, the last 25 years has seen Whittaker Engineering develop into a respected and reliable contributor to the North Sea oil industry, specialising in the design, manufacture, installation and maintenance of FPSO turret turning systems.
IDAC were required to provide FEA work in order to verify the repair scheme. Three different phases to this work were considered... (More) |
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First Subsea (formerly BSW Ballgrab)
Structural Analysis and Fatigue Assessment of a Subsea Mooring Line Connector
The UK's leading supplier of subsea connection systems.
IDAC and First Subsea have worked closely together on a number of projects covering a wide range of designs and load cases. The use of FEA allows First Subsea to not only optimise their designs but to also prove their load carrying capacity and fatigue life. These FEA results have been confirmed by in house physical testing of the connectors....(More)
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HBL Ltd :
Impact Analysis of a Golf Ball
HBL Ltd was a small self-funded company set up by Iain McCreary and Rani Osnat, with intellectual property contributions from Qinetiq, and engineering support from Plextek Ltd. HBL's intent was to provide real time, three dimensional tracking of golf balls in flight, giving accurate feedback on speed, spin, shot shape and curvature, in-air and on-ground distance.
HBL requested that IDAC predict the impacted behaviour of a golf ball containing a wide-band microwave transmitter unit. The impact analysis would be used to answer four sets of questions: 1.) How do golf balls behave under impact? ... (More)
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Metso Minerals :
Rotary Railcar Dumpers Analysis
Metso Minerals is a leading global supplier of equipment, services and process solutions to industries including quarrying and aggregates.
Designing dumper barrels with finite element analysis (FEA) software allows Metso Minerals engineers to evaluate high-stress areas prior to manufacture for optimum fatigue life thus improving productivity (More)
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WSP Enviromental :
Evaluation of wind comfort levels around building developments
When planning a new development, designers need to understand the local wind environment and what impact, if any, it will have on pedestrian comfort and safety.
IDAC have automated the analysis procedure so that new geometry supplied by WSP can be input very quickly and there is a quick turnaround of results. As such, IDAC have been able to carry out a great many of these analyses for WSP Environmental and they have proved to be a very valuable design tool. The analyses are quick and cheap compared with (More)
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HITEC :
Satellite Antenna Structural Analysis
IDAC was tasked with conducting a Linear Static Structural Analysis of two satellite antennas for HITEC. Both designs, namely VINA and GTTC, are built with the purpose of ground tracking the European version of the GPS constellation.
Using a combination of ANSYS Classic and Workbench interfaces, IDAC was able to deliver a design that maximized strength, while minimizing the overall weight under different loading conditions. At the end of the project, IDAC had the ability to provide a complete solution from model generation to post processing (More)
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National Physical Laboratory :
Parametric Calibration Analysis of an Atomic Force Microscope
The Atomic force microscope (AFM) is a very high resolution-scanning microscope and is used at NPL laboratories for imaging the surface of materials in the micrometer to nanometer length scales.
IDAC created a parametric model using ANSYS where the AFM probe was modelled by means of 8- noded 3D elements with large strain large deflection capability. The top surface of the cantilever was then coated with 4 noded shell elements to simulate the 30-50 nm thick layer which coats the device. The effect of the..... (more...) |
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LB Bentley :
Nonlinear Structural Analysis of a
Small Bore Subsea Gate Valve for LB Bentley Ltd
IDAC were contracted to to validate and assist in the development of a new metal seal that would set new
precedents in terms of product performance. (More...) |
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Alvis Vickers Ltd:
MRAV Full Vehicle Driving, Transportation and Recovery Analyses
IDAC were contracted to assist in the analysis of the MRAV.
The object of the analysis was to determine the suitability of the vehicle structure for some 75 load cases to simulate the operational loads that are applied to the vehicle (more...) |
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Expro North Sea Ltd.:
Nonlinear Structural Analysis of an Open Water Lubricator Valve
Jamie Walker, Expro Design Engineer who assisted
with the FEA Section of the project at Expro,
commented. “The speed of the response, the helpful
and professional attitude shown by idac on this
project was extremely appreciated by ourselves and
our client. The results that were produced by performing this analysis saved months of physical testing to
‘fine-tune’ the design in order to satisfy the needs of our client. Subsequent testing utilising strain gauges
provided results that correlated very closely with the analysis.” (more...)
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Mabey Hire:
Buckling Analysis of a Temporary Strut Support
Creation of a bespoke macro to calculate the buckling loads of
temporary strut supports, allowing many configurations and design
options to be investigated (more...)
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DePuy:
Structural Analysis of Replacement Knee Design
Analysis project undertaken by IDAC to investigate two sizes of
a replacement knee design at different angles of articulation using
the general purpose finite element software ANSYS (more...) |
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Whittaker Engineering:
Gypsy Wheel Structural Analysis
“Our new design had to withstand the same possible failure mode plus another failure mode which had not
been previously accounted for. The solution was impossible to load test safely and difficult to analyze
precisely by conventional hand calculations but IDAC, in their usual friendly and knowledgeable way,
worked with us until we were able to produce an engineering package which was acceptable to the Ship's
certifying authorities; we manufactured and installed the eight new chain gypsies and they are currently in
service in the North Sea.” (more...) |
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CCM Motorcycles:
Headlamp Mounting Analysis
Analysis project undertaken by IDAC to investigate the design and
support capability of a load far in excess of the load that would
be expected in normal service (more...) |
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Blazepoint
Drop Test Analysis of an AVANTIX Mobile Chip and Pin Machine
This month IDAC are highlighting the use of a Drop Test Analysis on a Mobile Chip & Pin Machine. The Advantix Mobile, which has been designed for issuing tickets whilst on the move, needs to be very robust and reliable. As such there is a need to verify that if the ticket collector drops the handheld device it would continue to work. See how IDAC and the use of ANSYS FEA software resulted in significant cost and time-scale saving. (more) |
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Capoco Design:
Side Impact Analysis of a Passenger Bus
using ANSYS/LS-DYNA
Analysis project undertaken by IDAC to evaluate energy
absorption and intrusion during a side impact of a passenger bus
(more...) |
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British Petroleum (BP):
Pig Analysis
This analyses allow BP to investigate loading
scenarios without having to construct additional
expensive test facilities. For
example, they have been used
to determine the largest feasible
load that would be experienced
by the pig, so that an equivalent
drop test of the pig may be
performed to verify its integrity. (more...)
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Martin Baker:
Sikorsky S-92 Armoured Crew Seat Analysis
Analysis project undertaken by IDAC to investigate
the structural behaviour of an armoured crew seat for the Sikorsky
S-92 helicopter (more...) |
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Whittaker Engineering:
FPSO Turret Rail Gripper Analysis
Analysis project undertaken by IDAC to assess the effect of design
changes on an FPSO anchor turret gripper (more...) |
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Bridon International:
Contact Analysis
Validation project undertaken by IDAC to perform a
non-linear structural contact analysis of cast sockets for steel
ropes. (more...) |
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Britten Norman:
Buckling Analysis
Aircraft Fuselage Buckling Analysis using ANSYS (more...) |
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Depuy:
Non Linear Contact Analysis
Insertion of a Duraloc Un-cemented Acetabular Hip
socket into the pelvic bone using ANSYS (more...) |
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Senior Flexonics:
Structural Analysis
60 inch, Stainless Steel Expansion Joint - Thermal & Structural
Analyses with ANSYS (more...) |
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UCL - Optical Science Laboratory:
Thermal Transient Analysis
Thermal Transient Analysis of a High Resolution Optical
Spectrograph using ANSYS. (Details advantages of using the powerful
ANSYS Parametric Design Language). (more...) |
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W T Henley:
Design Optimisation of Plastic Holding Tool
Optimisation project undertaken by IDAC to perform a structural
analysis and design of a plastic holding tool design, for W T Henley
Ltd. (More) |
| IDAC Consultancy Capabilities |
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2D model of a Vertical Wind Turbine
Velocity contour generated by the interaction between a rotating wind turbine and the wind. The simulation is made in Ansys Fluent and the flow field is obtained as a combination of a stationary domain and a moving mesh inside with a simple wind turbine model.
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Sloshing
Free surface movement of liquid fluid in a tank under an horizontal acceleration. The animation shows the interaction between the fluid and two baffle plates.
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Transonic Flow Around a 2D Airfoil
This animation shows the pressure of the flow field generated by a transonic flow around a 2D airfoil. To better capture the shockwave the Ansys Fluent mesh adaptation tool was used. Depending on a specific parameter (the pressure gradient, in this case) the mesh was refined only in some locations in order to improve the quality of the solution.
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Water Boiling
The animation shows a container of water at the temperature near the boiling point. The temperature of a portion of the bottom wall is above the water boiling temperature. Because of the heat transfer between the wall and the fluid, vapor bubbles form and rise due to the buoyancy. The vapor escapes through the free surface.
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Animation of a Multiphase Analysis Using ANSYS Fluent
Fluid flow using ANSYS Fluent software to simulate
liquid movement down through a pipe towards and filling a generic tank
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Modeling moving walls in CFD: Transient simulation with moving meshes
Consider the scenario where we want to know the flow field around two objects as they approach each other. Instead of keeping the model as a single domain, we can split the model such that each object is contained within a separate domain. Then in ANSYS CFX using Regions of Specified Motion, we can assign each domain a velocity V1 and V2, while also having them speak to each other via a Domain Interface. Read more |
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Fire Simulation and Risk Modelling
Fire engineering and risk assessment are integral parts of the design process within the Built Environment industry. Besides the obvious structural design, today's buildings pay special attention to designing a comfortable atmosphere for inhabitants, be it in terms of acoustic noise, sunlight or dispersal of dust particles exiting an air conditioning duct. Predicting temperatures and convection flow fields within an open plan office are typical engineering parameters that most designers are concerned with these days. In certain circumstances however, IDAC Ltd have been involved with modelling more severe scenarios such as fire and smoke dispersal. Read more |
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This ANSYS LS-DYNA analysis demonstrates that a scraper pig, which is used to clean oil and gas pipelines, can negotiate a check valve. The forces generated between the pig and the clapper and between the clapper and the valve body are also evaluated to check the integrity of the assembly. Other analyses also show whether elongated pigs can negotiate wye pieces. Read more |
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The top half of the window shows an electro-mechanical beam used as MEMS switch deflected by a differential voltage applied to the transducer elements underneath the switch. The movement is damped by air which flows through the two holes and the sides. The structural and fluidic problem has been solved using fluid-structure interaction (FSI) in ANSYS. |
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This is a parametric model of a woven composite fabric. This would be included in an ANSYS Composite Module. It represents a 2x2 unit cell twill fabric, which is the minimum repeatable unit of a fabric, made of fibres woven in two directions embedded in resin. |
| IDAC Featured Publications |
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Cad User Magazine - August/September 2007: Socket to me!
Picking up the thread with IDAC
IDAC uses Ansys/Mechanical 6.0 Finite Element Analysis software to validate Bridon Internationl's design for steel rope terminations, used to anchor offshore platforms
Bridon's Doncaster operation required a structural contact of some steel rope terminations for anchoring offshore plateforms before casting could take place. IDAC was engaged to perform the solid modelling and non-linear structural analysis of the designs. (More) |
| ANSYS and
DesignSpace Case Studies |
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Alcon:
Buckling Analysis
Well known for its racing brakes, Alcon Ltd has been tentatively
exploring the world of clutches. The fruits of these efforts is
a new range of racing units designed with the aid of ANSYS/DesignSpace. (More) |
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Siemens Power Generation:
'Up-Front' Turbine Structural
Simulation with DesignSpace
Rapid validation of design solutions is critical in the 'Refurbishment
of Steam Turbine' market. ANSYS/DesignSpace is used by Siemens to
optimise design performance. (More) |
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Tusas Engine Industries, Inc.
Tusas Engine Industries, Inc. (TEI) is a leader in developing and producing a range of high-quality aircraft engine parts for the worldwide aerospace industry. In developing the Tusas TEI-TJ-1X microjet engine used in unmanned air vehicle (UAV) applications such as target drones, the company needed to design a radial compressor impeller that was compact, lightweight and capable of reaching rotational speeds in the order of 100,000 rpm. Achieving such performance levels presented particular design challenges for Tusas engineers. (More) |
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GEALAN Formteile GmbH
Using Engineering Simulation to Design Technical Plastic Molded Parts
The entrepreneur-led GEALAN Formteile GmbH and its affiliated firms GEALAN CAXsolutions GmbH and GEALAN Czech s.r.o have designed and manufactured plastic parts for more than 20 years. GEALAN manufactures technical plastic molded parts and components for automotive and industrial applications that are designed to last over the entire lifecycle of the product or process.
"In order for our concept and product development teams to meet expectations - which include shorter development times, higher quality and lower manufacturing costs - it is of the utmost importance to use simulation techniques in the early stages of product design."
(More) |
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ALLCAD GmbH:
ANSYS MechanicalT, ANSYS WorkbenchT
As an ambitious engineering company, ALLCAD provides services in CAx
technologies and projecting of machine and plant manufacturing.
For its customers in mechanical and power engineering as well as automotive
and plant construction, ALLCAD supplies pre-coordination, development,
validation, design and documentation of individual parts as well as full plant
systems.
Companies use ALLCAD for its up-to-date knowledge, efficiency and consultant
capabilities for the customer's benefit... (More) |
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Pi Makina - Turkey :
Using ANSYS to easily accomplish design problems
Pi Makina has grown from a small company serving local needs to an international business delivering construction equipment all over the world.
As our business with other companies develops, customers today require higher quality products — in the construction world, that translates to more robust machines. In order to achieve this, we...(More) |
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Bühler Motor Group - Germany :
ANSYS MechanicalT
ANSYS EmagT ANSYS StructuralT
Bühler Motor Group is a global enterprise focused on developing and manufacturing sophisticated mechatronic DC drive solutions.
Prior to the first prototypes, methods
and processes are analyzed and
optimized.
The aim is to decrease time required
for design and development. (More) |
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Whirlpool Corporation SA :
Keeping Costs Down While Keeping quality High
Global competition in the appliance industry is placing ever increasing pressure on manufacturers to decrease costs while maintaining high quality. When Whirlpool Corporation looked to cut costs associated with producing a three-year-old, 450-liter double-door refrigerator, it needed to continue to meet the specific cabinet deflection and door drop limits of its current design; it also needed to maintain adequate cabinet stiffness (more) |
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Going With The Flow :
Predicting air flow in healthy and diseased lungs using CFD
Using computational fluid dynamics (CFD) combined with the data from a computed tomography (CT) scan aid in understanding the air flow in healthy and diseased lungs by simulating a virtual patient population. Flow patterns, relative pressure drops and drug delivery profiles are readily extracted from the simulation results. (More) |
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B.F.Goodrich:
Lightening the load on aerospace design
Reducing the weight of an aircraft lighting pod while 'keeping
an eye' on the vibrational characteristics of new component designs
with DesignSpace. (More) |
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London Eye:
Fast Track Structural Design of the London Eye
Ferris Wheel
Rapid lead time structural design of the British Airways London
Eye Ferris Wheel using ANSYS Finite Element Analysis Software. (More) |
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