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Huntsville, United States

Guo J.,ESI U.S. R&D | Scott S.,ESI North America Inc. | Cao W.,CompuTherm LLC | Koser O.,Calcom ESI SW
JOM | Year: 2016

Integrated computational materials engineering (ICME) is becoming a compulsory practice for developing advanced materials, re-thinking manufacturing processing, and engineering components to meet challenging design goals quickly and cost-effectively. As a key component of the ICME approach, a numerical approach is being developed for the prediction of casting microstructure, defects formation and mechanical properties from solidification to heat treatment. Because of the processing conditions and complexity of geometry, material properties of a cast part are not normally homogeneous. This variation and the potential weakening inherent in manufacturing are currently accommodated by incorporating large safety factors that counter design goals. The simulation of the different manufacturing process stages is integrated such that the resultant microstructure of the previous event is used as the initial condition of the following event, ensuring the tracking of the component history while maintaining a high level of accuracy across these manufacturing stages. This paper explains the significance of integrated analytical prediction to obtain more precise simulation results and sets out how available techniques may be applied accordingly. © 2016 The Minerals, Metals & Materials Society

De Alba Alvarez R.O.,University of Southampton | De Alba Alvarez R.O.,ESI North America Inc. | Ferguson N.S.,University of Southampton | Mace B.R.,University of Southampton | Mace B.R.,University of Auckland
Finite Elements in Analysis and Design | Year: 2014

A finite element spot weld is proposed. The model is only weakly sensitive to element size, in contrast to some existing models, for which predictions of the static and dynamic responses can be strongly sensitive to the size of the elements in the substructures to which the spot weld is connected, to such an extent that numerical results may not converge. The proposed model comprises a number of multipoint constraint connections to the attached substructures, so that they may have incompatible meshes. It involves stiffness elements distributed around the perimeter of the spot weld. The case of two plates connected by three spot welds is considered. Numerical results are presented and compared with those of CWELD models and with experimental measurements. The results from the proposed spot weld model show good accuracy, low sensitivity to the element dimensions and good convergence properties. © 2014 Elsevier B.V.

Vaz I.,ESI North America Inc. | Washburn K.,John Deere Moline Technology Innovation | Devries L.,John Deere Worldwide Product Development
SAE Technical Papers | Year: 2011

An existing system-level Statistical Energy Analysis (SEA) model of an enclosed operator station (cab) for a combine-harvester was improved through component-level analyses using Finite Element (FE) and hybrid FE-SEA methods. At mid to high audio frequencies, airborne transmission of machine noise is a dominant path for the cab. An SEA model was created for the cab using the VA One product. When model results were validated against experimental data derived from three idealized insonification load cases, the original model did not compare well with the measured data. The structural panels used in the cab feature various non-uniform cross-sections and varying radii of curvature. The former are not appropriately modeled with standard beam stiffeners, and the latter must be accounted for by some average curvature. Geometrically accurate Finite Element (FE) models of the panels were employed to estimate parameters including effective material stiffness, and effective material density. Further, hybrid FE-SEA modeling was employed to estimate panel radiation efficiencies and account for non-uniform curvature. Using the corrected parameters, the improved SEA model compared well with measured data; it can be used with confidence to predict cab interior sound levels for different field load cases, and to explore noise control treatments. Copyright © 2011 SAE International.

Connelly T.,ESI North America Inc.
SAE International Journal of Materials and Manufacturing | Year: 2013

SEA models are used to predict the performance of acoustic packages when assessing the performance of vehicle level or body noise reduction targets. One of the challenges faced by CAE engineers is the ability to estimate the performance of different materials used in the sound package at the design stage. Analysts can use measured data in the form of insertion loss and random incidence absorption if available or can predict the performance of materials using a Biot type description. The use of the full poro-elastic Biot model for materials requires knowledge of the fluid and elastic properties, however a limp or rigid model can be used to describe the material based only on the fluid properties and this is often sufficient to describe fibrous materials. In this paper a method will be outlined which will allow the material properties of fibrous materials to be estimated from basic normal incidence data that is provided by material suppliers. This approach will then allow the effect of compression on the material properties to be predicted and the impact on the acoustic performance to be estimated. In addition it will allow the analyst to estimate the effects of increasing or reducing the fiber weight. Predictions will be compared with measured data. © 2013 SAE International.

Iqbal O.,Chrysler Group LLC | Arora K.,Chrysler Group LLC | Sanka M.,ESI North America Inc.
SAE International Journal of Engines | Year: 2014

Accurate numerical prediction of an engine thermal map at a wide range of engine operating conditions can help tune engine performance parameters at an early development stage. This study documents the correlation of an engine thermal simulation using the conjugate heat transfer (CHT) methodology with thermocouple data from an engine operating in a dynamometer and a vehicle drive cell. Three different operating conditions are matched with the simulation data. Temperatures predicted by simulation at specific sections, both at the intake and the exhaust sides of the engine are compared with the measured temperatures in the same location on the operating engine. Copyright © 2014 SAE International.

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