Advanced Analysis Ltd

Best Virtual Engineering

Example PROJECTS

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Connecting Rod

Automotive, In-House
Powertrain

Stress, Fatigue

01


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Development of Python plugins to calculate and include loads from complete engine cycles with all inertia effects and (big | small end) oil film approximations.

Objectives

  • Calculation of high cycle fatigue of connecting rods.
  • Identify problem areas with finite life and recommend design modifications.

Solution

  • Advanced use of in-house dynamic load calculations and oil film modelling.
  • ABAQUS, FE-Safe, and complex material definitions.
  • Prediction of stress levels at every 1-degree crank angle throughout the engine speed cycle.
  • High cycle fatigue identifies areas with non infinite life.
Connecting rod and piston FEA

Engine Loads Software

In-House
Powertrain

Load Calculations

03


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AAL use MATLAB & SIMULINK to generate complete tailor-made calculation tools.

Objectives

  • Build a specific client tool for complex engine load calculations.
  • Build a user friendly graphical interface.
ENGLOAD software

Solution

  • Advanced use of MATLAB to generate a complete tailor-made calculation tool with a comprehensive graphical interface.
ENGLOAD software

Coolant CFD Analysis

Automotive
CFD

Thermal, Flow

04


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AAL use the tools AcuSolve and Converge to predict coolant steady-state or transient and in-cylinder transient flow.

Objectives

  • Water jacket flow optimisation, and export of data for thermal analyses.
  • Under-hood and external air flows.
  • In-cylinder transient flow with moving boundaries (piston, valves).
Water Jacket CFD

Solution

  • Advanced use of AcuSolve and Converge CFD packages depending on the application.
  • Investigate the system to gain a deep understanding and allow for design recommendation to improve flow and minimise fluid path losses.

Radar Systems

Defence
CFD, Wind

Flow, Wind Loads

05


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AAL use AcuSolve or ABAQUS/CEL to predict torques and force histories on radar systems under motion and wind loads.

Objectives

  • Predict torque histories on the antenna under different angle and wind scenarios.

Solution

  • Advanced use of AcuSolve (CFD) in the time domain with moving structures.
  • Detailed torque results were obtained for a large set of antenna angles and wind speed conditions.
  • CFD predictions help control system designers with realistic torque inputs for worst case conditions.
Wind Loads CFD

Cylinder Head Gasket

Automotive, In-House
Powertrain

Thermal, Stress, Sealing

06


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AAL has extensive experience in highly non-linear analysis of complex gasket designs. We have developed throught the years a comprehensive gasket modelling users guide for non-linear analysis.

Objectives

  • Calculation of sealant properties of head gaskets.
  • Perform a full non-linear analysis of mechanical and thermal cycle loads, to establish a settled state prior to a low and high cycle stress prediction.
Cylinder Head FEA

Solution

  • Advanced use of in-house thermal loads specification, ABAQUS and complex material definitions.
  • Identify areas of low gasket pressure.
  • Understand the reasons behind poor gasket sealing via identifying weak structural areas in the engine during cold and hot conditions.
Cylinder Head Gasket

Dual Tracking Motion Systems (DTMS)

Defence
NVH, Shock Wave

Stress, Vibration

07


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AAL use ABAQUS to simulate non-linear static and dynamics performance of complete (10m diameter) Dual Tracking Motion Systems (DTMS).

Objectives

  • Assess the integrity of critical metal and carbon fibre components.
  • Understand non-linear static and dynamic deflections in order to meet integrity and pointing accuracy targets.

Solution

  • Advanced use of ABAQUS in the time domain (modal superposition and/or non-linear transient) allows for detailed stress analysis due to dynamic loads.
  • Show the effects of non-linear assembly preloads in the dynamic transient response.
Dual Tracking Motion System

Cylinder Bore Distortion

In-House
Powertrain

Deformations

08


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AAL use Python scripting to automate the bore distortion post processing.

Objectives

  • Achieve low bore distortion when the engine is hot.
  • Identify cylinder bore out of shape concerns, which may revert into piston-cylinder poor performance.
Cylinder Bore Distortion

Solution

  • Advanced use of ABAQUS and in-house Python scripting to automate the bore distortion post processing.
  • Investigate the mechanics of the system to gain a deep understanding of the root causes for the cylinder walls distortion.
Cylinder Bore Distortion

Hybrid Systems

Automotive, In-House
NVH, Powertrain

Stress, Fatigue, Vibration

09


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AAL use Python scripting, ABAQUS and FE-Safe to automate comparisons to vibration measurements for different designs.

Objectives

  • Predict vibration induced durability.
  • Develop software to analyse and understand measured vibration data, and correlate to simulation.
Automotive Hybrid Systems

Solution

  • Advanced use of ABAQUS, FE-Safe and in-house Python scripting.
  • Analyse and understand measured data in terms of engine orders.
  • Gain a deep understanding of the mechanisms of failure including loading, damping and relevant mode shapes of the system.
Automotive Hybrid Systems

Automated Shape Optimisation

General
Optimisation

Organic Designs

10


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AAL use both ABAQUS and ALTAIR tools to optimise geometric forms, and generate ‘organic’ shapes.

Objectives

  • Optimise shape for best trade off of mass, stiffness, durability and/or dynamic response.
  • Generate new designs via organic shape concepts.
Topology Optimisation

Solution

  • Advanced use of ABAQUS or ALTAIR tools to gain insights into optimum structural shapes.
  • Amalgamation of optimised features into CAD format geometry.
  • Detailed pass-off tests on chosen form.
Topology Optimisation

Vehicle Noise at Driver’s Ear

Automotive, In-House
NVH, CFD

Fluid Loads, Noise

11


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AAL use AcuSolve, ABAQUS, OptiStruct (Nastran) and In-House software to predict noise levels in large vehicle models.

Objectives

  • Develop methodology to predict vehicle interior noise at driver’s ear from a fuel tank during a deceleration event.
  • Correlate with measurements and transfer analysis methodology to the client.
Fuel Tank Noise

Solution

  • CFD to calculate fuel loads.
  • In-House software to map CFD results to tank structure.
  • Transient solvers in ABAQUS with non-linear contacts to calculate load histories.
  • Full vehicle noise prediction to 500Hz in OptiStruct (Nastran).
Full Vehicle Noise

Mechanisms

Automotive
NVH, Powertrain

Stress, Vibration

12


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AAL use MATLAB, SIMULINK, ABAQUS and/or MotionSolve to simulate complex mechanism systems.

Objectives

  • Build a realistic multi-physics mechanism to understand worst load scenarios.
  • Identify any relevant non-linear dynamic behaviour.

Solution

  • MATLAB and SIMULINK to model overall system: power electrics, control system and mechanical components.
  • Use of transient solvers in ABAQUS with non-linear contacts, materials and loads. Use of finite elements allows for stress prediction.
  • Use of MotionSolve for unusual multi-body complex mechanisms.