structural analysis

Restraint system optimization for belted and unbelted occupants in frontal crashes

The objective of this study is to compare the performance of restraint systems optimized for belted only occupants with those optimized for both belted and unbelted occupants using computer simulations.

Mass Reduction and Energy Absorption Maximization of Automotive Bumper Systems

The main goal of automotive bumpers is to absorb kinetic energy during plastic structural deformation in order to prevent occupant injury.  Typically, the more mass a bumper has, the more energy it can absorb. However, more mass also means more material, higher costs and poorer fuel efficiency. modeFRONTIER was employed to carry out the optimization of the best possible bumper design given the two opposing objectives.

Multi-Disciplinary Multi-Objective Optimization of Solid Fins for Sounding Rocket

modeFRONTIER was employed to carry out the optimization of a fin on a sounding rocket. A sounding rocket, also referred to as a research rocket, is used to perform scientific experiments during its sub-orbital flight. Designing the fin results in a multi-disciplinary problem involving three main topics: aerodynamics, trajectory and structures with multiple conflicting objectives such as maximizing peak altitude, maximizing factor of safety and minimizing fin deformations.

Handling the Complexity of Mechatronic System Design

Two design projects highlight how ABB Group leverages optimization-based development to handle the complexity that automation and control systems entail and to maximize mechatronic product performance, meet reliability demands and ease overall environmental impact.

Structural optimization of Metro Honolulu under all operative load conditions

Working on the design for the new Metro Honolulu car body, structural engineers at AnsaldoBreda had to push  technological boundaries to ensure compliance with top level quality standards and achieve weight and cost reductions. The final design, identified using modeFRONTIER, allowed AnsaldoBreda to reduce weight by 6% (228 Kg) and achieved better thickness variation uniformity, ultimately simplifying the manufacturing phase.

Structural optimization of a Transversal Rolling Mill Component to Improve Flexional Stiffness

This is a preliminary study to understand if an increased stiffness of a structural component of the transversal mill (the bar component) can bring some effects in the product by stabilizing the process. This work analyzes the bar sustaining the plug, a component of the expander mill. The team must solve to increase the stiffness of the bar trying to keep the mill set up stable.

Computerized Crash Reconstruction of Real World Crashes Using Optimization Methodology

In this case study, the researchers modify the parametric methodology to include an optimization scheme to derive an optimal solution for the reconstruction problem in a given range of unknown parameters. Results of the simulations showed that the optimal solution correctly predicted both the occupant-vehicle contacts and the injuries sustained during the crash. 

Advanced shape for robotic torque sensor

In recent years, robotics has moved away from the rigid joint to a sensorized joint. The new optimized torque sensor design must not only fit perfectly within the current mechanism assembly, but also guarantee the required mechanical properties of the joint itself. 

Application of Optimization Methodology and Specimen Specific Finite Element Models for Investigating Material Properties of Rat Skull

This study represents a preliminary effort in the development and validation of FE models for the rat skull used to predict the reaction of traumatic brain injuries (TBI) in humans. modeFRONTIER automatically updated input parameters and submitted new keyword files to LS-DYNA, which ran in MPP mode, to reduce the time needed in completely the task. This same method can be used to other reverse engineering procedures to obtain accurate material parameters for FE models development.

A modeFRONTIER case study about the optimization of the windshield structure

DEMA SpA must assess the capabilities of a methodology for the smart analysis of the windshield structural behavior by using a FE (Finite Element) model integrated with modeFRONTIER for a new Canadian business jet. The methodology would be able to automatically change the thickness of the Global Finite Element Mode (GFEM) shell elements, run the new numerical analysis and finally obtain a configuration with a minimum mass target, but at the same time able to stay within a well-established threshold stress.