Abstract

The Spanish machinery-building sector is highly fragmented and focused on prototyping. Small and medium-sized enterprises (SMEs) cannot afford to test prototypes or to use advanced computer-aided tools. They do not share a formal knowledge base, but they unofficially copy the applied solutions in each other’s products. This conservative approach leads to the overdimensioning of components, and the lack of technical knowledge can lead to the underdimensioning of components for a new design. To bridge this gap, the present work describes the use of a low-priced simulation software to optimize the thickness of an autoclave vessel for the canning industry. The information that was provided by the simulations, which was similar to that obtained by Ansys, allowed the manufacturer to select the optimal thickness of the vessel. This demonstrates that day-to-day design and further innovation can be supported by high-end expensive tools and by affordable tools.

Abstract

Autonomous inflow control devices (AICDs) represent a successful technology utilized in maximizing reservoir sweep and increased oil recovery. They are an evolutionary enhancement over the passive inflow control device (ICD) such as a nozzle or helix type, which have a choke that is fixed for the lifetime of the well. This paper discusses a technique which accelerated the AICD development from defining the operational parameters to delivering a fully functional product, while considering the various mechanical and hydraulic loads that are critical in providing robustness during operations. Due to limited space availability between the AICD sub-assembly, basepipe dimensions, and complex loading conditions, iterative designs were established to meet the operational parameters. Simulations using finite element analysis (FEA) facilitated the development via performance evaluation of each design under various load conditions. The FEA simulation results provided the direction to refine, optimize and finalize the design. Mechanical loads evaluated in the simulations included: tension, torque, bending, and impact shock, while hydraulic loads included: collapse, burst, and injection pressure. On finalizing the design, the simulation results were validated with prototype testing. The final design met the operational parameters through FEA, that enabled the successful development of the product, saving more than 50% of a typical development cycle time. The FEA simulations provided stress information of each feature, modelling the anticipated loading during the service life, which contributed to the improved robustness and complex features reliability. Prototype test samples were manufactured based on the final design. A full range of validation tests were conducted to validate the final design of the simulation model and to establish appropriate operational limitations of the AICD assembly when subjected to various loads. A leak test was performed before and after the applicable tests to verify that a leak path had not developed. At the conclusion of every test, each AICD element (manufactured from tungsten carbide) was inspected for damage to verify the device had not failed. The test results proved the final design could achieve or exceed the minimum requirements under various load conditions using the simulation technique that accelerated the development process. This design has been used as the basis for various other sizes, with a similar mounting system, which have been successfully deployed in field applications. The use of this technique significantly accelerated the development process. It involved several design iterations and FEA simulations to evaluate various designs throughout the development cycle. FEA has been applied as a value adding tool to guide design optimization, which has been verified by testing, to successfully anticipate the loadings as per operational parameters. In addition to the shortened development process, the validation test development
cost was significantly minimized, using FEA, and a robust product was delivered. The validation test results aligned with the FEA predictions.

Abstract

Abstract

The new Geomiso DNL software is proposed to facilitate the use of isogeometric analysis for nonlinear inelastic dynamic applications. This hybrid software solution combines isogeometric analysis and 3D design with advanced spline techniques, such as NURBS and Tsplines. Its dual nature satisfies the rising industrial need for unification of the fields of computer-aided design (CAD) and computer-aided analysis (CAE), as it eliminates geometric errors by merging geometry design with mesh generation into a single procedure. This paper presents sample nonlinear applications in structural dynamics. Geomiso DNL is seen to handle these situations remarkably well, as the numerical examples exhibit significantly improved accuracy of the results, and reduced computational cost, when compared with finite element software packages. Geomiso DNL is not just a plug-in, but a both on-premises and cloud-based software, which enables engineers to simulate complex dynamic phenomena, whose impact on industrial products and structures in real-world environments can be more efficiently estimated. Taking advantage of the new horizons offered in the peak of the Industry 4.0 era, the physical twin feeds, via cloud technology, with real-time data its geometrically exact digital twin, while a dynamic analysis is performed and crucial results about structure safety and quality are obtained. It is argued that Geomiso DNL is a new, more efficient, alternative to FEA software. This is the first time ever such a cloud-based program has been developed.

Abstract

Abstract

Additive manufacturing technologies allow us the creation of 3D objects through layer overlay. This process is faster than other traditional manufacturing processes and it enables the customization of parts. Nowadays Fused Deposition Modelling (FDM) is the most used techonology. However, due to the nature of the process, resulting parts have complex mechanical behaviour, due to the fact that their properties vary according to the direction or the type of effort, which limits their applications in functional parts. To predict the behavior of a component Finite Element Analysis (FEA) are made. Although, the material models used by these analysis tools are not able to simulate the mechanical behavior of FDM products. Thus, a model supported by a finite element analysis tool, able to predict the behaviour of these materials has been developed. It works in the elastic and plastic region, for any geometry and load case. The model, feed by theoretical behavior models and experimental tensile, compression and shear tests, and implemented in FEA software, allows us to simulate the anisotropy of these materials in an easy and versatile way. The calculation methodology has also been experimentally validated.