FLOW ANALYSIS

Gain of knowledge through CFD calculation

Flow analysis by means of CFD simulations (Computational Fluid Dynamics) is essential in evaluating the functionality of internal and external fluid-handling components. Our range of services covers a variety of computational disciplines, starting from analyses of internal, external flows or rotating components, calculation of thermal processes and time-resolved, transient simulations up to the calculation of loads and temperatures for the calculation of fluid-structure interactions using coupled FEM calculations.

For the flow simulation we used the following programs:

• ANSYS CFX

• ANSYS Fluent

COMPONENT ANALYSIS

Knowledge gained through FEM-simulation

The component analysis using FEM-simulation (Finite-Element-Method) of mechanical behaviour is of critical importance during product development. The focus of our service portfolio is therefore on the performance of FEM-simulation in the field of structural mechanics. Our service portfolio comprises a wide range of calculation disciplines, from thermal, static and dynamic calculations up to the calculation of highly dynamic processes or fracture mechanics.

We utilise the following programs for FEM simulation for component analysis:

• Ansys

• LS-Dyna

• RSTAB

The component analysis is the basis for a subsequent strength verification, the analysis of deformation states, or fracture mechanics verifications.

Your product needs to comply with requirements regarding deformations that must be complied with, or 

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With more than 75% of the projects we have handled, a strength verification is required. Depending on the requirements, we perform

• Statics strength verification including stability verifications (buckling, bulging, structural stability)

• Verifications of low cycle fatigue

• Verifications of fatigue strength

• Fatigue limit verifications

The strength verification are always preceded by an analysis or calculation of component loads. The strenth verification can be carried out using various types of verifications (according to the standard). Depending on the type of verification, elastic or plastic analysis procedures are used in order to determine tensions, expansions, deformations and stress resultants. The verifications typically comprise:

• Basic materials such as

  • Metal sheets

  • Structural steel profiles

  • Cast components

  • Forged components

• Connecting materials such as

  • Weld seams

  • Screws

  • Rivets

  • Bolts

We produce the documentation based on your requirements – from a brief and targeted presentation of results through to comprehensive and auditable documentation of the strength verification. Many of our reports have already been audited by external auditors from various testing organisations.

Components through which electric current flows are subject to many requirements. As a rule, a combination of electrical and thermal conditions are at work, which ultimately also have mechanical relevance. Electrothermal simulations are therefore essential for evaluating these components in operation and effectively managing heat dissipation.

 In the field of electrothermal simulation, our range of services covers the following areas.

 In electrical simulation, a detailed analysis is carried out to evaluate the current carrying capacity and optimize the electrical current flow. To ensure a precise evaluation, stationary and transient conditions are taken into account.

 In order to represent and optimize temperature fields, we carry out electrothermal simulations taking into account the combination of electrical and thermal boundary conditions. Depending on the application, stationary and transient conditions, such as specific current profiles (driving profiles), are taken into account.

 These components can be exposed to natural and forced convection at the same time. Flow simulations (CFD) are used to take these fluid flow effects into account.

 Mechanical simulations follow electrothermal and fluid mechanical simulations to evaluate the thermomechanical load.

 The determination of the fatigue strength consists of comprehensive mechanical simulations to determine the service life of the system in the high cycle fatigue (HCF) or low cycle fatigue (LCF) range. Among other things, we take vibration loads, PSD analyses and thermal shocks into account.

 We analyze the stresses that can occur during assembly processes, such as welding or handling in the manufacturing process, to ensure the structural integrity of the system.

 Determination of thermal response times to optimize the use of sensor technology.

 By varying geometric parameters, we perform comprehensive parameter studies to optimize the system design and achieve maximum performance.

 The following programs are used for electrothermal simulation:

• ANSYS Workbench

• ANSYS mechanical APDL

• ANSYS Fluent

• Siemens Simcenter FLOEFD

 Our electrothermal simulation thus offers a holistic evaluation and optimization of the system, taking into account electrical, thermal and mechanical aspects in order to maximize performance, reliability and service life.