Putzmeister Concrete
Pumps
Putzmeister-Telebelt TB 105
Vertical
drilling systems masts (underground engineering technology)
Goods
wagon pivot chassis
COSAR model
updating
Heat transfer computation
Steam
engine pressure vessel
FE analysis of a
human knee joint
District heating pipe
components (Plastic-Jacket Piping)
Investigation
of insulating materials in district heating systems
Load
analysis of Worm Drive Hose Clamps
FE analysis of a rotary
head
FE
analysis of a re-directing lever
Experimental
investigations
For Putzmeister Concrete Pumps components (substructure with support, rotary head, mast and so on) a lot of comprehensive FE analyses based on COSAR were/are undertaken. The aims of these investigations are:
maximum reach
for minimum weight
to find unnessecary
material thickness
weak point analysis
optimization of
components
Deformation and stress analysis
A finite element displacement and stress analysis of a newly designed rotary head was undertaken. The geometric model description was achieved primarily through IGES data import. For the rotary head design, a 3-D shell model was chosen for the analysis, using COSAR semiloof-shell elements. With the aid of these analysis results, weak spots were identified and design changes made. The design was also optimized in those areas under less stress.
By courtesy of Putzmeister AG, Germany
Deformation and stress analysis
Within the scope of a complex displacement and stress analysis of an arm section, the highly stressed re-directing lever was also analysed. The lever was modeled using 3-D shell elements (Semiloof shell elements). Due to the symmetrical forcing acting on the arm it was possible to use just half of the full model geometry. After evaluation of various designs, this structure was also optimized, in co-operation with the customer's designers.
By courtesy of Putzmeister AG, Germany
Vibration tests on a Putzmeister concrete pump M42
The aim of the vibration test was to evaluate the influence of additional dampers and stiffnesses to the vibrating behaviour of the vehicle and to have potential vibrations during the work under control.
By courtesy of Putzmeister AG, Germany
Deformation and stress analysis
The TELEBELT is a mobile Telescopic Belt Conveyor. It conveys and places completely different materials, e.g. gravel and sand, chippings broken stones, humus, light concrete, non-pumpable concretes.
FEMCOS played a dicisive role at the successfull further development of the TELEBELT (more information about Telebelt)
Telebelt TB 105 (By courtesy of Putzmeister AG, Germany)
Conveyor Belt - FE model
Strength proofing and optimization
The SATVIA Maschinen- und Bohrgerätebau GmbH (Gommern, nr. Magdeburg, Germany) has been manufacturing all sizes of mobile vertical drilling systems since 1996. Due to continuous technical improvements, the firm has gained a good reputation and is highly competitive. Such success is only possible with the use of modern computational methods for the necessary strength proofs and optimization. Such analysis is carried out during the planning and design phases. For this reason, the company decided to integrate with FE analysts at FEMCOS, who have experience in such methods.
By courtesy of SATVIA Maschinen- und Bohrgerätebau GmbH, Gommern, Germany
Stress analysis and optimization of thin-walled steel structures
The pivot chassis of a goods wagon is a thin-walled, welded design. The trend towards lightweight structures, together with special manufacturing techniques seen in steel construction, has led to an increase in the number of analyses of these types of structures being performed. Using COSAR finite element software, and intelligent pre-processing tools, efficient solutions for these problems are being reached.
use of an intelligent,
heuristic, midplane generator
for import of 3-D
CAD geometry into a midplane-shell model (more
details)
use of powerful
shell elements (semiloof)
super element/substructure
technique
By courtesy of the ELH Eisenbahnlaufwerke, Halle GmbH & CO. KG, Queis. (graphical design by Zorn)
Model updating (model correction) based on experimental modal data
COSAR offers model-updating facilities based on measurement data obtained from experimental modal analysis (EMA). The measured modal data (natural frequencies and mode shapes) are the COSAR input data, and are used for location and model correction. The model-updating process allows the user a great deal of control over the various stages.
Arm of a smashing mill for coal grinding (firing systems)
A steady state and transient heat transfer of this arm - rotating in a hot gas stream (about 700° C) - was undertaken. The objective was to investigate the time-temperature behaviour of some arm areas. The double symmetric structure was modeled with 3-D elements. For the analysis the heat convection at the surface of the arm was considered as the dominating boundary condition.
Stress analysis of a steam engine pressure vessel with respect to design details
The „inner life“ of steam engine pressure vessels
is relatively complex. Over several decades, the expertise
of experienced engineers has, step-by-step, exhausted this design to its limits.
The kind of joints used between the fire room and the shell construction
of the locomotive engine boiler are of interest: cracks were regularly found
at stiffening sections during routine inspections, necessitating very expensive
repair work. A detailed FE analysis was first carried out to
find the cause these cracks, after which the supporting effect
of the stiffening sections was able to checked
in a general sense.
Deformation and stress analysis
Using COSAR, a finite element model was developed on the basis of a Magnetic Resonance-Tomographic Image (MRT) of a human knee joint. This model was analysed for displacements and stresses in the knee joint.
Finite Element Analysis of a 90° Bend
A 90° bend in a plastic-jacket pipe model was investigated
with a three-dimensional finite element model, where, using
symmetry, half of the full geometry was used. The pipe components
(steel-pipe, foam, jacket) were reproduced and the bedding material
(sand) also introduced into the model.
The aim of this FE analysis
was to determine and analyse both the deformation and the stress
distribution in the whole system (bedding-material, multi-component
bend). The effect of the surrounding conduit was approximately described
by pre-defined displacements at the ends of the pipe. Furthermore, the contact
relationship between the sand and the jacket
surface was also taken into account.
As a result of the analysis,
the global deformation of the pipe bend was able to be shown, as well as high
demands on the indivdual components.
Computation of the long-term behaviour
Plastic-jacket pipes (steel inner-pipe with
a polyurethane foam insulation) are generally laid in the ground
for use in district heating systems. Previous thermal insulation materials contained
CFCs, and require replacement due to environmental reasons.
With time scales
of between 30-40 years, the proof of the long-term integrity
of the foam material represents an important aspect of the layout of district
heating systems.
The foam of the thermal insulate experiences severe operating
conditions (temperatures upto 160° C, mechanical loading due to soil, etc.),
and thus suffers from creep.
In order to reduce the cost and time involved
with experimental testing, the feasibility of a numerical simulation
was to be investigated, using the potential of COSAR's material
behaviour analysis.
Firstly, experimental results of creep in the
insulating material were to be analysed, in order to determine the
necessary material parameters.
One result of the caclulations was that
improved material property information was able to be determined, thus assuring
better long-term predictability through numerical simulation.
Because of their function the demands for quality and safety hose clamps are very high. They are designed for defined span moments and a certain lifespan. During that time they should neither coming loose nor should one of the components fail.
By courtesy of Gemi Metallwarenfabrik GmbH & Co, Marsberg
The objective was to investigate the behaviour of the structure under work and maximum load. The results obtained were the basis for structural optimization.