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Infotech helps Customer in delivering critical engine products |
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Infotech
helped
the
customer
in
delivering
critical
engine
products
to their
customers
for
their
new path
breaking
technology.
Infotech
was
actively
involved
in the
program
supporting
the
customer
in all
the
components
of the
system.
Infotech’s
support
on
Windmill
Motor
Driven
Pump
right
from the
preliminary
stage to
the
delivery
stage
was very
well
appreciated
by the
customers.
Infotech
team
took the
ownership
of
Windmill
Motor
Driven
Pump for
Engineering
/ Design
&
Drafting
/
Structures
/
Operations
and
successfully
worked
through
out the
program
with
minimal
support
from
customer.
A
Windmill
Motor
Driven
pump is
a
positive
displacement
two
stage
vane
pump,
driven
by a
constant
speed
electric
motor.
This is
latest
technology
developed
by HS
through
Infotech,
to
lubricate
the FDGS
Journal
bearings
and
scavenge
the #1 &
#1.5
bearing
compartments,
during
engine
windmill
operations. |
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Design
Challenges |
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Engineering
calculations
for pump
sizing,
performance
and
stack-ups. |
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Generation
of
Conceptual
Design
Components
&
Assemblies
and |
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redesigned
pump
elements
in
Unigraphics. |
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Involvement
in
presenting
the
design
to
Customer’s |
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Customers
in all
Design
reviews. |
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Generations
of
manufacturing
drawings
as per
customer
standards
and |
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involve
in
drawing
signoff
process
for
release
of
drawings
for |
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manufacturing. |
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Involvement
in
hardware
assembly
and
Acceptance |
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Test
Procedure
(ATP) of
the
Pump. |
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Appreciation
from
Customer |
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“Infotech
is an
integral
member
of the
team and
continually
makes
positive
contributions
to the
program
efforts.
Infotech’s
ownership
in the
windmill
pump
preliminary
and
detail
design
efforts
has
resulted
in
excellent
work” |
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Paper
presented
in ANSYS
conference |
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Stack up
analysis
on
Impact
of
manufacturing
Tolerance
on Inlet
ducts of
Air oil
cooler
systems
in
commercial
aircraft
engines |
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Infotech’s
client
is a
subsidiary
of a
fortune
100
company
and is
among
the
largest
global
suppliers
of
technologically
advanced
aerospace
and
industrial
products.
The
company
designs
and
manufactures
aerospace
systems
for
commercial,
regional,
corporate
and
military
aircraft,
and is a
major
supplier
for
international
space
programs.
The task
for
designing
some of
the
components
was
given to
Infotech
considering
its
experience
in
aircraft
component
design.
Inlet
ducts
are the
part of
air oil
cooler
used as
the
passage
for
cooling
system
for
different
parts of
commercial
aircraft
engines. |
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The
objective |
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The
objective
was to
perform
stack-up
analysis
to study
the
Impact
of
Manufacturing
Tolerances
on upper
inlet
ducts
and to
recommend
permissible
Upper
Limits
for
Deviations. |
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Infotech
Solution |
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Rigorous
Analysis
was
carried
out to
get the
deformed
shape of
the
distorted
flange
by
imposing
measured
deviations
and
update
the
coordinates
of the
F.E.
Model (UPCOORD).
Later
assemble
along
with
target
surface
(mating
flange)
and
analyze
using
contact
pairs.
Apply
force at
the bolt
locations. |
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Tools
used |
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ANSYS,
LD Dyna. |
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Paper
presented
in ANSYS
conference |
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FE
modeling
in the
variable
vane
Actuation
system |
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Infotech’s
client
is a
world
leader
in the
manufacture
of
aircraft
engines.
This
engine
manufacturer
has a
reputation
for
leading
the
industry
in
innovating
superior
engines.
To
manufacture
efficient
engines
the
client
uses
various
design
solutions. |
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Variable
Vane
actuation
system
is a
complex
subsystem
located
at the
front
end of
the
compressor.
Typically
contains
three to
five
stages.
This
system
in the
engine
experienced
few
kinematics
faults
with
occasional
binding
of
actuation
system.
Another
observation
was that
the
component
showed
no
evident
teardown
though
inspections
showed
all
parts to
be
within
acceptable
tolerance
limits. |
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The
objective |
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The main
objective
was to
create a
model to
overcome
the
challenges
of
different
loads
and
different
Bumper
locations.
The
other
objectives
were to
calculate
the vane
angle
errors
and
build a
macro
that can
initiate
an
analysis
and
summarize
the
iteration
for
different
loading
conditions. |
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The
challenges |
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The
challenge
was to
understand
the
kinematics
mechanism
using
ANSYS to
simulate
the
kinematics
behavior
and
Modeling
the
complex
geometry.
Another
challenge
was to
capturing
the
exact
geometric
features
through
sections. |
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Infotech
Solution |
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Sync
ring,
link
side
bracket
and
non-link
side
brackets
were
modelled
with
Beam 188
element.
Mass 21
element
is used
to
define
vane pin
locations.
Contact
178
element
was used
to
represent
sliding
motion
between
the
bumper
and
case.
The
models
were
tested
for
robustness
by
applying
different
displacements
at drive
link end
and by
varying
the
bumper
gaps to
handle
extreme
load
values.
Tangential
displacements
at vane
pin
centres
and
reaction
forces
at drive
link end
and
bumper
case
nodes
were
summarized.
These
results
were
used to
calculate
vane
angle
errors
for each
stage.
The
contact
status
results
reveal
some
bumper
location
to have
open
gaps,
which is
due to
the
ovalization
of the
ring
assembly
due to
the
applied
loads.
The
boundary
conditions
were
applied
for
Airfoil
Gas
Loads,
Displacement
Constraints,
Friction,
Gap. |
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Tools
used |
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ANSYS |
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Minimizing
Analysis
Errors –
Recommended
Best
Practices |
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ABSTRACT |
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The
paper is
concerned
with the
common
errors
that are
committed
by users
while
using
finite
element
analysis
packages.
Particular
focus is
on what
is known
as
“Black
Box
Syndrome”
and
steps to
be taken
to
minimize
this in
day-to-day
usage of
finite
elements.
The
basic
requirement
is
identified
as good
fundamental
knowledge
of
Strength
of
Materials,
Theory
of
Elasticity
and
Finite
Element
- Theory
and
Application. |
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The
paper
first
emphasizes
on the
need for
setting
the
priorities
right.
What is
recommended
is “Do
the
right
thing
first”
and
later
concentrate
on
“Doing
the
thing
right”,
in line
with
Peter
Drucker’s
management
philosophy.
To do
the
“Right
Thing”
it
becomes
essential
that the
user
meets
the
following
requirements: |
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Understand
the
Physics
of the
problem. |
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Understand
the
software
being
used.
And |
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Understand
the
results
generated
by the
program |
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In order
to meet
the need
as above
the
recommended
actions
are 1.
Proper
Simulation,
2.
Benchmarking
Exercises
and 3.
Lessons
in
proper
interpretation
of the
results.
The
paper
goes
deep
into
these
aspects
and
comes
out with
Best
practices
to be
adopted.
Case
studies
are
included
in
support
of the
practices
recommended. |
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The
important
thing
about
Simulation
is that
the
boundary
conditions
are
properly
understood.
As a
first
step it
is
recommended
that the
user
generate
simpler
models
that
would
simulate
the
mechanics
of the
problem
precisely.
Such
simpler
models
would
permit
the user
to have
insight
into the
essentials
of
analysis
such as
Loads,
load
path and
reactions.
The
simpler
study
models
would
also
facilitate
parametric
studies
or
sensitivity
analyses.
Another
important
aspect
of
simulation
is the
appreciation
of
subtle
differences
in
certain
boundary
condition
simulations
that may
often
make big
differences
in
results.
A few
typical
cases
cited in
the
paper
include
use of
rigid
regions
for load
transfer,
proper
boundary
conditions
for
structures
subject
to self
equilibrated
loads
and
proper
way of
dealing
with
interfaces
at
mismatch
of
element
like
solid-shell,
2D-3D
and
axisymmetric-plane
stress. |
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Benchmarking
is
essential
to
ensure
that
program
is
behaving
the way
that we
would
expect
it
behave.
This is
particularly
true of
the
elements
available
in the
program.
Of all
the
category
of
elements
that are
used one
that
need to
be
understood
more
deeply
are the
shell
elements.
All
program
packages
offer a
wide
choice
of shell
elements
and it
becomes
essential
to
understand
fully
the
performance
and
behavior
characteristics
of the
different
types
before
applying
them in
practical
problems.
It also
becomes
essential
to know
the
theoretical
basis of
the
formulation,
equations
used for
transverse
shear
deformation
and
stresses
and also
the
options
associated
with the
so-called
Drilling
DOF
stiff
nesses. |
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Another
facet of
benchmarking
is to
assess
relatively
one or
more
analysis
options
that
would be
available
for a
given
task.
One such
case
pertains
to
implicit
and
explicit
codes
for
transient
dynamics
problems.
Some
interesting
results
are
presented
and
discussed
in the
paper
dealing
with
implicit
and
explicit
codes. |
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A third,
but
equally
important,
facet
with
regard
to
benchmarking
is
validating
the
analysis
results
with
reference
to
textbook
information.
The
sources
for such
problems
are
Strength
of
Materials
formulae
for
simple
problem,
advanced
problems
from
Theory
of
Elasticity
and more
importantly
problems
in
Machine
Design.
A few
typical
case
studies
are
included
in the
paper. |
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The
third
very
important
aspect
relates
to
Interpretation
of
results
of
analysis.
Whereas
all the
results
need to
clearly
understood
and
translated
into
useful
design
information,
it is
recognized
that
interpretation
of
stresses
is very
vital.
The main
reason
is that
the
focus of
analysis
is
stresses
more
often
than
not. The
second
reason
is that
there
are many
pitfalls
in
interpreting
stresses
and
stresses
need to
be
viewed
from
different
angles.
In order
that the
stress
analysis
results
are
correctly
understood
and
applied,
the
following
steps
are
recommended
to be
followed
in the
same
sequence. |
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General
nature
of
stress
or
overall
distribution |
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Convergence
aspects |
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Identification
of
stress
singularities
and
assessing
the
nominal
stresses |
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Assessment
of
“damage
potential”
of a
given
peak
stress |
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Recommended
best
practices
for each
of the
above
are
listed.
Of
particular
importance
is the
damage
potential
of a
given
stress.
It is to
be
recognized
that no
stress
is to be
taken at
the face
value.
The
damage
potential
can be
assessed
on the
basis of
design
rules
applicable
for the
component.
In
absence
of
specific
guideline
it is
recommended
that
ASME’s
“Design
by
Analysis
(DBA)”
rules be
followed.
It is
also
demonstrated
that use
of
elastic-plastic
analysis
is very
useful
in
getting
a closer
look
into the
damage
potential. |
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