Practical experience of finite element simulation in machinery heavy industry

The general machinery industry covers industrial products and covers a lot of industrial fields, which is the basis of various industrial application fields. In the stages of product development, design and operation, safety, stability, economy and other indicators must be considered while meeting the work requirements. Therefore, CAE analysis technology is an indispensable technology and means for the development and design of general machinery. Mechanical heavy industry finite element analysis has a wide range of applications, including all kinds of power machinery, drive machinery, engineering machinery, transmission machinery, hydraulic control machinery, all kinds of processing machinery and equipment.

Our finite element simulation solutions are widely used in the field of machinery heavy industry, such as: rotary machinery, motors, boilers, wind power generation, transmission machinery, pumps, valves, construction machinery, processing machinery (machine tools), elevator equipment and other related industrial products research and development design work.

Case 1. Static strength analysis of bolt connecting wind wheel coupling and wheel hub

The wind wheel coupling is connected to the wheel hub and the gearbox, and the bolt connection strength between the wind wheel coupling and the wheel hub is also very important. In the analysis, the model is simplified, the mesh of the concerned parts is refined, the connection bolts are created, the bolt preload is applied, and the contact relationship between the parts is defined.

At present, the most critical problems in the wind power industry are mainly the reasonable simplification of models, the simulation of bearings, the simulation of blade composites, the bolted connection, the fatigue analysis of welds, and a large number of contact nonlinear and geometric nonlinear analysis.

For all kinds of linear, nonlinear, contact, modal and other static, dynamic problems concerned in the field of wind power manufacturing, as the world's best nonlinear analysis software - Abaqus targeted to provide the corresponding analysis solutions. The finite element analysis capability of Abaqus has been tested and widely recognized by the world's well-known wind turbine manufacturers and their related project service providers and scientific research institutions.

Case 2. Static strength analysis of the rear base and static strength analysis of bolts connecting the main base to the rear base

The main base is the main load-bearing component on the fan, and it is installed with main bearing, gear box, engine room cover and other components. In the analysis, the model is simplified according to the needs, the local mesh is optimized, the connection of bearings is defined, and the contact connection between the components is defined. The load needs to add the mass of gear box, generator, electrical cabinet and engine room cover.

The general machinery industry covers industrial products and covers a lot of industrial fields, which is the basis of various industrial application fields. In the stages of product development, design and operation, safety, stability, economy and other indicators must be considered while meeting the work requirements. Therefore, CAE analysis technology is an indispensable technology and means for the development and design of general machinery.

Case 3. Finite element simulation of gear reducer

Finite element simulation strength, fatigue and multi-body dynamics analysis of a gear reducer. The main difficulties of the project are the mesh division of gears, gear contact definition and nonlinear solution control.

During the meshing process, the tooth surface is prone to surface fatigue wear. Based on the maximum shear stress theory of fatigue wear, the maximum shear stress occurs near the contact surface. If the maximum shear stress exceeds the yield stress of the material, plastic strain will occur, and with the repeated action of external load, cracks will appear at the plastic strain. Therefore, when the shear stress is lower than the yield stress, the surface fatigue wear is not easy to occur.

Fatigue analysis type

Stress fatigue simulation (uniaxial/multi-axial fatigue, principal stress fatigue, VonMises stress fatigue, BS7608 weld fatigue, DangVan infinite life fatigue)

Strain fatigue simulation (uniaxial/multi-axial fatigue, maximum principal strain fatigue, maximum shear strain fatigue, Brown-Miller combined strain fatigue, cast iron fatigue)

Case 4. Finite Element simulation of diesel engine - strength fatigue analysis

Finite element simulation of a piston cylinder of a diesel engine for strength analysis, thermal, and fatigue analysis. A total of 3 prototypes, 9 working conditions. Key points of analysis: Virtual topology technology is used to combine broken lines and broken surfaces to reduce mesh quantity and optimize mesh quality; The fatigue module of ANSYS was used to fit the SN curve.

Case 5. Finite element analysis of CNC machine tools

Aiming at a machine tool, the position of fulcrum of bed base is optimized by cae analysis. The deformation of the machine bed is studied by adjusting the position of fulcrum under the condition that the machine bed body weight is mainly considered (without considering the structural weight of the upper part of the bed), and a relatively reasonable support method for fulcrum is given through analysis.

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See more cases: Heat dissipation analysis Thermal Simulation Analysis Collision analysis Modal Analysis CFD Analysis Electromagnetic Field Simulation Analysis Drop analysis Fatigue analysis