The second edition of the award for "the International Poster Award: A poster for CAE" has been really successful, both in terms of participants and quality of the submitted works.
This initiative has been promoted and sponsored by EnginSoft, being one of the promotion and dissemination activities that the company is constantly committed in to foster simulation culture. This award has a double aim: the first is to acknowledge the quality and innovation of the project developed in the universities and the second is to offer a privileged context in which academic experiences and industrial world could meet and get mutually known.
41 posters, submitted by Italian and foreign universities and research centres, passed the selection; 5 projects won the award and 4 deserved the "mention of distinction".
Posters were evaluated and voted by registered users and by the Scientific Committee members, consisting of professionals committed in transferring and disseminating numerical simulation techniques and knowledge, both on academic and industrial level, therefore able to influence the future of R&D: Aronne Armanini (Università di Trento, Italy), Sanzio Bassini (CINECA, Italy), Roberto Battiti (Università di Trento and co-founder of Reactive Search, Italy), Franco Bonollo (Università di Padova, Italy), Gabriele Dubini (Politecnico di Milano, Italy), Natalie Fedorova (ITAM SB RAS, Russia), Giorgio Fotia (CRS4, Italy), Michael Gasik (Aalto University, Finland), Carlo Gomarasca (Ansys, Italy) Gianluca Iaccarino (Stanford University, USA), Giuseppina Maria Rosa Montante (Università di Bologna, Italy), Enrico Nobile (Universita di Trieste, Italy), Bernardo Schrefler (Università di Padova, Italy), Christos Theodosiu (DTECH Corp., Greece) and Giorgio Zavarise (Università del Salento, Italy).
The winners were celebrated on October 21st in the frame of the International CAE Conference, held in Lazise (Verona). During the ceremony, presented by Luca Viscardi of Radio Number One, the five best posters were officially announced in front of the audience and their authors personally awarded with a tablet pc by Stefano Odorizzi, enterprising and prominent expert of Computer-Aided Engineering and Maurizio Cheli, astronaut, pilot, test driver and successful manager.
A design by optimization, based on the coupling between a multiobjective optimization algorithm and a panel code through ModeFRONTIER, is applied for the definition of a Controllable Pitch propeller geometry to reduce, at a given delivered thrust, the cavitating phenomena (and the radiated noise) and, at the same time, to increase its efficiency. Numerical results are validated by means of an experimental campaign carried out for the original and for the optimized propellers. Experimental results confirm the numerical predictions and the effectiveness of the proposed design approach.
In HPDC process, the final quality of castings, in terms of trapped air, is highly correlated to the first stage of injection due to the dynamics of formation of melt wave. The minimization of this value has been achieved through the development of numerical and mathematical model. The first one consists in the implementation of thermal equation into an open-source CFD code and the second one in a DOE generation and execution. The models allow to determine the response surface that shows the percentage of trapped air as a function of variable parameters.
A FEM structural analysis, the mathematical model and control of a hexacopter is presented. Rotors are located on the hexagon vertices; the propulsion system consists of three pairs of counter-rotating fixed-pitch propellers. The structure has been made up by a composite sandwich configuration characterized by CFRP skins and closed cells foam core. The analysis has been performed by ANSYS V 14.5 Academic Version with the ACP tool to pre-postprocess the composite structures. An efficient mathematical model with a robust control technique is implemented by MATLAB to describe the drone motion.
Flow-induced thrombosis is a major issue concerning heart valve replacement. This work presents an innovative CAE approach for analyzing the fluid dynamics and the thrombogenicity of a novel polymeric prosthesis for aortic valve replacement. Through the combination of FEM and CFD simulations, blood particles flowing through the valve and within the aortic arch were tracked in time using Discrete Phase Modeling and their stress accumulation was computed. Results showed that the hemodynamically and functionally optimized prosthesis limited its impact on the flow-induced thrombotic risk.
Computational simulations of stenting procedures in idealized geometries can only provide general guidelines and their use in the patient-specific planning of percutaneous treatments is inadequate. Conversely, image-based patient-specific tools that are able to realistically simulate different interventional options might facilitate clinical decision-making and provide useful insights on the treatment for each individual patient. The aim of this work is the implementation of a patient-specific model that uses image-based reconstructions of coronary bifurcations and is able to replicate real stenting procedures following clinical indications. Two clinical cases are investigated focusing the attention on the open problems of coronary bifurcations and their main treatment, the provisional side branch approach. Image-based reconstructions are created combining the information from conventional coronary angiography and computed tomography angiography while structural finite element models are implemented to replicate the real procedure performed in the patients. First, numerical results show the biomechanical influence of stents deployment in the coronary bifurcations during and after the procedures. In particular, the straightening of the arterial wall and the influence of two overlapping stents on stress fields are investigated here. Results show that a sensible decrease of the vessel tortuosity occurs after stent implantation and that overlapping devices result in an increased stress state of both the artery and the stents. Lastly, the comparison between numerical and image-based post-stenting configurations proved the reliability of such models while replicating stent deployment in coronary arteries.
Computational simulations of stenting procedures in idealized geometries can only provide general guidelines and their use in the patient-specific planning of percutaneous treatments is inadequate. Conversely, image-based patient-specific tools that are able to realistically simulate different interventional options might facilitate clinical decision-making and provide useful insights on the treatment for each individual patient. The aim of this work is the implementation of a patient-specific model that uses image-based reconstructions of coronary bifurcations and is able to replicate real stenting procedures following clinical indications. Two clinical cases are investigated focusing the attention on the open problems of coronary bifurcations and their main treatment, the provisional side branch approach. Image-based reconstructions are created combining the information from conventional coronary angiography and computed tomography angiography while structural finite element models are implemented to replicate the real procedure performed in the patients. First, numerical results show the biomechanical influence of stents deployment in the coronary bifurcations during and after the procedures. In particular, the straightening of the arterial wall and the influence of two overlapping stents on stress fields are investigated here. Results show that a sensible decrease of the vessel tortuosity occurs after stent implantation and that overlapping devices result in an increased stress state of both the artery and the stents. Lastly, the comparison between numerical and image-based post-stenting configurations proved the reliability of such models while replicating stent deployment in coronary arteries.
How reliable is a hazard mapping procedure for debris-flows? This topic has been faced through a comparison between a real event back analysis and a hazard mapping procedure both based on the Trent2D debris-flows model. In the back analysis, appropriate parameter calibration of the model was performed obtaining a good reproduction of the event. On the contrary, hazard maps were obtained applying the model in a blind mode, i.e. using reference parameter values. The good agreement between the two approaches shows both the model capabilities and the reliability of the used hazard mapping approach.
A number of visual analytics tools has been proposed and effectively used for multiple criteria decision analysis (MCDA) problems of textile composite materials selection. The critical behavior of the woven textile composites during draping and further involved simulations and analysis are included in the process of optimal design and decision making with the aid of LIONsolver.
Understanding the dynamics of drop impact is the key to the study of diverse natural phenomena and to a wide range of technical applications. Drop impact dynamics is far from being understood both because of its complexity and the large number of parameters which influence it. The most important parameters are the Weber (We = (DV 2)/), the Reynolds (Re = (DV )/μ) and the Ohnesorge (Oh = μ/(D)1/2) numbers which are dimensionless groups. Three-dimensional numerical simulations of non-normal drop impact on thin liquid films are presented in this poster. The drop impinges the liquid film with different impingement angles, that is the angle between the trajectory of the drop and the free surface. The focus is on the description of the grid refinement technique used to follow the dynamics of the impact.
LANL introduced the DTE - Dynamic Tensile Extrusion test - for the characterization of material at high strain rate and large strain. In this, a projectile is launched into a conical dime and subjected dynamic extrusion and the grain size is reduced in the nano meter range. Results on OFHC Cu showed that ductility increases with larger initial grain size. In this work an advanced constitutive model is used to simulate material deformation. Results show that accurate prediction of the number, size and shape of the jet fragments are obtained using implicit FEM with direct integration algorithm.
It is known that resolution varies as a function of distance, scatter and the gamma camera's characteristics. From a diagnostic point of view, it is useful to know precisely the resolution and its uncertainty to make appropriate corrections. Three methods for calculating FWHM from a planar scintigraphy were tested and compared. An open package "Resolution Calculator" was created to obtain the theoretical resolution of a gamma camera and compare it with real data obtained from the acquisition of a line source located at different distances from the collimator.
LIONsolver with a novel implementation of machine learning plus optimization provides a highly advanced environment for predictive analytics. In this poster a case study from the LIONbook is presented where the energy consumption for a new house project is predicted. The predictive analytics environment of LIONsolver in this case study has transformed the optimal design from a very complicated and time consuming process to a very speedy and simple strategy for design and decision making.
Enzyme reactions, blood flow and diffusion in human vasculature play interacting and fundamental roles in blood coagulation. In this complex mechanism, the balance between blood and clot is a delicate equilibrium, whose tight regulation is vital to avoid pathologies such as bleeding and thrombosis. The secondary hemostasis triggered by tissue factor in platelet poor plasma is studied up to fibrin production and thrombus formation. The effect of both hemodynamic and chemical factors is investigated to understand their impact on the coagulation burst and the clot development.
The attention to the protection of industrial facilities against natural phenomena has raised after the recent seismic catastrophic events that produced severe damages to people and environment. Taking into account this topic, this research focused on the behavior of some industrial structures, in terms also of damages produced by analyzing some industrial equipment. The goal of this research is to study and understand the complex behavior of industrial structures under seismic action and to analyze the possible effects induced by the collapse of these structures or by the collapse of their components. The research underlines also the possibility of adopting some new engineering techniques to prevent these effects.
The aim of activity was to build up a numerical model of boriding process.The modeling of the process was performed on the basis of experimental results, which were collected in a database and processed in modeFRONTIER® in order to obtain metamodels in the form of analytical formula by using the ED algorithm. Then the physical models have been calibrated and validated through a detailed analysis in modeFRONTIER®. The analysis led to the prediction of surface hardened layers dimensions and hardness in commercial steels
A finite element (FE) approach was developed to simulate the implantation and function of a Transcatheter Aortic Valve (TAV) device within an MRI-based aortic root model with valvular calcifications. Post-implantation TAV configuration and dynamics well agreed with in vivo imaging data. Contact forces on the surrounding biological structures were consistent with the device specifications. The presence of calcific aortic leaflets led to an asymmetric stent deployment with localized stress concentrations, suggesting the importance of including calcifications in modeling TAV through FE analysis.
Strain localization refers to the phenomenon by which deformations are localized into narrow bands of intense straining. As it is well-known, localized deformation is closely related to material softening which leads to ill-posedness of the (initial) boundary value problem when a classical Cauchy continuum model is used. As a consequence, simulations of strain localization with the finite element method show an excessive mesh sensitivity of the results. In order to overcome this pathological mesh sensitivity the ill-posed problem has to be regularized. Many different methods for can be found in the literature. This study attempts to avoid the mesh sensitivity problem in strain localization simulation of multiphase geomaterials in quasi-static and isothermal conditions. To this end, viscoplasticity is adopted as regularization technique in the post bifurcation regime. In particular, a local viscoplastic constitutive model of Perzyna type [Perzyna, 1966] and its consistent viscoplastic tangent operator have been formulated and implemented in the finite element code Comes-geo developed at the University of Padua [Gawin & Schrefler, 1996; Lewis & Schrefler, 1998; Sanavia et al., 2006; Sanavia et al., 2008; Gawin & Sanavia 2009, 2010] based on the multiphase porous media model developed in Lewis & Schrefler, 1998. The Drucker-Prager yield surface with isotropic linear hardening/softening and non-associated plastic flow has been used for simplicity. The viscoplastic regularization has been analysed by the finite element simulation of an undrained plane strain biaxial compression test on water saturated dense sand inspired by Mokni & Desrues, 1998. Mesh sensitivity of the results has been examined by using three spatial discretizations, namely a 5x17- mesh, a 10x34-mesh and a 20x68-mesh for a rectangular sample of homogeneous soil of 34 cm height and 10 cm width.
The microstructural and mechanical properties of metal-metal cold spray deposits are studied. Different spray particles coatings (Al-, Ti-, Ni-based particles) deposited on different substrates (Al-, Ti-, Fe-, Ni-, Mg-based bulk materials) were produced and their mechanical and microstructural properties were characterized. Different weight of the processing parameters affecting the mechanical and microstructural properties of the deposits was calculated by modeFRONTIER.
We present Orione (http://orione.crs4.it), a Galaxy-based framework consisting of state-of-the-art software and specifically designed pipelines to build complex, reproducible workflows for NGS microbiology data analysis. Enabling microbiology researchers to conduct their own custom analysis and data manipulation without software installation or programming, Orione provides new opportunities for data intensive computational analyses in microbiology and metagenomics.
An exchanger for the sterilization of tomato concentrate has been analyzed by means of 3D CFD models, in order to optimize the quality and safety of the treated food. A multidimensional two-phase model of steam injection inside a non-newtonian pseudoplastic fluid was used to evaluate the thermal history of the product. CFD simulations allowed to examine the effects of the different process parameters (sterilization temperature, steam flow rate) on the resulting product. Better performance of the exchanger was obtained in terms of temperature distribution of the treated product.
A design by optimization, based on the coupling between a multiobjective optimization algorithm and a panel code through ModeFRONTIER, is applied for the definition of a Controllable Pitch propeller geometry to reduce, at a given delivered thrust, the cavitating phenomena (and the radiated noise) and, at the same time, to increase its efficiency. Numerical results are validated by means of an experimental campaign carried out for the original and for the optimized propellers. Experimental results confirm the numerical predictions and the effectiveness of the proposed design approach.
Nowadays an increasing interest on thermo-hydro-mechanical analysis of multiphase porous media is observed because of a wide spectrum of application in civil and environmental engineering. The onset of landslides caused by rainfall or earthquake, the onset of catastrophic landslides, the seismic behaviour of deep radioactive waste disposal and concrete or earth dams are just few and challenging examples. As novel aspect, this work presents the development of a mathematical and numerical model for the analysis of the thermo-hydro-mechanical behaviour of multiphase porous materials in dynamics. The fully coupled multiphase model for non isothermal deformable porous media is developed within the hybrid mixture theory. In order to analyse the thermo-hydro-mechanical behaviour of a soil structure in the low frequency domain, e.g. under earthquake excitation, the u-p(-T) formulation is advocated for the finite element discretization, neglecting the relative fluids acceleration and their convective terms. As a consequence, the number of the independent variables is reduced to four: gas pressure, capillary pressure, temperature and solid skeleton displacements. Moreover, the dynamic seepage forcing terms in the mass and enthalpy balance equations and the compressibility of the solid grain at the microscopic level are neglected. The standard Bubnov-Galerkin method is applied to the governing equations for the spatial discretization, whereas the generalized Newmark scheme is used for the time domain discretization. The final algebraic, non linear and coupled system of equations is solved by the Newton method with a monolithic approach. The formulation and the implemented solution procedure are validated through the comparison with literature benchmarks, finite element solutions or analytical solutions when available.
Flow-induced thrombosis is a major issue concerning heart valve replacement. This work presents an innovative CAE approach for analyzing the fluid dynamics and the thrombogenicity of a novel polymeric prosthesis for aortic valve replacement. Through the combination of FEM and CFD simulations, blood particles flowing through the valve and within the aortic arch were tracked in time using Discrete Phase Modeling and their stress accumulation was computed. Results showed that the hemodynamically and functionally optimized prosthesis limited its impact on the flow-induced thrombotic risk.
Engineering problems solved with computational methods require the solution of very large sistems of equations. The related matrices may have even millions of unknowns and their solution may be very expensive in terms of both CPU time and memory. FSAIPACK is an advanced software tool developed for Symmetric Positive Definite (SPD) matrices and designed to run on parallel computers. In this work the performance provided by this innovative software is experimented with on two large size civil engineering problems and compared to the wellestabilished direct solver PARDISO
The SPES project (Selective Production of Exotic Species) aims to develop a facility at Legnaro National Laboratories (LNL) to produce Radioactive Ion Beams (RIB). The facility operates according to the isotope separation on-line technique (ISOL): the driver, a cyclotron, supplies a 200 μA 40 MeV proton beam to the SPES Front-End producing RIBs, thanks to the Target-Ion source system. To obtain higher ion beam energies, a series of subsystems (Beam Cooler, HRMS, Charge Breeder, RFQ) are being designed to allow the use of the post-acceleration PIAVE-ALPI.
Massive amount of data have an inevitable role nowadays. Life scientists, health care and medical Professionals are important communities which need to face with these massive and precious data. Medical professionals should effectively explore available data and make informed decisions in critical medical and health situations. As a result, the science of data management and visual analytics is improving to enable organizations interact with data and discover multiple set of relevancies in one place and time. In this viewpoint, we demonstrate two real life study case which are treated by the innovative framework of LIONsolver to highlight the opportunities it can offer. LIONsolver is a solution to deal with big data which improves understanding of the problem and brings visualization to the new level of usefulness.
In the last decades, the passive Radio Frequency IDentification (RFID) technology allows the growth of new item level tagging applications in retailing and manufacturing industries. For those applications in which reader antenna and tag are close each other, the near-field features of the electromagnetic field can be exploited to improve system performance. In this framework, two different topologies of near-field antennas operating in the UHF band are designed and characterized: a 8x8 near-field focused microstrip array (2.4 GHz) and a CPW travelling wave antenna (865-928 MHz).
In HPDC process, the final quality of castings, in terms of trapped air, is highly correlated to the first stage of injection due to the dynamics of formation of melt wave. The minimization of this value has been achieved through the development of numerical and mathematical model. The first one consists in the implementation of thermal equation into an open-source CFD code and the second one in a DOE generation and execution. The models allow to determine the response surface that shows the percentage of trapped air as a function of variable parameters.
Evaluation of the induced heating from internal damping: This paper proposes a method for thermal effect evaluation caused by material internal damping, which is based on an iterative procedure to estimate the temperature at which a specimen subject is carried to cyclic loads. The approach adopted evaluates the hysteresis cycle area through an harmonic analysis and considering this area as an internal heat generator in a following thermal static analysis.
We present a kernel-based method for the reconstruction of medical images from CT scans. Altough various approaches to the problem of the numerical inversion of the Radon transorm are known, our methods has some new and useful features. Namely, we can reconstruct the original image when a part of the data is missing or corrupted, and also select a small subset of the Radon lines which gives the best approximation. We show some numerical example on different phantoms to test our method in various situations.
Torque sensors are used to measure the interactive force acted on an end effector in order to reach higher quality results in manufacturing process, telemanipulation, in robots which use force control feedback. In this work we present the optimization design process of a 1DOF torque sensor of Hydraulic Quadruped robot:HyQ. It weighs about 70kg, it is 1m long and 1m tall with fully stretched legs; this platform is designed to perform high dynamic task like walking, running and climbing to help man in the dangerous situations: earthquake, fire, etc. The final shape satisfies several commitments.
This poster presents an innovative Permanent Magnet Heater for aluminum billets preheating, realized by InovaLab in cooperation with Laboratory for Electroheat of Padova University (LEP). A comparison between software simulation results and a set of laboratory electrical and thermal measurements, performed on an industrial scale prototype, is reported.
A FEM structural analysis, the mathematical model and control of a hexacopter is presented. Rotors are located on the hexagon vertices; the propulsion system consists of three pairs of counter-rotating fixed-pitch propellers. The structure has been made up by a composite sandwich configuration characterized by CFRP skins and closed cells foam core. The analysis has been performed by ANSYS V 14.5 Academic Version with the ACP tool to pre-postprocess the composite structures. An efficient mathematical model with a robust control technique is implemented by MATLAB to describe the drone motion.
RLW Navigator aims to develop an innovative Process Navigator to configure, integrate, test and validate applications of Remote Laser Welding (RLW) in automotive assembly. RLW is emerging as a promising joining technology for sheet metal assembly due to benefits on several fronts including reduced processing time, (50-75%) and decreased factory floor footprint (50%), reduced environmental impact through energy use reduction (60%), and providing a flexible process base for future model introduction or product change. Currently, RLW systems are limited in their applicability due to an acute lack of systematic ICT-based simulation methodologies to navigate their efficient application in automotive manufacturing processes. The project aims to address this by developing a Process Navigator simulation system. Firstly, the most critical obstacle that currently prevents the successful implementation of RLW is the need for tight dimensional control of part-to-part gap during joining operations, essential to ensure the quality of the stitch. Secondly, the existing assembly system architecture must be reconfigured to provide the opportunity to evaluate the RLW system in terms of its feasibility to perform all required assembly tasks. Finally the project will develop systematic evaluation and learning methods to assess and improve the overall performance, costeffectiveness and eco-efficiency of the RLW system.
In this poster, a design procedure for Quasi Resonant type induction hobs is presented. Multiphysics analysis are performed on 3D FEM model of the inductor, coupled to a circuital model of the frequency converter and a control system. Simulation results will be discussed and compared with experimental data.
Rotary Shouldered Connections (RSC) are vital components of the extraction equipment in the oil and gas industry. Although the standards propose practical rules for drawing working limits for these mechanical parts, the combination of make-up torque and tensile and compressive external loads often produces damage and breakages during drilling operations. In order to model the complex non-linear effects, a FEM model of the threaded pin-box shouldered connections is developed, describing friction contact and including plastic effects by a linear elastic – perfectly plastic model. Due to the complexity of the geometry, 2D axialsymmetric eight –node biquadratic elements are adopted. The effects of traction on the pin and compression on the box generated by the make-up torque are simulated introducing a suitable heat load, by considering a virtual orthotropic coefficient of thermal expansion. Results are validated against experimental data.
Rising product complexity has led to an increase in the number of product Key Performance Indicators (KPI's) used for quality evaluation. The conflicting behaviour of the KPI's results in nonlinearity in process behaviour. Thus, for optimal process control the relationship between process parameter and KPI's needs to be established. The current research focuses on developing a systematic methodology for developing response surfaces with the required accuracy by integrating physical experiments with computational analysis. The proposed approach is validated using Remote Laser Welding (RLW) process on automotive door assembly.
Process-induced variation has significant impact on product quality and productivity. The complexity of products coupled with increasing flexibility and responsiveness in processes enhances the challenges of process control. For example, in the Remote Laser Welding (RLW) process several Key Process Indicators (KPI's) such as penetration, interface width, topsurface concavity and bottom surface concavity are used to evaluate the product quality. The efficient detection of any variation in the KPI's needs to be captured in real time to improve the quality and productivity of the process. The current research explores 4 options to link process monitoring with weld KPI's.
The research presented in this paper focusses on the numerical modelling and investigation of the hydro-thermo-mechanical consolidation processes due to mechanical and thermal loads. A fully coupled finite element model for non-isothermal elasto-plastic variably saturated geomaterials based on Porous Media Mechanics has been developed. Consolidation of a Boom clay column is studied in detail, in order to analyse the coupled effects of mechanical and thermal on this material, which is a candidate for an underground nuclear waste storage facility. A case where the temperature is above the boiling value and water phase change develops is presented.
The aim of this work is to provide a useful tool to compute the trajectory of a small sounding rocket and show how this kind of simulation can influence the overall system design. In particular it will be presented the interface with the telecommunication subsystem of the Roxanne I-X rocket up to the determination of the link budget. Stochastic simulations will help to robustly determine useful parameters regardless of the scarcity of available data on the whole system.
Ultimate R&D goal is to develop methods and an appropriate software toolbox that support the configuration of for Remote Laser Welding (RLW) workstations together with the planning, programming, evaluation, and simulation of their operation. The current research scope includes workstations with a single welding robot – a typical setup in the automotive industry for assembling components of cars. An integrated workflow has been developed where the closely interacting tasks aimed at determining the configuration and the behavior of RLW workstations are solved in close interaction. According to experiments in industrial settings the proposed method leads to a substantial reduction in the cycle time of the welding operation.
In the GREEN KITCHEN project, financed by the European Union inside the Industry-Academia Partnership and Pathways program (Marie Curie actions), the main objective is to develop a new generation of home appliances connected together to build a household environment with a reduced energy consumption and a higher energy efficiency. In this poster complementary approaches to study the heat and mass transfer processes occurring in domestic ovens are explained. The standard energy consumption test in the European Union is used to validate the theoretical predictions.
Simulation has become an fundamental factor in the development of highly competitive and advanced electric systems. CAE methods play a main role in defining new concepts for automatic and hybrid transmissions. System analysis and process description to design an electric Oil Pump, through the connection of a lumped parameters Mechatronic System and an hydraulic part optimization, in order to reduce the emissions while optimizing the car efficiency, developed through the interaction of several software are shown in this poster.
Simulation with simple or complex models of the dynamical behavior of mechanical systems is not only essential for design but also for processing measured data. Two examples are shown related to blade vibrations and Tip-Timing Measurement results. Tip timing blade vibration measuring systems have become nowadays common for monitoring blade vibrations, due to rather easy and non-intrusive installation of sensors. The data collected by the sensors must be heavily processed in order to get the vibration time histories of all blades at rated speed or during a run up or run down transient, extract resonant/natural frequencies, amplitude and phase of each blade vibration with respect to the keyphasor. One or more sensors are positioned on the casing in correspondence of the blade row for detecting the blade tip passing in front of the sensor. Theoretical blade arrival time is calculated considering the position of the un-deformed blade and the shaft revolution period. Comparing the actual arrival time with the theoretical time allows to evaluate the difference (advance or delay) in time and consequently its apparent deflection amplitude. The direction of the vibration and the frequency are not directly measured. Here the help of simulation is needed: an accurate 3D model of the system is able to predict natural frequencies and modal shapes, that allow then to define the direction of the vibration. The "real" vibration amplitude is evaluated taking account of that direction of vibration which is generally different from circumferential direction where the actual arrival time of the blade is measured. Also the corresponding natural frequency allows to fit the frequency in the correct range of the different engine order excitation frequencies. Natural frequencies and corresponding modal shapes are generally calculated applying cyclic symmetry to the 3D finite element model of a single blade or of a blade sector, which requires linear models. Linearization of contact forces between blades is affected by uncertainties. These uncertainties and the non-linearity which arises from friction contacts between blades, may affect natural frequencies and direction of vibration, introducing some uncertainty in the measuring system results. The two examples are related to non-synchronous vibrations due to an instability and synchronous vibrations during a run up a turbine. In the second example it is also shown how simulation is essential for avoiding resonances in blade systems at rated speed. The software of the tip timing system aims also to evaluate the modal damping ratio of the blade row, by comparing measured results gathered when passing a blade row resonance with simulated results of a reduced modal model of the blade row (1 d.o.f. system). The resonant vibration must be uncoupled, then an estimate of the half power width, corrected by a least square curve fitting procedure can be used for evaluating the damping ratio. But the evaluation of the modal damping ratio may be highly inaccurate when the acceleration of the frequency of excitation (which is the engine order multiplied by the angular acceleration of the rotor) is not sufficiently low: in this case the resonant condition is passed during a transient and the half power width applied to the transient frequency curve is not applicable. Again simulation helps: the acceleration is known, a least square procedure allows to select the best fitting transient frequency response curve among the different curves obtained with different damping ratios. With that damping ratio also the amplitude of the exciting force distribution can be evaluated. It has been shown that simulation with complex models or even with very simple models is essential for extracting reliable results from blade vibration tip timing measurement system.
The case of a steam turbine casing that had leakage problems during the hydraulic test is presented. The simulation with the 3D model of the casing that allowed both:
is described. The numerical results are further compared to and validated by experimental results obtained by means of pressure sensitive films. During the hydraulic test at 1.5 of nominal pressure some leakage occurred in two points of the connecting flange of a steam turbine. In order to investigate the cause of the leakage and propose some modification in the design, a rather refined model of the casing was prepared. Non-linear contact must be used in all the contact surfaces, bolt preloads have been applied as external forces, and internal water pressures have been applied. Results of the non linear calculations confirmed the loss of contact in two restricted zones where the leakage occurred. In order to check the theoretical results, which do not take into account surface irregularities that are within specified tolerances, it was decided to perform a test with pressure sensitive films as partial validation of the obtained numerical results. The contact surfaces were equipped with thin pressure sensitive films suitable for a pressure range of 10 to 50 MPa. The casing were closed and only 25% of the nominal load was applied to the bolts. It was obviously not possible to apply internal pressure. Deformation of casing and contact surfaces were different from full load calculated case. A simulation with reduced load on bolts and no internal pressure allowed to compare calculated and measured results. Basically the test confirmed very low or zero contact pressures in the identified critical regions. The next step was to simulate some modification in the design in order to overcome the problem. The size of some bolts could be increased but that measure alone was insufficient. It seemed that the connection between wall of the casing and flange was too stiff. Increasing the flexibility of the wall would allow the flange to deflect more under the load of the bolts. These modifications have been introduced in the model and its effects have been simulated. Some bolts in the critical points have been substituted by bolts of bigger size. In order to increase the local flexibility of the flange without reducing its thickness it was necessary to reduce the thickness of the wall at the inside of the casing as close as possible to the flange. The effect of machining of two internal pockets in the casing was simulated with the model, and dimensions, shape and position have been optimized for getting the desired flexibility and avoiding stress concentration. The pockets will allow the complete closure of the flange under the action of the bolts. The simulation shows the final results as contact status and pressure distribution, under the action of the internal pressure and the nominal load on the bolts. These solutions have been adopted, and the successful hydraulic test validated the simulated results.
In the steel industry one of the major problems is the extreme wearing of the refractory materials employed in the several equipments in the steel chain production. The process starts at the blast furnace main trough and ends at the continuous casting model. The causes of the wearing are not clearly know, since they can be of several origins, like recirculation of the flow, turbulent intensity, chemical reaction among others. This poster presents a numerical solution of the multiphase flow in the blast furnace main trough with the main goal of trying to correlate experimental observations of the wearing with the characteristics of the fluid flow, like turbulence intensity and stress. The ANSYS CFX package was used for solving the 3-D turbulent multiphase flow of steel and air in the blast furnace main trough. The results were very promising, indicating that the numerical simulation is a strong tool for investigating this problem.