Mechanical and Thermal Analysis

Customer Need:

We listened to the customer who had a large tower design for a system to be deployed at worldwide ports of entry.  There was a range of environmental conditions.  The effects of extreme winds or hot and cold temperature conditions needed to be analytically evaluated.

Added Value:

Working with the customer,  we defined the worst case conditions being 150 mph winds and 135 degrees F.  We then determined the worst case wind direction scenario.  We developed an FEA model that simulated this loading on the structure.  This data was reviewed with the civil engineer and we determined the number of fasteners and locations required at the tower base for the bolted connection to concrete foundation.

With temperature we completed thermal studies to determine active cooling requirements necessary due to changing environmental conditions and the heat being generated within the system. 

Result:

Our deliverable was a complete structural and thermal test report estimating system performance.  The end result was achieved by iterative changes to the hardware design based on the FEA results. Customer satisfaction was achieved since the contracts for the first systems were fulfilled and the first system was CE certified.

Spinal Implant Compression

Customer Need:

We listened to the customer and they had a spinal implant design requirement. Part of the verification process by the FDA was an empirical compression test on the actual machined Peek part.  The customer wanted to simulate the test conditions so that the design could be optimized to pass the empirical test.

Added Value:

Working with the customer, we determined which of a family of implant sizes and configurations would be most vulnerable to the physical testing.  Techniques simulating the boundary conditions and loading of the FDA test were applied to the solid model.  Average and peak stresses were compared.

Result:

Our deliverables were an analytically verified design and report.  Parts were then manufactured to selected design configuration and are scheduled to be tested in the near future.  Customer satisfaction was achieved because we followed a logical process and worked together to get the desired result.  They were also satisfied with our strategies and techniques to provide a technically sound FEA model.

Frequency Analysis

Customer Need:

We listened to the customer who sought a high performance, glass filled, nylon bicycle bottle carrier.  They wanted a moldable design that would lead to a reasonably priced mold. They also wanted to improve strength and resistance to the potential shock and vibration.

Added Value:

Working with the customer we established project objectives and the shock and vibration inputs from the road.  Key components were modeled and frequency analysis was performed to compare resonate frequencies with typical road frequencies.  Adjustments were made to the shapes of the structures to separate the frequencies.  Other changes included wall thickness, direction of draft, and parting lines.

Result:

Our deliverable was a completed frequency and shock analysis report and an optimized design including mounting inserts. The customer was satisfied  with the quality of the design and report and were able to commit to a mold with confidence.

Press Fit Simulation

Customer Need:

We listened to the medical device customer who was developing a catheter assembly process that press fit two minute parts together. The challenge was pressing a thin walled cylindrical shell on to a bulkhead without compression force damage to either part.

Added Value:

Working with the customer  we determined that an FEA model would help to solve this problem.  We modeled a shrink fit condition of the shell to the bulkhead.  This enabled us to estimate the global forces between shell and bulkhead.  Then we used a free body diagram to arrive at the compression force needed during the press fit.  The result was used as the force target for the manufacturing press fixture.

Result:

Our deliverable was calculated press fit force just below the point of a buckling yield when the parts were compressed.  That 12 lb load was then designed into the production fixture.  Customer satisfaction was achieved as we met the objectives and have since validated the assembly process.  At least 5 systems are in place at the Mexico manufacturing facility.

Antenna Shadowing

Customer Need:

We listened to the customer who needed to optimize the  range of telemetry  for an air vehicle.  The goal was to develop a method for projecting the signal from the antenna and to map the shadowing affect of the vehicle.  The method would be used to optimize the antenna placement.  The output was to be a logic table in polar coordinates that could subsequently be input into another analytic tool.

Added Value:

Working with the customer, we developed an accurate 3D representation of the vehicle and established the data syntax for the logic table.  TriAxial then developed a solid model method that allowed the configuration to accurately model the data captured.  It was fully parametric, enabling the location of the antenna to be easily repositioned.

Result:

Our deliverable was an innovative method utilizing a robust photorealistic rendering tool.  A point light source positioned at antenna location on aircraft  cast a shadow on spherical shaped feature enclosing the aircraft model.  The spherical coordinates were then reduced to a text file for upload into the next analytical tool.  The customer was satisfied as we achieved the goal of a tool for accurate modeling.  The method was reduced to a process, so that further studies could be done by our customer in house.

Random Vibration and Mechanical Shock

Customer Need:

We listened to the customer  who had the need for a robust electro mechanical power supply and heatsink design for a robust vehicle.  They asked TriAxial to analyze the design with computer simulation.  The goal was to determine if the design would meet the random vibration and mechanical shock of General Motors specification GMW3172.  They wanted this result before building, to ensure that the hardware would perform as required.

Added Value:

Working with the customer we established the key physical properties, the mounting scheme, and what input functions had to be used for the simulation.  TriAxial simplified the complex assembly utilizing remote masses and shell modeling to apply loading and boundary conditions.  The model was then analyzed with the outputs being compared to the test criteria.

Result:

Our deliverables,  based on test results, were identifying the material thickness changes in the component housing and mounting fasteners. TriAxial then completed a technical report of the revised configuration.  The customer was satisfied with the results of the study and have used the guidance as they pushed the design forward and into production.