ANSYS Blog: Advances in Simulation Drive Efficient Design for Sprays, Erosion and Metal Forming

ANSYS Blog: Advances in Simulation Drive Efficient Design for Sprays, Erosion and Metal Forming

July 2nd, 2019

Nonconventional metal forming simulations can help engineers design for the complexity of this manufacturing method.

Every new product generation is smarter and increasingly complex. At the same time, product designers and product development engineers must control costs and release products faster to maintain a competitive advantage.

Simulation has long been part of the product verification and testing process. However, as products grow more complex, companies can realize even more benefits if engineering simulation is applied right from the very beginning of design — from ideation into operation.

By eliminating less feasible designs early, using pervasive engineering simulation, engineers can explore more designs and manage complexity to truly create products that the market requires. This not only saves time and costs, it also empowers companies to develop the best-possible products.

Driving design with engineering simulation is one of the themes of this year’s NAFEMS World Congress and ANSYS is participating in a wide range of activities.

Driving Design with Engineering Simulation: Getting the Drop on Nozzles

A transition model enables the accurate modeling of sprays.

Spray nozzles are employed across many industries — including automotive, art and cleaning applications.

The performance of a nozzle depends on the shape and size distribution of the drops it generates.

Because of the range of length scales in the spray — from near nozzle blobs to tiny droplets — ensuring these details are correct is a simulation challenge. A transition model developed by ANSYS, to handle this range of sprays, ensures that simulations will be detailed and accurate.

Driving Design with Engineering Simulation: Wearing Away Sand Damage

A reduced-order model with high-fidelity simulation allows for the understanding of sand entrainment in oil and gas equipment.

Sand entrainment is a challenge when extracting oil and gas from the ground. Erosion from the entrained particles causes damage to pipelines, fittings and control equipment. Predicting erosion, to minimize and control it, through good design, is critical for petroleum engineers.

CFD simulations can model erosion, but the analysis requires a lot of knowledge, time and resources. This typically makes it impractical for real-time monitoring or predictive maintenance.

Reduced-order models (ROMs), built from high-fidelity simulations, provide engineers with the ability to perform what-if analyses within seconds without compromising simulation accuracy.

Driving Design with Engineering Simulation: Metal Forming Without Milling or Drilling

Accurate, dynamic simulations predict the final shape of a part built using nonconventional metal forming.

In conventional metal forming, tools such as lathes or milling machines apply direct physical contact to cut workpieces to shape. However, nonconventional metal forming uses mechanical energy, thermal energy or electromagnetic energy to shape a work piece, without touching it directly.

Nonconventional metal forming has advantages over the traditional method when:

  • Material is difficult to handle/cut
  • Parts have tight tolerances
  • Pieces are small
  • Cuts are irregularly shaped

Nonconventional metal forming processes are based on the use of very high forces acting on a material over a very short time. Some examples include electromagnetic, hydrodynamic and explosive forming. These strong, fast forces require accurate, dynamic simulations to predict the shape of the final part.

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This blog was originally posted on ANSYS’ website here.

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