Our experienced technical team has helped companies assess thousands of structures for integrity and performance. When applied correctly, FEA provides many benefits over hand calculations and prototype testing for productivity and innovation.
Successful stress, deflection and thermal simulations require models to be set up and interpreted correctly, including quality meshing and realistic assembly contact. Our breadth of software capabilities and in-house expertise enable us to choose the right analysis approach to match the application, covering beam, shell and solid meshing, contact modelling and handling of static and dynamic loading conditions. In many cases, these models have to adhere to the requirements of regulatory standards and codes.
We regularly undertake design assessments regarding compliance with regulatory standards and codes, including all types of static, dynamic and buckling simulations for fabrication and assemblies. We also perform the bespoke assessment of designs not in-line with conventional codes and standards.
We have a large consulting team for structural analysis project work and to help our clients expand their FEA capacity and skills at short notice.
Structural analysis projects typically include the identification and risk assessment of failure modes. Common failure modes are mechanical overloading, plastic collapse, localised yielding or wear. We are familiar with assessing structures to various design codes such as ASME VIII Div. 2, BS EN ISO 3449:2008., DEF STAN 08-123, BR 3021, MIL-STD-810, RTCA DO-160 and DN-RP-F112.
However, we have also investigated other potential causes of failure such as hydrogen embrittlement and ageing, including stress corrosion cracking of stainless steel subsea equipment to DN-RP-F112.
We can predict progressive failure using advanced fracture mechanics capabilities, including application of the Paris Law for aluminium structures.
Often structural stress is caused by temperature gradients. Both steady-state and transient thermal analysis have been undertaken using Ansys and other FEA codes.
We have simulated thermal cracking of ceramic refractory tiles due to quenching processes, in addition to thermo-mechanical simulations for a diverse range of products including engine ice protection systems, ceramic catalysts, oil well plug systems and roof tiles. Results have been validated through physical test data and thermal shock tests.
Our structural analysis and fluid dynamics capabilities can be combined to study fluid-structure interaction (FSI) behaviour, including both thermal and pressure loading.
We regularly undertake design assessment for code compliance. We are very familiar with PD5500, Eurocode and ASME VIII & ASME V Design by Analysis for pressure vessel and related equipment, including stress linearisation. We also undertake the bespoke assessment of designs not in-line with conventional codes and standards.
We also run a popular software-neutral Design By Analysistraining course to help engineers meet the requirements of ASME VIII Div. 2 using Finite Element Analysis (FEA).
We support both implicit and explicit dynamic analysis with Ansys Mechanical and Ansys LS-DYNA, in addition to kinematic (rigid body) simulations to extract dynamic loads from reciprocating machinery. Natural frequency (modal), harmonic, response spectrum and random vibration applications are common to understand how a system performs relative to its critical frequencies.
Projects range from automotive after treatment systems, fuel oil coolers, nuclear gloveboxes to gas holders. Sources of dynamic loads vary widely, from gas pulsations within internal baffles and rotating equipment to road vibrations and seismic events.
Through our long-term relationship with the off-road vehicle industry, we are highly experienced in transient dynamic analysis such as the assessment of falling object protective structures (FOPS) to BS EN ISO 3449:2008. Impact or blast simulations have included mobile phone drop tests to regulatory requirements and explosion-resistant safety enclosures for ATEX certification, together with shock testing for marine applications to recognised standards such as BV 0430.
A major consideration for many load-bearing structures, we predict buckling-capacity safety-factors using both linear and non-linear approaches. Some examples of recent projects include offshore fabricated towers, railway masts, bridges and outdoor storage tanks subject to variable wind loading.
Fatigue life prediction of structures and systems has been one of our most common applications over three decades, correlating results with physical test data where it is available. Whether the excitations are static or dynamic, regular or completely random, we ensure designs meet their requirements for safe-life or damage-tolerant design.
We have experience in fatigue life predictions within many industries, from mixing vessels and ship-based rotating equipment to speciality bridges subject to multiple crossings, applying relevant codes such as Eurocode, PD5500 and DNV CN30-7.
In addition to ‘linear’ metallic materials, we are also very familiar with hyperelastic and creep modelling of polymers and rubbers for seals, housings and other products.
We can translate complex non-linear behaviour into efficient material models suitable for FEA. This includes the project management of material physical tests and development & validation of constitutive models to implement within our clients’ analysis software.
We have significant experience handling large deformation problems involving extensive contact and rigid body motion, covering nuclear, aerospace, automotive, electronic and consumer products among other industries. Some of these applications exploit our complementary capabilities to model metal forming processes.
With specialised skills in the analysis of GRP, sandwich, honeycomb and other anisotropic composite materials, we have undertaken a range of projects in aerospace and other industries requiring strong, lightweight structures.
Our structural polymer capabilities are also supported by our injection moulding simulation experience.
There is no substitute for experience. We have been helping companies through our simulation consulting services since 1980, when the technology was still emerging and immature.
Delivered by our large inhouse team of Chartered Engineers, Metallurgists and Physicists, we have undertaken in excess of 5,000 projects for start-ups, SMEs and multinational engineering companies.
Image Courtesy: Forum Energy Technologies & Helix Canyon Offshore
We can offer you much more than a simple yes/no on whether your design, process or strategy is working well. Through our team of Chartered Engineers, we can generate insight, fresh ideas and potential solutions through experience, engineering knowledge, advanced analysis technologies and evolving optimisation methodologies.
This ranges from design guidance on machined & welded structures and support when developing products with 3D printing and other advanced manufacturing processes, through to specialist expertise on sealing & tribology and mentoring on design-for-reliability improvement programmes.
With an experienced and highly qualified technical team, we can undertake projects on your behalf while maintaining close contact with your in-house operations regarding progress and technical issues. Our flexible project options enable you to control your budgets and avoid the risk of overspend while assured of a timely, reliable and quality solution.
Flexibility is key to our services.
We run projects as short a half a day for a straightforward verification exercise to multi-year contracts to support and optimise new product development.
Most standard project work is undertaken within our head office in the UK for efficiency but this can be combined with on-site Secondments and Technology Transfer services.
Close communication ensures we deliver to your requirements.
You are allocated an account manager who works alongside our consulting staff to ensure both your commercial and technical objectives are met.
The scope of any project is clearly agreed and defined upfront and we ensure that you are kept informed of progress. This includes any discoveries, issues or concerns that arise from intermediate results that may influence the direction and duration of the project.
Project meetings are important and encouraged, particularly for complex assignments or design optimisation services. These can take place either at our headquarters or your offices. In addition, to minimise your project costs and delivery times while adhering to our Environmental Management policy, we promote web conferencing as much as possible.
Clear and meaningful presentation of results is an essential way for us to add value. Various levels of reporting are available to suit your requirements
Extensive – often required for regulatory authorities
Standard – Full report, but without the detail of the Extensive report
Summary – Limited to basic facts and important conclusions, often presented in a slide format
If you would like to continue the project in-house, we can also deliver the results databases from any analysis tools used to enable you to recreate the analysis and further investigate the results. This can include the provision of appropriate software licenses.
After agreeing a scope of work and timescales, we can structure the pricing of your project in many ways
Fixed Price, against fixed quotation.
Reimbursable, against target price.
How Can We Help?
For more information or to arrange an informal, no-obligation discussion on your requirements, please complete the form opposite or contact us using the details below.
From an initial phone call we can often give you an idea of price and time scales.
With subsequent details, we can then send you some solution ideas, scopes of work and a formal quotation.