PHYSICAL ENGINEERING SERVICES

PART OF ELECTROMECHANICAL COMPANY

OUR EXPERTISE

Automotive

Engine manufacturing

Energy and mining

Agriculture and Heavy industry

Marine

Aerospace and Defence

CALCULATION, DESIGN AND ANALYSIS OF GEARS

We perform geometry, strength and contact analysis calculations for all types of gears.

Calculations are carried out in accordance with ISO, DIN, AGMA, VDI (plastic gears), RV –  RINA and GOST standards.

Spur gears

Planetary gears

Bevel gears

Belt and chain drives

Worm gears

Facegear

SYSTEM CALCULATIONS: DESIGN, CALCULATION AND OPTIMIZATION OF GEARBOXES AND TRANSMISSIONS

We perform system calculations and complex  solutions analysis, solving any engineering  optimization task.

Our core competencies allow us:

  • to identify and optimize layout options, efficiency  and durability
  • to perform NVH analysis (noise, vibration and  harshness)

Our experts will carry out all the necessary work to  ensure that your product meets the criteria of quality,  reliability and economy.

MULTIDISCIPLINARY TASKS

The multidisciplinary analysis allows you to  combine different calculation methods:

  • finite element methods
  • kinematics and dynamics analysis of  machines and mechanisms
  • finite difference method  
  • finite volume method

This approach allows modeling and analysis across all engineering concepts.

Application examples:

  • topology optimization based on hydrodynamics features  
  • coupled thermal analysis
  • associated vibroacoustic analysis
  • analysis of buckling based on the initial imperfection

DYNAMICS OF MULTIBODY SYSTEMS

World-class motion analysis solutions allow us to  simulate and test virtual prototypes of mechanical  systems, saving you the resources required for  prototyping and field testing.

With MBD analysis we can take into account  electronic control systems, pliable parts and their  connections, vibration, friction and noise and  quickly evaluate the design.

Application examples:

  • behavior of the car in turnings
  • quasi-static analysis and rectilinear motion  
  • analysis of steering and suspension systems
  •  behavior of bulk solids (DEM method)

NOISE AND VIBRATION

We carry out calculations and modulations of acoustic and vibration loads for your  company.

Using Finite Element Analysis (FEA) and Multibody Dynamics (MBD), our experts can  model and predict what vibration and acoustic loads a component or system will  experience under different conditions.

Application examples:

  • analysis of real and natural  frequencies and forms
  • analysis of vibration transferring  paths
  • calculation of the contribution of  individual sections of vibrating  structures to the acoustic or  structural response

ADDITIVE MANUFACTURING

In the field of additive manufacturing, we solve tasks  of topological and topographical optimization (in  terms of mass and stiffness) of isotropic, anisotropic  and composite structures and assemblies.

Optimize 3D printing processes with:

  • topological and topographical optimization of  production technologies
  • parametric optimization of design

Result:

  • reduced production costs
  • improved reliability
  • increased production productivity

COMPUTATIONAL FLUID DYNAMICS

Methods of computational fluid dynamics help to maintain the quality and safety of  the product. Using computational fluid dynamics, our teams can create optimal  designs early in the development cycle, saving you time and money.

Application examples:

  • solving problems of hard  splashdown
  • sloshing
  • any type of FSI problems  
  • heat and mass transfer  problems on any scale

DURABILITY AND FATIGUE

Our specialists use analysis methods based on finite element models to predict  fatigue failures. This approach lets us avoids the cost of natural experiments,  obtaining the maximum amount of data.

The result of this analysis can include:  

  • safe working loads
  • warranty claim schedules
  • high-temperature effects
  • manufacturing process loads and assembly  operations

Additionally, our specialists carry out:

  • fatigue and vibration analysis for welded joints by  various methods
  • the destruction of the material prediction  
  • cracking prediction

NONLINEAR ANALYSIS

Ignoring the non-linear behavior of materials and products can lead to product  damage, safety issues, and additional costs for manufacturers.

Our engineers can carry out all kinds of non-linear analyses.

Modeling of non-linear processes can be  used:

  • to simulate crash tests (including  automotive ones, according to the  world’s leading standards, including  NCAP)
  • to simulate impact and explosive effects,  bird resistance and hail resistance in  aviation
  • to determine the strength and  destruction of composite structures

DYNAMICS OF ROTARY MACHINES

Our experts can conduct analyses of dynamic loads and dynamic stability.

To solve complex problems, we use various methods that allow us to take into account  many factors at the design stage.

Application:

  • calculation of real and complex eigenvalues,  natural frequencies and vibration modes  
  • modeling the frequency response of products,  considering the nonlinear elastic and damping  characteristics of the rotor supports  
  • calculation of the dynamic response in case of  blade breakage, rotor touching the stator and  other inharmonious influences

Mechanical engineering software and services for reliable manufacturing

  • The purpose of Computer-Aided Engineering (CAE)
  • The complex approach in 3D simulation and Analysis
  • Types of software tools, simulations, and services.

Computer-aided engineering (CAE) software enables designers and engineers  to simulate product and process performance to achieve:

  • The excellence and reliability of the product;
  • Avoiding failures of product parts and the whole mechanism;
  • Prognosing product lifecycle and behavior in real life
  • Damaging the costly machines and tools during production;
  • Optimization of production costs, material usage, and
  • Noticeable increase in efficiency (speed, noise, fuel consumption).

Computer Aided Engineering Tools

Gears, Shafts, Bearings and Gearboxes design, calculations, optimization

Multidisciplinary structural analysis

Meshfree liquid flow simulation software

Multibody Dynamics (MBD) software

Computational fluid dynamics

Powerful acoustic simulation software

Advanced nonlinear simulation solution

FE based fatigue, durability & random response solution

Forming & welding simulation, simulation of metal-based additive manufacturing processes

Unified CAE environment for virtual product development

Explicit dynamics and fluid structure interaction

The nonlinear multi-scale material and structure modeling platform

Application industries

Engine manufacturing

Automotive

Energy and mining

Agriculture and Heavy industry

Marine

Aerospace and Defence

Case Study:
Preventing Failures of the Defense Transportation Truck with CAE

Pic. 3 – Winch housing failure (crack)

(Click image)

Pic. 2 – Frame failure (crack)

(Click image)

Pic. 4 – Gearbox housing failure

(Click image)

Winch failure execution

Pic. 8 – Winch housing crack

The winch housing cracked  on the real car during the warranty period

Winch housing analysis and failures prediction

It could be calculated and predicted on a design stage  to avoid losing on cost repairment, brand reputations,  other released and sold tracks failures risks

Pic. 9.1 – Winch housing simulation and failure prediction
Pic. 9.2 – Winch housing simulation and failure prediction

Frame failure

Pic. 5 – Frame crack

Frame analysis and calculation  were not performed and not  tested during design and R&D

The frame of the fresh manufactured truck  cracked during the exploitation

How it could be avoided?

Pic. 6 – Created calculation model of the truck

With the executed calculation and  simulations to get predictions about  critical failures using engineering  experience and special software

Multidisciplinary structural  analysis performed by

Truck simulation

Animation 1 – Truck model analysis

Preparing and simulation the  dynamics of the product in real  conditions is necessary before  production or even prototyping

Frame analysis and failures prediction

Pic. 7 – Frame analysis and detection of the crack

Calculation results help to predict failures, optimize the design and  increase a product service life. A professional engineer will  simulate  load and see the weak part of the frame

Gear pair and gearbox housing failures

Entire gearbox simulation and analysis

Geartrain simulation and calculations

Gearbox housing analysis and failure prediction

Bevel gearbox failures

Necessary fields of a gearbox analysis

Gearbox lubrication simulations and analysis

Gearbox durability simulations and analysis

Gearbox vibration simulations and analysis

Warranty and repair costs for manufacturer per exploitation year