International FEMFAT Usermeeting 2017

The 11th user meeting – a forum between users and experts as well as industry and science – dealt with the rapid technical changes taking place in vehicles, especially concerning drive systems.

We were able to engage Professor Alfons Esderts from the Institute for Plant Engineering and Fatigue Analysis of the Clausthal University of Technology for the plenary talk, and he provided an overview of the manufacturing influences which the forming of thin sheet metal structures has on operational strength. Of special interest for FEMFAT users was the systematic approach employed to obtain the experimental results and models, which were ultimately implemented as a “forming influence” and which have now been available for a number of years with interfaces for deep-drawing simulations.

Several lectures during the first morning dealt with non-metallic materials, including those of Mr. Dennis Baiz, VW, on a short-glass-fiber-reinforced pendulum support made of polyamide, Dr. Adi Adumitroaie, JKU, on an analysis of aerospace laminates and Mr. Ralf Beck, EMS, on notching effects, again with short-glass-fiber-reinforced polyamides. The general overall impression given was that the forecast quality for composites has improved significantly over the last decade, although, when compared in absolute terms to that of many metallic materials, it still appears to lag behind.

An interesting contribution was made by Dr. Genbao Zhang, VW, on a new support effect concept for notches, which offers theoretical advantages, but for which the issue of its general implementation is still unclear. 

During the subsequent presentation of the new program features in V5.3, the implementation of the weld analysis for stochastic loads (WELD for SPECTRAL) proved to be of special interest.

As a fitting adjunct to this, Michael Tryfonidis, BETA CAE, and Klaus Hofwimmer, ECS, explained in a lecture presented later the modeling and analysis process of the SolidWELD method that has been available since V5.2.

Afterward, Dr. Robert Ehart, BMW, lectured on a number of different progressive analysis methods for safeguarding the service life of diesel engines. Of prominent importance here were influences such as microstructure and complex residual stresses arising from the aluminum heat treatment process.

Due to the technical depth and systematic approach employed, Dr. Ehart was ultimately presented the well-deserved “FEMFAT Best Lecture Award” for the third (!) time.

The topic of robustness was addressed in a lecture by Mr. Ralf Lampert, Dynardo, in which the efficient coupling of OptiSLANG with FEMFAT was demonstrated.

Subsequent to this, Dr. Hidekuni Fukao, Toyota, presented a lecture on the implementation of spot-type laser-welded connections on vehicle body structures and Caner Dönertas, Mercedes-Benz Türk, gave a talk on fatigue analysis validation for truck leaf springs.

The evening was closed with the much-praised “Schmankerlroas” culinary specialty at Gasthof Mayr as well as a glass or two in the wine cellar, and our own upper management honored us with their presence while fascinating discussions took place with many different people.

The second day was opened by Mr. Jochen Heizmann, Hirschvogel, with results of the cooperation with the ECS. The main focus was the recording of the manufacturing influences which arise from autofrettage treatment of injection rails through the coupling of FORGE and FEMFAT and increasing the accuracy.

Mr. Tobias Winter, Hatz Diesel, reported on the endurance limit analysis of aluminum crankcases, which has been greatly improved through the inclusion of casting residual stresses.

Mr. Reinhard Helfrich, Intes, – a lecturer and exhibitor of many years – lectured on the new possibilities of PERMAS with FEMFAT concerning forming optimization and dynamics.

In a lecture by Mr. Franz Strametz, SinusPro, a process was explained which allows the anisotropic material properties of forged crankshafts to be analyzed utilizing existing FEMFAT features.

This was followed by an application-focused lecture from Paul Pochatila, Pioneer Solutions, USA, on weld analysis in accordance with SBS 7808, a lecture on an engine-bearing application of ELASTOLOADS by the winner of the best lecture award in India, Srinivas Kurna, Eicher CV, as well as Dr. Oliver Grieshofer, ECS, with a talk on dynamic load generation, including contact effects (MAMBA + FEMFAT LAB).

The second day came to a fitting close with an unforgettable trip on the Steyr Valley Railway to Grünburg and back. The rustic cars and the solid steam locomotive technology made quite an impression all everyone, especially as the journey was enjoyed socially with beverages and hot foods.

The free Advanced Workshops and company tours on Friday in St. Valentin were attended by 50 participants, and afterwards, we wished a warm farewell to the last guests after a very successful 11th User Meeting.