Especially in mass production, every gram of weight is decisive. Through targeted optimization of the component and the use of high-quality materials, both the costs can be reduced and the service life of the components increased. An optimization always aims at least to one parameter (e.g. weight,) and tries not to influence any other objectives (e.g. stiffness). In the example the weight of the primal geometry was optimized. It could be reduced to 80% whereby the stiffness and stresses in the part have remained almost identical.

  • Process
  • Reference Geometry
  • Optimization
  • Optimization vs. Reference
  • Simulation
  • Optimized Geometry

Strenght assessment

Strength calculations identify areas of an component that are subject to high and low loads. The analytical strength verification provides insight into the static and cyclic safety of the parts. If no limits are set by the authority, regulations can be used such as the FKM-code, AD-2000, Eurocode or ASME to calculate the safety of a component. Using specially programmed tools, we can quickly make a statement about components. Team H2 can give a fast report on safety and optimization suggestions. The FKM code covers almost all manufacturing possibilities and verification criteria.

  • Welded and non-welded parts
  • Static and cyclic (service life) strength assessment
  • Fracture mechanics analysis
  • Global and local utilization
  • FKM - static assessment
  • Stress-Strain Curve
  • Comparison FKM-Eurocode
  • Eurocode - fatigue assessment

Service life calculation

A design for fatigue strength is often not possible. Components under high dynamic loads basically have a limited service life. If the loads are known, the service life of the components can be determined using various rules and calculation methods. Dynamic loads can be determined analytically, via numerical modal analysis and structural response calculation or experimentally via strain measurement via strain gauges.

Welding and manufacturing technology

Modern welding processes are characterised by the reduction of residual stresses and an almost matched strength range of the weld seams. By using different preheating temperatures, welding consumables and weld build-up types, these parameters can be precisely tailored to the requirements of the components.

  • Simulation welding seam
  • Welding process

Computational Fluid dynamics

Whereby the finite element analysis is used to analyse solid structures and their behaviour under static and dynamic loads, computation fluid mechanics (CFD) is used so analyse fluids. Pressure distributions, losses due to fittings in pipes, 2-phase behaviour in weirs and dams and other behaviours can be modelled in cfd to obtain the best design for hydraulic components. Examples for cfd analysis are:

  • Discharge capacity of a hydraulic spillway
  • Dynamic pressure distribution on steel components
  • Heat transfer in heat exchangers
  • Mixing behaviour of fluids with different properties (e.g. temperature)
  • Weir discharge 2d
  • Weir discharge 3d
  • Distributor flow

Fracture mechanics

The fracture mechanical consideration of a component is necessary for a wide variety of applications.

  • evaluation of cracks in the component (found via NDT)
  • fracture mechanical design (static, service life)
  • fracture mechanical strength of materials used
  • crack growth analysis
  • damage analysis after component failure

With our experience and the use of the latest calculation methods in numerical and analytical fracture mechanics, we can quickly discuss your problem and find an appropriate solution.

  • Fracture mechanics specimen
  • Crack meshing
  • Crack growth calculation

Strain gauge measurement

Strain gauges are mainly used to determine real strains and stresses on components in use. With our highly sensitive measurement units from DEWESoft we can parallel measure up to 16 strain gauges. With higher lead time even more strain gauges can be measured. Strain gauge measurements are highly complex and require an exact application, structured working methods and a wealth of experience from the executers. Those measurements are carried out inter alia in order to validate numerical or analytical models, proof of regulations from authorities or on-line measurement of load spectrums.

  • Applied Strain Gauge
  • Stress-Strain Curve
  • Measurement unit
  • Strain gauge, 2-axis

Vibration measurement and analysis

Components under dynamic loads as well as rotating machines are always be exposed to vibrations. If the loads due to vibrations are to high, cracks can arise, and the components can be damaged. With numerical methods natural frequencies and forms can be calculated. By clever changes of the stiffness or mass of the components those parameters can be influenced to reduce vibrations. By the use of our measurement units’ natural frequencies and forms as well as the amount of vibration velocities or accelerations can be determined.

  • Measurement
  • Sine wave
  • Measurement unit

Corrosion protection

Especially on components designed for a high service life, corrosion protection is an important criterion. Decreasing mechanical properties such as pitting corrosion, stress corrosion or the simple loss of material thickness should be prevented by an optimal corrosion protection. With high-class coating materials, an optimized working process depending on the application situation, protection times of about 40 years are possible. A lot of tests, such as cross hatch tests, coating thickness measurement, can be obtained to determine the condition of existing coatings. Even bevore the coating is applied, tests such as the roughness of sandblasted surfaces or the salt concentration on washed surfaces, can help to obtain an optimal grade of coating.

  • Corroded flange
  • Thickness measurement
  • Cross hatch test