CASE STUDIES
The following real world case studies offer a glimpse into the capabilities of Enginise. Note that some of the images have been recreated with alternative geometry due to client confidentiality.
Piston Durability Study
A piston fractured part way through a durability test on a new engine model. The fracture surfaces were analysed and a fatigue fracture mechanism was identified as the root cause of failure. We inspected pistons from the same manufacturing batch and all dimensions and material properties were found to be within design specifications. We carried out FEA considering thermal, inertia and combustion loads and found a low fatigue safety factor in the region of fatigue initiation. Simply adding material to the piston was not an option as this would have knock on effects to the bearing sizes and balancing of the engine. Instead, we specified a different grade of aluminium alloy and optimised the shape of the piston to increase the fatigue safety factor to acceptable levels in all regions of the geometry. After further physical testing, the piston successfully completed the required durability test.
Setup Of Simulation Team in Automotive OEM
During Matt's career he led a project to create a new simulation team within the design department of the automotive company where he was employed. The objective was to do more simulation in house to allow the organisation to achieve ambitious technical targets on new motorcycle models. In collaboration with his team he was responsible for developing simulation methodology, deciding what software and hardware was needed and most importantly he was responsible for recruiting and developing the right people. A decade on the team is still going strong and an integral part of the organisation.
Venous Flow CFD
To demonstrate problem-solving beyond the automotive sector, here is a project undertaken in consultation with surgeons from Cambridge University Hospitals NHS Trust, UK and John Hopkins Hospital, Baltimore, USA. In this case, a methodology was developed that mapped the venous anatomy in the head and neck from medical scans, and created a CFD model that could then predict blood pressure at different points in the venous system. The simulated pressures were validated using catheter pressure transducers on actual patients. The surgeons were able to simulate the effect of removing different flow restrictions in the venous system prior to any invasive procedures, reducing the risk for the patient and improving outcomes. The methodology has now been handed over to PHD students at Cambridge University who are investigating how it can be applied more widely.
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matt@enginise.co.uk
