Cases
Into a higher gear with Materialise scan-to-FEA technology
A precise digital replica with integrated CAD components in less than 3 days
In our industry FEA is a crucial component of the R&D process, so accurate results are absolutely paramount. Materialise proved to be a dynamic partner and perfectly prepared our data for FEA, enabling us to easily yield extremely accurate analysis results. Instead of spending weeks on geometry preparation, we were able to concentrate all our resources on simulation, analysis and most importantly the optimization of the design.
The Belgium-based Hansen Transmissions is an established global wind turbine gearbox and industrial gearbox designer, manufacturer and supplier. They have strong in-house testing and quality control capabilities and devote significant resources to their research and development operations to maintain and enhance their technological leadership. Simulation is a crucial element in this R&D process. Typically, the majority of the simulation project time is spent on geometry preparation, particularly when scanned data is involved. Faced with the need to perform analysis on a legacy part, Hansen Transmission took a wise shortcut by applying Materialise’s scan-to-FEA expertise. In less than 3 days, the Materialise Engineering Services team provided Hansen Transmission with an optimized digital model of the legacy part (see fig.1), ready for CAE.
In just 1 day Materialise digitized the gearbox (see fig.2) with our in-house ATOS II system.
Quick and easy repair of defective scan data
A pre-requisite of scanning is that not every detail of the geometry can be captured. The scanning of the legacy part was no different, in that the scanned geometry was in need of healing and reconstruction. This was done in a breeze using 3-matic’s advanced, semi-automated tools. Holes resulting from deep areas that couldn’t be completely scanned were easily filled using 3-matic’s advanced hole filling capabilities. Areas where the scanner was unable to capture all the information (see fig.3) were redesigned using the sketcher. All unevenness in the 3D model, resulting from the scanning was quickly smoothened. De-featuring was then carried out in order to simplify the mesh and enable faster analysis.
Easily combine CAD and scanned data into one project
3-matic is able to interface directly with geometry generated by multiple sources e.g. CAD systems and scanning. This feature enabled the scan data of Hansen’s legacy component, along with the CAD data of various covers and subcomponents to be handled in one project (see fig.4), treating them uniformly on polygon level. By integrating CAD components with the 3D models generated directly from scan data, significant time savings were achieved.
Powerful mesh optimization in just 4 hours
Once the scanned data was turned into a watertight 3D model with just the amount of detail required for FEA, the engineer started mesh optimization. Using the advanced inspection tools he identified the non-manifold edges and enabled the processing and remeshing of this non-manifold assembly. The entire assembly was then optimally re-meshed in no time using 3-matic (see fig.5). 3-matic’s wide range of advanced tools enables the automatic surface mesh generation, while giving the user full control over the resulting mesh density.
A handy shortcut to FEA
Materialise granted Hansen a valuable shortcut to FEA for their legacy component. Without the use of Materialise’s innovative software and extensive know-how, this project would have been considered impractical due to the complexity of the data and the extensive amount of time it would have taken to create an optimally skewed mesh. However with Materialise onboard, Hansen were able to easily overcome these barriers and streamline their complete FEA preparation process.
About Materialise scan-to-FEA technology
Materialise scan-to-FEA technology offers forward engineering. Instead of reverse engineering the scan data back to CAD, Materialise Engineering Services applies the design tools of its 3-matic software to reconstruct and manipulate the scan data directly. Transforming scan data and/or CAD assemblies directly into a mesh ready for CAE saves significant amounts of time. Click here to find out more.
Materialise Engineering Services –save time and money
Let us take the hassle out of your mesh optimization and reverse engineering steps while also saving you time and money! Complex geometries, such as large CAD assemblies or scan data, no longer pose a problem for your analysis. By employing our innovative software we can easily remesh, optimize and modify faceted data, consistently enabling you to achieve the most accurate analysis results. Click here for more info.
Image descriptions
1.Legacy part of a wind turbine gearbox
2. Digitizing of the gear box using Materialise’s in-house ATOS scanner
3. Areas where not all info was captured during scanning (e.g. within the yellow circle) are easily reconstructed with 3-matic powerful sketcher and hole fill operations (section view)
4. The scan data was easily combined with the CAD data of various covers and subcomponents into one project
5. The entire assembly was optimally re-meshed for FEA purposes in a few hours
6. Analysis of the final model
