Innovation and collaborative, synchronized program management for new programs
South Ural State University is one of the largest Russian universities, and is among the country’s top 10 schools according to the Russian Ministry of Science and Education. In 2010 it was awarded national research university status.
South Ural State University is one of the largest Russian universities, and is among the country’s top 10 schools according to the Russian Ministry of Science and Education. In 2010, the university was awarded national research university status, and granted access to public financing for research programs supporting the manufacturing of advanced, mission-critical products for the aerospace and automotive industries. The university has developed excellent research and development (R&D) capabilities available through its Experimental Mechanics Research and Education Center.
The Experimental Mechanics Research and Education Center was established in 2012. Now the Center mostly supports the university’s joint projects with industrial companies in the field of components testing, computational dynamics and strength analysis carried out under federal action programs and Russian government directives. The Center’s experts believe their primary objective is rendering professional experimental research services to support complex product development.
The major reason the university purchased licensed seats of the advanced Simcenter™ solutions was the drive to further develop the university’s capabilities by obtaining the latest equipment and technologies. “As we considered the testing of mission-critical products that require excellent skill and fine-tuning, the Simcenter capabilities could hardly be overestimated,” says Dr. Pavel Taranenko, director of the Experimental Mechanics Research and Education Center at South Ural State University.
Various computer-aided engineering (CAE) solutions are used by the university’s departments for finite element (FE) modeling.
“We were very interested in the unparalleled multi-domain 3D modeling and virtual testing capabilities available in the Simcenter suite from Siemens Digital Industries Software,” says Pavel Taranenko. “Simcenter supports a combination of analysis and physical testing that their competitors do not offer.
As the university developed its requirements, the school’s research council approved it, and a bid was announced. There was a competitive bidding process to select a hardware and software vendor. The winner was OOO Novatest, a company that had already successfully cooperated with South Ural State University. It supplied the following equipment and software from product lifecycle management (PLM) specialist Siemens Digital Industries Software: four shakers, Simcenter SCADAS™ hardware with a measurement system and sensors, modal vibration generators, Simcenter Testlab™ software for closed-loop vibration control testing system, Simcenter Testxpress software, LMS Virtual.Lab software and Simcenter Amesim™ software.
“Back then I had just a vague idea about the system’s capabilities,” says Pavel Taranenko. “I gradually learned more and more about it. Today, I see it not just as a unit that combines computational analysis and physical testing, but as a new approach to product development.”
The researchers at the Experimental Mechanics Research and Education Center realized it would be unwise to buy the expensive equipment and software and not to fully master it. For this reason the university purchased not only the advanced hardware and the software, but also hands-on training from Simcenter Engineering services. The Experimental Mechanics Research and Education Center’s experts have made three visits to Siemens Digital Industries Software’s Simcenter headquarters in Leuven, Belgium, to learn how to use Simcenter technologies in the aerospace industry. The training and a virtual shaker project implemented jointly with Simcenter have helped them master the modal analysis methods; the Simcenter Testlab modules for sine, random, and impact shaking tests; and basic LMS Virtual.Lab capabilities. In addition, the Experimental Mechanics Research and Education Center’s scientists have developed Russia‘s first virtual shaker test procedure for the most complex products.
The procedure is based on advanced Siemens Digital Industries Software technologies, which are not available from Russian vendors. The development of the new procedure is an emerging approach to modeling and testing, which is new to Russia.
“Our procedure is intended for shake testing of mission-critical and high-priced structures in which physical testing can be costly since any damage to the product being tested is very expensive,” says Pavel Taranenko. “For example, consider a satellite. Prior to launch it needs to undergo shaker qualification tests. It would be very bad if it were damaged during testing since there is only one unit.””
The Experimental Mechanics Research and Education Center’s researchers are the first team in Russia to master the virtual shaker testing procedure. A good correlation between the physical testing results (an actual sine shaker test with frequency sweeping) and the virtual modeling results (a 3D product-shaker-control system model) shows that the developed model is correct. The analysis model combines a modal shaker model (a set of experimentally identified frequency response functions), a product finite element method (FEM) model, a shaker’s electromechanical components model and a shaker controller model. Each of the subsystems has been verified against the physical testing results. All this greatly improves the analysis model accuracy in terms of matching frequency responses measured with physical testing.
“Since it was a joint experiment performed at our facility, we mastered the modal analysis technology and gained hands-on experience with experimental natural frequency and mode identification in various structures,” says Pavel Taranenko. “Efficient learning is only achieved by solving a real-life problem.”
The virtual shaker tests have helped the company to avoid the major problem associated with physical tests, such as random factors. Suddenly, for some reason, a shaker test may go wrong, the product may encounter unacceptably high-vibration acceleration and may be damaged. Also, when the product being tested is as heavy as the shaker, it forms a new product- shaker coupled system with unknown dynamic properties. So its behavior is unpredictable in physical tests. Finally, there is the human factor and errors made by the shaker operator.
Companies that are going to use the procedure should realize that the proposed approach takes a lot of tedious effort. “I can only imagine it as a joint project,” says Pavel Taranenko. “Our expertise will be combined with the domain-specific knowledge of the product developers.”
South Ural State University has executed a number of commercial projects with, AO SKB Turbina and PAO KAMAZ. The results clearly confirm the efficiency of Siemens Digital Industries Software’s technologies and their applications.
For instance, now the researchers are working on a dynamic model of a vehicle and its subsystems. The model is to be developed early in the design stage. It is a joint project with PAO KAMAZ.
The Simcenter suite enables South Ural State University to work on advanced projects for the Russian industry, and the ongoing research activities start with undergraduate projects and go all the way to doctorate theses.
“I’m confident the Experimental Mechanics Research and Education Center will be able to further expand its mutually beneficial cooperation with the industry in the field of virtual and physical testing,” concludes Pavel Taranenko.