EL.V.AL. S.A. is the major aluminum production and processing company of the VIOHALCO Group, the largest metals group in Greece. The new industrial roller to be installed at EL.V.AL. was designed by TEKA Systems S.A. a company offering engineering services for the industry. A roller in an aluminum processing company is a very important piece of machinery that needs to operate safely and efficiently. This can be achieved only if the large assembly of the roller parts works elastically, otherwise the large piston forces of 150 to 200 tn required for the thickness reduction of the aluminum slabs will cause undesirable or even disastrous results.
TEKA Systems ordered to SIMTEC a FEA model for the roller, which was constructed in ANSYS Mechanical for the simulation of its static structural behavior in standard (150 tn) or overload (200 tn) operating conditions. Initially, the roller assembly of 3123 parts, was imported from AUTODESK Inventor into ANSYS DesignModeler. Fig. 1 shows the assembly as viewed in AUTODESK Inventor, whereas Fig. 2 presents the symmetric model in ANSYS DesignModeler after the import and the optimization process. Next the FEA mesh was constructed as shown in Fig. 3. The final step was to provide the loads of the symmetric model, i.e. the rolling piston force, the self-weight and the moments arising from omitting the gear box that drive the roller’s two vertical shafts from the FEA model.
The resulting strain and stress field for both 150 and 200 tn piston force, showed that inelastic deformation was detected only in very small and confined regions near corners. This is very typical in FEA of “false” high stress values, which does not reflect to reality. In most of these few regions bends or chamfers were substituted by sharp-cornered equivalents during geometry simplification, therefore their stress-relief effect was not represented in the FEA model. Concluding, the FEA model showed that the roller will perform elastically for loads up to 200 tn. Fig. 4 shows the Equivalent Stress in MPa of the vertical roller for the overload case of 200 tn and Fig. 5 the total deformation in mm of the machine for the standard case of 150 tn.
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KRONOSPAN is the global leader in the production of particleboards, MDF (Medium Density Fibreboard), laminate flooring and UF/MUF/MF resins for wood-based panels. It is one of the fastest growing enterprises in woodworking industry worldwide and located in 22 European countries, USA and China. The group’s revenue reaches 4 billion $ (2015).
In several production stages of the company, a batch reactor is utilized in order to mix liquids and solids that are used at the manufacturing process. KRONOSPAN decided to design a larger reactor, which will come from the scaling up of an existing one that operates satisfactorily in several production sites. However, intense heat generation and viscosity changes are sometimes exhibited in a number of production stages. So, it was decided to firstly create a CFD model in order to verify the proper functioning of the new reactor prior to manufacturing.
This consulting project was assigned to SIMTEC. The purpose of the CFD study was to verify that the new scaled-up reactor will still provide efficient mixing and heat transfer, which are very crucial not only for high output and quality of the product but also to avoid off-limit conditions that may range from discarding the batch to completely destroying the reactor due to content solidification (run-off).
The 3D solid geometric model was imported into ANSYS DesignModeler for processing. Next, the computational mesh was constructed (ANSYS Meshing) needed for the simulation process. The CFD solution leveraged an appropriate turbulence model of the Reynolds-Stress family, capable of capturing the flow characteristics, especially the swirl effect caused by the impellers rotation. The later was prescribed by the Multiple Reference Frame (aka Frozen Rotor) algorithm. Fig. 1 shows the velocity magnitude in various planes inside the reactor. Simulation results confirmed the efficiency of the new design in terms of rapid and sufficient mixing rates, which guarantee the intended thermo-chemical performance of the design.
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SIMTEC organized succesfully workshops on Structural Mechanics, Computational Fluid Dynamics and High & Low Frequency Electronics simulation in Sofia at 7-8 December 2016. They were addressed to engineers that are involved in the designing process and in the Research and Development (R&D) of innovative new products and processes. Companies, research institutes and universities from Bulgaria that participated the event, had the opportunity to be informed about the latest simulation analysis techniques and the ANSYS simulation software solutions. Below are presented some photos of the event.