Ing. Stefano Odorizzi EnginSoft CEO and President

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1 Year 8 n 4 Winter 2011 Multi-objective Optimization with modefrontier Applied to Systems Biology EnginSoft CAE Conference 2011 Welcomes an Audience of 600 CAE users EnginSoft ha proposto una tavola rotonda sulla competitività d impresa presso il nuovo centro di ricerca Synergy between LS-DYNA and modefrontier to Predict Low Velocity Impact Damage on a Composite Plate Structural Optimization of a Car-body High Speed Train An Innovative Analysis and Design Methodology Electromagnetic issues for a IEEE RuBee tag dipped in a fiber/composite laminate FSO and Shuttle Tanker in Tandem Configuration Hydrodynamic Analysis

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3 Newsletter EnginSoft Year 8 n 4-3 EnginSoft Flash For many of us, December is a time for reflection, for harvesting the fruit of our work and our personal efforts of the year. Our Simulation and CAE environments almost constantly see new developments, upcoming software releases and changes. We are asked to be always ready for the new. While this is sometimes a challenge for most of us, every year also brings many new human encounters. In our fields of business, we can consider ourselves lucky to have the opportunity to meet people from the CAE community, from around the world. While we learn about new and different technologies, the human, the engineer, its broad knowledge and experiences, always remain at the core of our attention. By sharing our knowledge, especially on occasions such as the EnginSoft International Conference, we help to shape the future path of CAE and to support the next generation of CAE engineers. In this Newsletter, we speak about the EnginSoft and ANSYS Italian Conferences 2011, the two annual events that offer one of the major knowledge platforms to CAE users in Europe and beyond. ANSYS is the provider of the world s leading software for engineering simulation and EnginSoft s number 1 partner. EnginSoft and ANSYS were delighted to welcome 600 delegates to Verona on 20th and 21st October, to a wealth of topics on today s use of simulation and design tools. In this issue, we also inform our readers about the Round Table Meeting of 100 Top Managers on the occasion of the opening of EnginSoft s Research Center in the Scientific Technology Park Kilometro Rosso. The use of ANSYS Maxwell v.14 is shown in the article on electromagnetic issues for a IEEE RuBee tag dipped in a fiber/composite laminate. The capabilities of modefrontier are described in AnsaldoBreda s work for the structural optimization of a car-body high speed train. Our readers also hear about the use of ANSYS AQWA and the ANSYS Workbench platform for the structural verification of the FSO Mooring System complemented by EnginSoft s broad experiences as a partner to the Oil&Gas industries. The Università degli Studi di Ferrara presents their work with ANSYS CFX 13.0 while University of Debrecen Hungary informs us of how Grapheur can help its users with multiple criteria decision- making problems. Ing. Stefano Odorizzi EnginSoft CEO and President CIRA, the Italian Aerospace Research Centre, illustrates the Synergy between LS-DYNA and modefrontier to predict low velocity impact damage on a composite plate. We hear from EnginSoft Nordic in Sweden on how multi-objective optimization is being applied to systems biology. Here, we encourage our readers to watch the movie Insulin Signaling (SignalPathways) via the link provided! We are pleased to introduce our customer and ANSYS user the company Almacis, and AMD, our partner in the area of High Performance Computing. Digimat is a powerful software for material modeling which is now distributed in Italy by EnginSoft. More software news covers the LIONsolver by Reactive Research, NVIDIA s Tesla GPU, EnginSoft s activities for composite materials with ESAComp and ANSYS Composite Prep/Post as well as MAGMA s release 5.2. The powerful Sculptor tool allows users to parameterize any mesh based on arbitrary cubic bezier control points. Sculptor was recently presented by EnginSoft GmbH at the ANSYS Conference and 29th CADFEM Users Meeting in Stuttgart. Furthermore, we hear about Gruppo Ferroli s project with EnginSoft, the recent introduction of the BENIMPACT project in China and about the Minimaster and the Training Programs of TCN and EnginSoft. Our Japan Column tells us about the CAE University while some of the activities of JANCAE, The Japan Association for Nonlinear CAE, are explained to us in the article by Hideo Takizawa. Please mark your diary for the modefrontier Users' Meeting 2012, which will be sponsored by ESTECO and take place on 21st and 22nd of May 2012 in Trieste. We hope that you enjoy reading the articles on the following pages of this last Newsletter of We always welcome your thoughts, your feedback as well as your ideas for future publications! EnginSoft and the Editorial Team wish you and your families a very happy, healthy and a prosperous New Year 2012! Stefano Odorizzi Editor in chief

4 4 - Newsletter EnginSoft Year 8 n 4 Sommario - Contents EVENTS 6 EnginSoft CAE Conference 2011: 600 partecipanti all annuale appuntamento 8 EnginSoft CAE Conference 2011 welcomes an audience of 600 CAE users 10 EnginSoft ha proposto una tavola rotonda sulla competitività d impresa presso il nuovo centro di ricerca CASE STUDIES 12 Electromagnetic Issues for a IEEE RuBee Tag Dipped in a Fiber/Composite Laminate 15 Structural Optimization of a Car-body High Speed Train - An Innovative Analysis and Design Methodology 18 FSO and Shuttle Tanker in Tandem Configuration Hydrodynamic Analysis Finalized to the Structural Verification of the FSO Mooring System 19 FEM analysis in Oil&Gas Industry 20 Numerical Analysis of a Micro Gas Turbine Combustor Fed by Liquid Fuel 23 Reconsidering the Multiple Criteria Decision Making Problems of Construction Workers Using Grapheur 26 Synergy between LS-DYNA and modefrontier to Predict Low Velocity Impact Damage on Composite Plate 29 Multi-objective Optimization with modefrontier Applied to Systems Biology TESTIMONIAL 31 Eccellenza tecnologica e qualità: Almacis SOFTWARE/HARDWARE NEWS 32 CAE Simulations and Innovations within the High Performance Computing HPC 33 DIGIMAT per la modellazione avanzata dei materiali 34 LIONsolver: Learning and Intelligent Optimization 36 GPU Accelerated Engineering with ANSYS 37 EnginSoft continua l attività sui materiali compositi EVENTS 38 EnginSoft presenterà la release 5.2 di MAGMA a METEF La simulazione di processo nella progettazione di radiatori 39 modefrontier Users Meeting EnginSoft GmbH Silver Sponsor at the ANSYS Conference & 29th CADFEM Users Meeting 2011 The EnginSoft Newsletter editions contain references to the following products which are trademarks or registered trademarks of their respective owners: ANSYS, ANSYS Workbench, AUTODYN, CFX, FLUENT and any and all ANSYS, Inc. brand, product, service and feature names, logos and slogans are registered trademarks or trademarks of ANSYS, Inc. or its subsidiaries in the United States or other countries. [ICEM CFD is a trademark used by ANSYS, Inc. under license]. (www.ansys.com) modefrontier is a trademark of ESTECO srl (www.esteco.com) Flowmaster is a registered trademark of The Flowmaster Group BV in the USA and Korea. (www.flowmaster.com) MAGMASOFT is a trademark of MAGMA GmbH. (www.magmasoft.de) ESAComp is a trademark of Componeering Inc. (www.componeering.com) Forge and Coldform are trademarks of Transvalor S.A. (www.transvalor.com) AdvantEdge is a trademark of Third Wave Systems. (www.thirdwavesys.com) LS-DYNA is a trademark of Livermore Software Technology Corporation. (www.lstc.com) SCULPTOR is a trademark of Optimal Solutions Software, LLC (www.optimalsolutions.us) Grapheur is a product of Reactive Search SrL, a partner of EnginSoft (www.grapheur.com) For more information, please contact the Editorial Team

5 Newsletter EnginSoft Year 8 n 4-5 RESEARCH AND TECHNOLOGY TRANSFER 42 BENIMPACT Suite has landed in China TRAINING 43 Alta formazione: TCN punta ad una specializzazione sempre più avanzata JAPAN CAE COLUMN 44 CAE Seminars in Japan CAE UNIVERSITY 46 NPO Activity for Implementation of Anisotropic Elasto-plastic Models into Commercial FEM Codes Newsletter EnginSoft Year 8 n 4 -Winter 2011 To receive a free copy of the next EnginSoft Newsletters, please contact our Marketing office at: All pictures are protected by copyright. Any reproduction of these pictures in any media and by any means is forbidden unless written authorization by EnginSoft has been obtained beforehand. Copyright EnginSoft Newsletter. Advertisement For advertising opportunities, please contact our Marketing office at: 50 EnginSoft Event Calendar 52 Corsi di addestramento software 2012 PAGE 8: ENGINSOFT CAE CONFERENCE 2011 WELCOMES AN AUDIENCE OF 600 CAE USERS PAGE 12: ELECTROMAGNETIC ISSUES FOR A IEEE RUBEE TAG DIPPED IN A FIBER COMPOSITE LAMINATE PAGE 15: STRUCTURAL OPTIMIZATION OF A CAR-BODY HIGH SPEED TRAIN AN INNOVATIVE ANALYSIS AND DESIGN METHODOLOGY EnginSoft S.p.A BERGAMO c/o Parco Scientifico Tecnologico Kilometro Rosso - Edificio A1, Via Stezzano 87 Tel Fax FIRENZE Via Panciatichi, 40 Tel Fax PADOVA Via Giambellino, 7 Tel Fax MESAGNE (BRINDISI) Via A. Murri, 2 - Z.I. Tel Fax TRENTO fraz. Mattarello - Via della Stazione, 27 Tel Fax COMPANY INTERESTS ESTECO srl TRIESTE Area Science Park Padriciano 99 Tel Fax CONSORZIO TCN TRENTO Via della Stazione, 27 - fraz. Mattarello Tel Fax EnginSoft GmbH - Germany EnginSoft UK - United Kingdom EnginSoft France - France EnginSoft Nordic - Sweden Aperio Tecnologia en Ingenieria - Spain ASSOCIATION INTERESTS NAFEMS International TechNet Alliance RESPONSIBLE DIRECTOR Stefano Odorizzi - PRINTING Grafiche Dal Piaz - Trento The EnginSoft NEWSLETTER is a quarterly magazine published by EnginSoft SpA Autorizzazione del Tribunale di Trento n 1353 RS di data 2/4/2008

6 6 - Newsletter EnginSoft Year 8 n 4 EnginSoft CAE Conference 2011: 600 partecipanti all annuale appuntamento La Fiera di Verona ha ospitato l edizione 2011 del maggiore appuntamento in Italia dedicato al calcolo scientifico: l EnginSoft International Conference, CAE Technologies for Industry e l ANSYS Italian Conference. Oltre 600 i congressisti, esperti ed opinion leader in metodi e tecnologie CAE, che il 20 e 21 Ottobre scorso si sono incontrati, presso il Centro Conferenze del polo fieristico di Verona. Molte le aziende presenti, tra cui: Ansaldo, Piaggio, Magneti Marelli, Avio, Tetra Pak, Ferrari, Iveco, ENI, a dimostrazione dell utilizzo crescente del CAE in ambito industriale. Tra gli obiettivi della Conference vi è stato quello di offrire ai partecipanti una visione d insieme del comparto, attraverso il contributo di esponenti del mondo dell'industria, dell'università e della ricerca e dai numerosi sviluppatori di tecnologie intervenuti. La Conference ha spiegato Stefano Odorizzi, CEO di EnginSoft è nata nel 1984 quando le tecnologie in fatto di sperimentazione virtuale erano solo oggetto di ricerca da parte delle università. Convinti che queste tecnologie avrebbero avuto un evoluzione importante, abbiamo deciso di abbracciare la sfida e oggi continuiamo a perseguire l obiettivo di trasferire agli operatori del settore le informazioni e le conoscenze relative a questi ambienti di simulazione e supporto alla progettazione. Dopo la sessione plenaria di apertura che, oltre alla Vision da parte del Vice Presidente di ANSYS Inc., ha ospitato un mini simposio dedicato alla tematica del geo-modeling, l evento è continuato su sessioni parallele, ognuna delle quali Fig. 1 - Stefano Odorizzi - CEO di EnginSoft - in sessione plenaria. focalizzata su una macroarea tecnologica o applicativa: meccanica, fluidodinamica, ottimizzazione, simulazione di processo, compositi, ecc. Di grande appeal sui partecipanti e di interesse perchè d attualità, l esperienza presentata da Ansaldo Energia di Genova in tema High Performance Computing. Stefano Santucci, IT manager di Ansaldo, ha illustrato le ragioni della migrazione da una struttura formata da sole workstation ad un cluster in cui l hardware distribuito e HPC non solo convivono felicemente ma si integrano in un tuttuno estremamente efficiente sia in termini di performance di calcolo che di ritorno dell investimento per tutta l azienda. Fig. 2 - Scorcio della sala conferenze di Verona nel corso di uno dei workshop.

7 Newsletter EnginSoft Year 8 n 4-7 Nel corso dei lavori relativi alla sessione sulla simulazione meccanica sono stati presentati alcuni importanti progetti tra i quali lo sviluppo di un innovativo sistema di contenimeto di argon liquido, commissionato dal CERN di Ginevra, che consentirà di approfondire la ricerca scientifica sui neutrini. EnginSoft ha inoltre illustrato il progetto di un veicolo filoguidabile, realizzato in collaborazione con WASS, finalizzato all esplorazione subacquea sino a quattromila metri di profondità. La sessione dedicata alla simulazione CFD (Computational Fluid Dynamics) ha, invece, reso evidente quello che è oggi, rispetto al passato, il ruolo centrale del progettista che, attraverso sofisticati strumenti di simulazione di cui può disporre, ha l opportunità di focalizzarsi principalmente sull aspetto ingegneristico del problema, delegando al software l onere di governare gli aspetti matematici di base. Progettare in CFD oggi si traduce nella necessità di avere: efficienti funzionalità di dialogo con i sistemi CAD, procedure automatiche di meshing e parametrizzazione del modello. Tema centrale della sessione dedicata all ottimizzazione è stata l analisi dello stato dell arte sulla simulazione multiobiettivo, tematica molto utilizzata in ambito automotive, dimostrato dalle testimonianze di Ferrari, Iveco e Continental. Novità e successo di pubblico anche per il workshop dal titolo La progettazione delle strutture in materiale composito coordinato da Marco Perillo e dal suo team di ingegneri. Scopo del seminario è stato quello di condividere lo stato dell arte dei metodi di progettazione e degli strumenti di analisi strutturale sia sul piano teorico/concettuale, sia sul piano applicativo. A dimostrazione di molte tematiche verticali sostenute da EnginSoft, grazie anche all esperienza nel progetto BENImpact, è stato inserito nel programma un workshop dedicato all utilizzo del CAE in campo ECO-Building e progettazione sostenibile, il riscontro è stato notevolmente positivo e ha dimostrato l ottima integrazione del CAE anche nelle tematiche di frontiera. L attività congressuale, inoltre, è stata affiancata da un area espositiva, in cui quasi 30 tra le più importanti software house CAE, sviluppatori hardware e di applicazioni complementari hanno condiviso con i partecipanti le novità relative ai loro prodotti. Particolarmente emozionante la Cena di Gala organizzata presso il vicino Museo dell Auto e della Tecnica Nicolis. Qui i visitatori, prima delle portate, hanno potuto osservare automobili, motociclette e oggetti unici da collezione di epoche differenti. Le tecnologie di simulazione rivoluzioneranno i processi progettuali attualmente adottati dalle aziende manifatturiere ha concluso il CEO di EnginSoft. Oggi si dice che queste tecnologie si integrano nel processo progettuale; in futuro oramai prossimo, queste tecnologie diventeranno il processo progettuale. Con questo messaggio diamo ai lettori appuntamento all edizione 2012 della CAE Conference EnginSoft, sperando di accrescere ulteriormente la community di analisti e imprenditori che credono nell innovazione attraverso l utilizzo delle tecnologie di sperimentazione virtuale. Per ulteriori informazioni: Luisa Cunico, EnginSoft ATTI DELLA CONFERENZA 2011 Sono disponibili in download gli atti della Conferenza EnginSoft 2011 all indirizzo: Fig. 3 - L area espositiva in cui i congressisti hanno avuto l opportunità di dialogare direttamente con i produttori di tecnologia presenti in sala.

8 8 - Newsletter EnginSoft Year 8 n 4 EnginSoft CAE Conference 2011 welcomes an audience of 600 CAE users The Exhibition Centre in Verona (Verona Fiere) hosted the 2011 edition of the major event in Italy on simulation based engineering and sciences, the EnginSoft International Conference, CAE Technologies for Industry, and the ANSYS Italian Conference. EnginSoft and ANSYS had the great pleasure of welcoming over 600 attendees, among them many CAE experts and opinion leaders, to the Congress Centre in Verona on 20th and 21st October. Representatives of large companies participated and contributed to the conference program as well: Ansaldo, Piaggio, Magneti Marelli, Avio, Tetra Pak, Ferrari, Iveco, and ENI, to name just a few. Their involvement underlined how CAE technologies are being used more and more in industry. One of the goals of the Conference was to offer the participants an overall view of such technologies with presentations from industry, universities, research organizations, and technology developers. The Conference explained Stefano Odorizzi, CEO of EnginSoft was organized for the first time in 1984, when technologies in the field of virtual prototyping were just studied in universities. At the time, we saw great evolution, and this is what made us decide to invest in these technologies. Today, our goal is to transfer as much information and knowledge as possible about these simulation and design tools to the experts in this field. Fig. 1 - Swaminathan Subbiah - Vice President, Corporate Product and Market Strategy at ANSYS - during his speach talking about future developments. The Plenary Session that opened the event, featured the Vision of the Assistant Director of ANSYS Inc. and a Mini-Symposium on geo-modeling. Later on in the afternoon, the program offered to the audience a number of parallel sessions focused on different technological fields: mechanics, fluid-dynamics, optimization, process simulation, composites, etc. One of the particularly captivating presentations on current topics was the contribution by Ansaldo Energia of Fig. 2 - Welcome desk at EnginSoft area.

9 Genova on High Performance Computing. Stefano Santucci, the IT manager of Ansaldo, explained the reasons why the company has left a structure with only workstations for a structure with a cluster, where the distributed hardware and the HPC were perfectly integrated thus generating an efficient computation performance and ROI for the company. In the session about mechanical simulation, some important projects were presented, such as the development of an innovative storage system for liquid argon - committed by CERN (European Organization for Nuclear Research) in Geneva that allows to perform in depth studies on neutrinos. On this occasion, EnginSoft explained the project of a wireguided vehicle, implemented with WASS, for underwater exploration activities of up to 4000 m under sea level. The CFD session stressed the central role of the designer nowadays, compared to the past. Today, we can focus on the engineering side of the problem, thanks to sophisticated simulation tools, by entrusting the management of the basic mathematical processes to the software. Designing in CFD means: effective connections with CAD systems, automatic mesh procedures and model parameterization. The session about optimization emphasized the state-of-the-art of multi-objective simulation, a topic commonly discussed in the automotive field as Ferrari, Iveco and Continental assured us. The workshop titled The design of structures in composite materials, managed by Marco Perillo and his team of engineers, also turned out to be a great success. The workshop s aim was to share the state-of-the-art of the diverse design methods and the structural analysis tools, both from a theoretical/conceptual and applicative level. Another interesting workshop was connected to the BENImpact Project and the ECO-Building field. The results were incredibly positive and demonstrated how perfectly CAE is integrated in the frontier topics. Fig. 3 - Some beauties inside of the Nicolis Museum - Verona. An important aspect of the annual event is the exhibition area. This year, nearly 30 of the most well-known CAE software houses showcased their hardware and software products. The conference attendees could hear about the latest developments and news in personal talks with some of the developers. Finally, another highlight was the Conference Gala Dinner, held at the Nicolis Museum of Cars, Technology and Mechanics, which houses a private collection of vintage cars and motorbikes of Mr. Luciano Nicolis. On this Newsletter EnginSoft Year 8 n 4-9 occasion, before the dinner started, our guests from around the world enjoyed a guided tour of the large exhibition rooms of the museum. The CEO of EnginSoft closed the Conference saying that Simulation technologies will radically change the design processes currently used in manufacturing companies. Now we are saying that such technologies are integrated in the design process; but in the next years they will be the design process itself. With this message in mind, we ask our attendees and readers to keep an eye out for the 2012 edition of the EnginSoft International CAE Conference hoping that the Virtual Prototyping Community will grow further and further until we meet again! For more information: Luisa Cunico, EnginSoft CONFERENCE PROCEEDINGS Conference Proceeding are now avaliable to download on:

10 10 - Newsletter EnginSoft Year 8 n 4 EnginSoft ha proposto una tavola rotonda sulla competitività d impresa presso il nuovo centro di ricerca Il 24 Novembre scorso si è tenuta a Bergamo, in occasione dell inaugurazione del nuovo Centro di Ricerca EnginSoft presso il Parco Scientifico Tecnologico Kilometro Rosso, una Tavola Rotonda dal titolo Lean Design e Competitività d Impresa - Innovazione e moderni strumenti per il management strategico. All evento, al quale hanno partecipato oltre 100 Top Manager delle più importanti imprese manifatturiere italiane mentre al tavolo dei relatori si sono seduti: Roberto Formigoni (Presidente Regione Lombardia), Alberto Bombassei (Vice Presidente Confindustria), Antonello Briosi (Vice Presidente Confindustria Trento), Mirano Sancin (Direttore Generale e Consigliere Delegato del Parco Scientifico Tecnologico Kilometro Rosso), Massimo Egidi (Presidente della Fondazione Bruno Kessler), Giancarlo Michellone (già Presidente di Area Science Park di Trieste e ora Presidente GMC Consulting), Marie Christine Oghly (Presidente MEDEF, Parigi), Sergio Savaresi (professore al Politecnico di Milano) e Stefano Odorizzi (CEO EnginSoft). Durante la tavola rotonda, condotta e moderata da Federico Pedrocchi - giornalista scientifico di Radio 24-Il Sole 24 Ore, gli opinion leader, provenienti dal mondo delle istituzioni, dell impresa e della ricerca scientifica si sono confrontati sul tema dell innovazione quale fattore chiave di successo e competitività d impresa anche, ma soprattutto, in tempo di crisi di mercato. È Alberto Bombassei ad entrare in tema affermando che le strategie applicate dalla maggior parte delle aziende italiane - non solo PMI - fondate sull innovazione incrementale e di processo, sostanzialmente finalizzate ad abbattere i costi di produzione e migliorare la qualità dei prodotti, non sono più sufficienti. Aggiunge il presidente di Brembo Spa in un mercato Globale, dove i paesi in via di sviluppo e con mano d opera a basso costo la fanno da padrone, occorre sempre più innovare per essere competitivi e mantenere la leadership. Gli fa eco Mirano Sancin, Direttore Generale di Kilometro Rosso, che aggiunge è l innovazione radicale e di prodotto che contribuisce maggiormente a spostare le attività economiche, e produttive, da un elevata concentrazione di manodopera (sempre più difficile da reperire) ad una elevata concentrazione di conoscenza (tipica dei sistemi più evoluti) e ad aumentare la competitività delle imprese a livello internazionale. Anche le istituzioni collaborano, con l imprenditoria e la ricerca strutturata, alla causa comune della competitività dell impresa-italia attraverso veri e propri strumenti finanziari costituiti dai Bandi. Chi non ricerca non cresce è Fig. 1 - Alberto Bombassei, Vice Presidente di Confindustria, che commenta il contesto di mercato entro cui le aziende italiane devono operare lo slogan citato da Roberto Formigoni e promosso da Regione Lombardia che nel biennio ha stanziato fondi per oltre 80 milioni di Euro destinati alla ricerca e all innovazione industriale. Nonostante le difficoltà, le aziende virtuose continuano ad innovare, innovare e ad investire nella crescita accenna il Governatore di Regione Lombardia - in un momento di difficoltà generalizzata, le aziende investono in ricerca per cercare nuovi margini di profitto e aprirsi a quel contesto di conoscenza distribuita che caratterizza la società moderna. È questo il dato positivo - conclude Formigoni - che emerge dai primi risultati del Bando Regionale. Le nuove tecnologie di simulazione e di analisi predittiva sono di fatto riconosciute da molte aziende un effettiva rivoluzione dei processi progettuali ha affermato Giancarlo Michellone. In questo contesto di ricerca applicata ed incubatore tecnologico si inserisce a pieno titolo anche EnginSoft che da tempo collabora con l R&D di Brembo per la simulazione di sistemi frenanti e con l Istituto Mario Negri per applicazioni farmacologiche: realtà entrambe insediate nel Parco Scientifico. Con oltre 30 ricercatori ed ingegneri impiegati

11 Newsletter EnginSoft Year 8 n 4-11 Fig. 2 - Overview della platea di Imprenditori e Top Manager che hanno partecipato alla tavola rotonda organizzata da EnginSoft a Bergamo nella sede di Bergamo, l azienda investe sul proprio futuro e rilancia la presenza in Italia trasferendo una delle sedi all interno di un incubatore tecnologico d eccellenza qual è il Kilometro Rosso. È dal 2007 che collaboriamo con il Consorzio Intellimech e con altri laboratori di ricerca inseriti nel Parco Scientifico Tecnologico - afferma Stefano Odorizzi, Presidente di EnginSoft in questi anni abbiamo toccato con mano l importanza di far parte di questa struttura che condivide la nostra stessa mission: sviluppo di tecnologia e innovazione. L evento di oggi promosso da EnginSoft, in uno dei rari casi in cui istituzioni, ricerca universitaria e impresa si riuniscono a confronto su temi strategici e di vitale importanza per il sistema-italia, è la riprova del consenso e dell autorevolezza che l azienda, negli anni, ha riscosso sul mercato. Per ulteriori informazioni: Mosè Necchio - EnginSoft La gestione progetto in ottica Lean Design Sviluppare processi di progettazione e sviluppo-prodotto sempre più rapidi ed affidabili è oramai riconosciuta quale una necessità strategica imprescindibile. È quanto è emerso, in estrema sintesi, dal simposio di Bergamo. Per esplorare diverse alternative di soluzioni è necessario essere rapidi e tempestivi nell apprendere i limiti e le potenzialità di ciò che stiamo ideando e progettando. La velocità e l efficacia nell esplorazione delle alternative, quindi, sono profondamente legate alla capacità di sperimentazione attraverso un numero significativo di prototipi ognuno funzionale alla verifica delle intenzioni di progetto e la loro corrispondenza alle necessità del cliente. Questo approccio, mediante l impiego di prototipi fisici, potrebbe richiedere tempo e risorse in numero incompatibile con il budget disponibile. Anche nei processi di innovazione-prodotto esistono forme di spreco definibile in: qualsiasi attività che non crea Valore per il cliente. Il tema su cui riflettere è che tali sprechi non sono immediatamente visibili e non sono, quindi, facilmente aggredibili se non attraverso le giuste metodologie per individuarli. La riprogettazione dei processi di innovazione-prodotto, in chiave sperimentazione virtuale, può liberare enormi energie creative e di conoscenza che frequentemente sono già presenti negli uffici tecnici e di calcolo. EnginSoft, su questo tema, sta elaborando e sviluppando iniziative ad hoc finalizzate a diffondere le metodologie di Lean Design con la relativa valutazione del ROI soprattutto attraverso l impiego della Simulazione e della Sperimentazione Virtuale.

12 12 - Newsletter EnginSoft Year 8 n 4 Electromagnetic Issues for a IEEE RuBee Tag Dipped in a Fiber/Composite Laminate The IEEE RuBee communication standard defines the air interface for radiating transceiver radio tags using long wavelength signals (up to 450 khz). Conforming devices can have very low power consumption (a few microwatts on average), while operating over medium ranges (0.5 to 30 meters) and at low data transfer speeds ( bps). In this article, the approach to model a loop tag operating at khz through ANSYS Maxwell v.14 is described when the sensor is dipped in a multilayer fiber/composite laminate. Some preliminary results are shown in terms of input inductance and magnetic fields. Free standing antenna modeling Fig. 1 shows the prototype and the numerical ANSYS Maxwell model of a magnetic loop antenna for the short range RuBee protocol. The antenna (Fig.1a) is a 42mm radius multi-turn coil made of 33 loops of a copper wire with a section radius equal to 0.25mm. The numerical model is made of a solid single wire with a circular section Fig. 2 (a) - Prototype of the multi-turn microstrip coil and (b) Maxwell 3D model. The PCB connector is visible in the bottom of Fig. 1a. The two side copper plates are helpful to tune the antenna input impedance. CPW fed antenna is made of 16 properly distanced 0.6mm wide microstrip copper line turns. The background scenario was modeled by imposing radiation boundaries to the problem region in order to simulate free emission into space. In the operational environment, the latter could be a lossy and/or conductive media like sea water and oil (see Table I for more details) and it should be consequently modeled with the correspondent electric characteristics. Table I - Dielectric characteristics of some media compared with free space Fig. 3 shows a sample of the electric current density along the loop and on the solid wire section. The imposed Fig. 1 (a) - Prototype of the 33-turn copper wire coil and (b) geometrical details of the Maxwell 3D model. In the top of Fig. 1a the microstrip feeding line and the PCB connector are visible. radius rls equal to 0,143cm. As indicated in the bottom of Fig. 1b, this value corresponds to the radius of a circumference with a surface equal to the sum of the 33 wire sections. The second element is a multi-turn printed loop on a 0.8mm thick FR4 laminate and it is shown in Fig. 2. The Fig. 3 - Sample of the current density distribution along the loop

13 Newsletter EnginSoft Year 8 n 4-13 stranded current, constant on the wire section, is visible in the bottom left detail and, as expected, the current is constant along the loop. Fig. 4 shows a sample of the magnetic induction distribution in a plane containing the loop axis. This B field distribution is a well-known result, according to basic electromagnetic theory. Indeed, the loop length is much smaller than the free space wavelength at 131 khz (around 2.3km), so resulting in an elementary loop design. For such elements the near field is mainly magnetic and completely decoupled by the electric field. some other aspects could make the printed square loop preferable, like its mechanical stability and the more accurate repeatability of the prototyping. Table II shows the simulated and measured values of the input inductance for the two configurations. For the solid loop case, the calculated value is obtained from a correspondent analytical Fig. 6 - H field distribution along the loop axis for the wire solid ring and the printed microstrip square loop. Table II Input inductance for the two antenna configurations Fig. 4 - Sample of the magnetic induction in a plane orthogonal to the sweep. Even if the device is an antenna, this consideration justifies the use of ANSYS Maxwell 3D rather than ANSYS HFSS because the magnetic near field characterization provided by Maxwell 3D fully satisfies the design requirements. model and this is in good agreement with the simulated one. The measured inductance is around 10% less than the previous cases. This disagreement results from the mismatch between the transverse section areas of the solid loop of the simulated and calculated cases and the 33-turn one of the prototype (see the bottom detail of Fig.1b). A 0.9 fill factor (Fig.1a) corresponding to the missing lighter areas of the prototype with respect to the numerical models should be considered to compensate it. An excellent agreement between simulations and measurements is apparent for the printed element. Electromagnetic modeling and analysis of the composite laminate The two prototypes would be dipped in a composite material as shown in the sample of Fig. 7. A composite laminate can be schematized as a stack-up of several plies, each of them made of a sheet of fibers filled Fig. 5 - Details of the mesh characteristics for the microstrip printed loop Fig. 5 shows a sample of the mesh for the microstrip printed square loop. Around tetrahedra were used for the computational domain and around for the loop. For the solid wire loop tetrahedra were necessary for the computational domain and were used for the loop. Fig. 7 - Sample of rectangular loop dipped in a fiberglass composite laminate. Fig. 6 shows the H field distribution along the loop axis, for both configurations. The H field is higher for the wire loop, suggesting the use of this antenna type. However,

14 14 - Newsletter EnginSoft Year 8 n 4 isotropic, in the sense that only their intrinsic dielectric characteristics are known. On the other hand, the structures in Fig. 8b and c are generally anisotropic, as a result of the applied methodology. The permeability and permittivity tensors need to be calculated according to the material properties and to the problem geometry, as: Fig. 8 - Single composite ply: (a) schematic model, (b) equivalent model for the intermediate fiber/resin layer, (c) equivalent model for each single ply where: and g is a function of the ratio between the fiber and the resin volume in the intermediate layer of Fig. 8a. Fig. 9 shows the Maxwell 3D model with 4 plies above and 4 plies below the wire antenna. Fig. 9 - Example of a composite laminate made of 8 plies: 4 above and 4 below the wire loop antenna with some dielectric resin, as shown in Fig. 8a. An df thick intermediate layer made of some fibers and resin lies between two dr thick single layers of resin. This structure could generally be dissipative, conductive and anisotropic, the latter depending on the characteristics and the distribution of the fibers. An effective approach to model this structure is to define an equivalent layer for each ply. Many models have been recently presented, resorting to different approaches but all of them afford a specific problem without deeply challenging a general approach. In the framework, the approach to model an equivalent layer for each ply is to apply the method described in for the intermediate layer of Fig. 8a, in order to get an equivalent anisotropic intermediate one, shown in Fig.8b. Then, a circuital approach can be applied to the multilayer structure shown in Fig. 8b to result in a single layer equivalent anisotropic model. It is worth noticing that all the constitutive materials (fibers and resin) in Fig. 8a are Each ply has been modeled in Maxwell 3D, including all the material anisotropies and dielectric properties. The work on the analysis of the effect of a number of plies up to 64 is in progress. They have been fully parameterized in order to take into account a number of possible ply configurations and materials. Conclusions In this work, the approach to analyze the electromagnetic performance of a tag antenna for the IEEE Rubee protocol has been described through the use of ANSYS Maxwell. Preliminary results have been shown in terms of radiated magnetic field and input inductance for both numerical models and prototypes. Simulated and measured results are in excellent agreement, proving the tool reliability. The methodology to model a multi-ply composite fiber material has been defined and numerical analyses on the antennas performance in its presence will be the main topic of some future investigations. Per ulteriori informazioni: Andrea Serra, EnginSoft Thanks to Federica Bolognesi, IDNOVA

15 Newsletter EnginSoft Year 8 n 4-15 Structural Optimization of a Car-body High Speed Train - An Innovative Analysis and Design Methodology In the past, the main challenge was to achieve a very high speed, but today the criteria such as energy efficiency, high transport capacity, comfort and low environmental impact are becoming more and more important. For this reason the philosophy of AnsaldoBreda is to combine a settled design process with innovative approaches to optimize the reliability, safety, low power consumption and an easy maintenance. In order to be competitive in the market, especially in this economically challenging period, it is necessary to push the envelope of the available technologies to ensure compliance with top level quality standards. A new methodology approach has been developed by exploiting the new capabilities of the multi-objective design environment modefrontier and it has been applied to the design of the carbody structure of a new generation of High Speed trains. In this context, the aim of the activity was the design optimization of the aluminum carbody structure in terms of weight and dynamic behavior, respecting all project constraints according to the high standard structural and crash requirements of European EN Category P-ll (Fixed units) and TSI Rolling Stock. modefrontier optimization platform to achieve the requested goals. The FE parametric model has been divided into two different main parts: 1. The central parts of the carbody (named fuselage ) as shown in fig.1a; 2. The terminal tapered parts of the carbody as shown in fig.1b. The fuselage geometry (fig.2) is completely parametric in terms of: Starting from the CAD model of the original configuration, the FE comprehensive parametric model has been developed by ANSYS APDL procedure and integrated into the Fig.2 - Section profile of carbody a) number of the profile reinforcements; b) angle, position of reinforcements; c) thickness of reinforcements; d) thickness of external and internal skin of profiles. The aims of the optimization process of a carbody in modefrontier are: a. Minimizing weight b. Maximizing two first own frequencies Fig. 1a - Fuselage Parametric part of high speed train: it has been completely development in ANSYS APDL. Fig. 1b: No -parametric part of high speed train: terminal tapered parts are fixed geometry with the following constraints: a. Max Von-Mises stress for static analysis

16 16 - Newsletter EnginSoft Year 8 n 4 b. Max Von-Mises stress for equivalent crash analysis c. Max Von-Mises stress for fatigue analysis d. Min buckling factor for linear instability analysis The original configuration, only referred to the parametric part of the carbody, weighs Tons. The main goal is the weight reduction by min. 500 Kg, maintaining the first bending frequency of 11 Hz. The static structural analysis and fatigue analysis have been performed for both welded and unwelded region (fig.3), which have different material features: Only the modal analysis has been performed to find out the best region for weight and frequency with no timeconsuming run (less than 1 hour on the cluster machine). The results of this first optimization loop has been used as a starting DOE (Design of Experiment) for the second one, where objectives/constraints related to displacement under pressure loads and to the 5-6 strongest load cases (fig. 4) have been introduced. This step is more time-consuming than the first one (5 hours on the cluster machine). After these optimization loops, some variables have been changed in agreement with AnsaldoBreda, and the final Fig.3 - Section of a carbody structure Due to the high number of time-consuming simulation and the high number of input variables, a progressive approach has been studied for the optimization analysis. Therefore, the optimization analysis has been carried out in three steps: Step1: Screening, driving towards the best designs region; Step2: Rough refinement, including the most important constraint conditions; Step3: Final refinement, achieving the optimal solutions. A total of 23 different working -load cases have been considered, with an additional specific comfort requirement about Static Pressure load (-8 KPa inside Tunnel) which constrained the side walls displacements (Uy < 3mm and Uz < 4.5 mm) The whole simulation took 3 weeks on cluster machine with 8 parallel simulation (32 core). The first optimization step has been carried out taking into account the two most important objectives of the problem (increase of frequency and weight reduction) which lead the designs to the best region and allows to reduce the design space of the input variables. Fig.4a - History of weight convergence (green points: 1st optimization loop; blue points: 2nd optimization loop). optimization run has been done to achieve the best solutions. Since this step was really time-consuming (15 hours on the cluster), the problem has become to monoobjective: only the weight has been considered, while the other objective has become constraints (fig. 5). The set of best designs belonging to the new Pareto frontier has been verified for each operative load condition and the best designs have been chosen using decision making tools. The optimal designs selected on the basis of stress and weight values have a considerable variation of both external and internal skin thickness, which can cause manufacturing problems. In order to avoid such problems, another post processing analysis has been done to find out Pareto solutions with a homogeneous distribution of thickness Fig.4b - displacements in y direction (mm)

17 Newsletter EnginSoft Year 8 n 4-17 along external and internal skin. New post processing using parallel chart applied on best design has been carried out in order to find a suitable solution matching the new requirements introduced a-posteriori (fig. 6). Table II shows the comparison between the best design selected at the end of the optimization analysis (Design ID 378) and the best design after the last post processing considering a thickness uniformity (Design ID 339). Thanks to the implemented methodology and the optimization routine, a considerable weight reduction has been reached. The chosen solution, Design ID 339, has a weight reduction of 546 Kg (- 9.2%) and it has a more uniform thickness variation which simplifies the carbody manufacturing. This work aims to shows how to exploit new design methodologies and new technologies in order to manage industrial design processes that involve a large number of variables (more than 50), several constraints and objectives, finding the best solution according to industrial timing. It is possible to summarize the most important steps of this activity, as follows: The design optimization procedure developed has been completely automated: this allowed to make the most of all available hardware and software resources, completely exploiting the downtime (nights and holidays). The requested weight reduction has been achieved respecting every structural and comfort requirements: this has totally fullfilled the expectations of the modefrontier industrial users. The additional requirement about manufacturing has been fulfilled without rerun any analysis thanks to the new methodology approach: this has been possible thanks to the really powerful capabilities of the post-processing tools of modefrontier. The optimization methodology can be completely re-used for other design processes: this activity was dedicated to a specific carbody but this approach can be easily adapted also to other railway vehicles. For more information: Francesco Franchini, Enginsoft Fig.5 - The workflow of modefrontier with all input and output variables, the final objective and constraints Table I - The table above summarize the optimization strategy adopted. The total number of design has been run in 20 days Fig.6a - Parallel chart of the best designs Fig.6b - The selected design (Design ID 339) with homogeneous thicknesses Table II - comparison between the original solutions and the optimized solutions Table III - Thickness comparison of the side walls of fuselage (profile ref )

18 18 - Newsletter EnginSoft Year 8 n 4 FSO and Shuttle Tanker in Tandem Configuration Hydrodynamic Analysis Finalized to the Structural Verification of the FSO Mooring System Strength and Fatigue Verifications of an FSO mooring system have been performed basing the results on proper hydrodynamic analysis (developed inside ANSYS-AQWA) and structural analyses (developed inside ANSYS-Workbench) of the system and relevant components. Hydrodynamic Analysis The FSO ( DWT), operated by Edison, is moored on the Rospo Mare Offshore Oil Field. The FSO mooring is guarantees via 6 chains connected to a rotating turret, installed at the FSO bow. During the oil offloading operation, the Shuttle Tanker ( DWT) is moored, via an hawser, at the FSO aft end. The offloading operation takes place under proper sea conditions, with waves characterized by significant height (Hs) ad zero up-crossing period (Tz). To each sea state, consistent current and wind have been accounted for. The hydrodynamic model (performed inside Ansys-AQWA suite), simulating the FSO and the Shuttle Tanker (this one moored, at its stern, to a Tug via a mooring cable), refers both to aligned and misaligned meteo conditions (current incoming at 50 degrees with respect to wave direction, wind incoming at 25 degrees with respect to wave direction). On the model (FSO + Shuttle Tanker + mooring lines), time domain hydrodynamic analysis has been performed for each defined sea-state, obtaining, for each mooring chain and for the hawser connecting FSO and Shuttle Tanker, the axial tension as function of time. In order to check the strength resistance of mooring components (such as Chain Stoppers and 'Ecubier') installed at the rotating turret, besides hydrodynamic analyses under offloading conditions, also hydrodynamic analyses of FSO in moored condition, for extreme storm case (100 years return period), have been performed. Strength and Fatigue Verification of Chain-Stopper and Ecubier Based on results of hydrodynamic analysis performed for both extreme and offloading conditions, strength and fatigue verifications of Chain Stopper and Ecubier have been performed. Strength checks have been based on results obtained from contact non-linear analysis performed of Finite Element Model of Ecubier + Chain Stopper under extreme load case (practically the chain minimum breaking load). Fatigue checks have been developed according to spectral approach as required by DNV OS-E301 (Position Mooring), assuming proper S/N curve data as reported in DNV RP-C203 (Fatigue Design of Offshore Steel Structures). The assumed hypothesis at the base of fatigue spectral approach is that the stress range, S, is a random variable characterized by a probability density equal to p(s) and that, for each sea-state, the number of cycles having stress variation in the range of S and S+dS is directly related to n i p(s), where n i is the total number of cycles of that sea-state. Based on this and on the fact that, for offshore structures, the probability density of stress ranges, p(s), can adequately be represented by a Rayleigh distribution, the Fig. 1 - Hydrodinamic Model of FSO, Mooring Lines, Shutter Tanker Fig. 2 - Von Mises Stress distribution on Ecubier and Chain Stopper

19 Newsletter EnginSoft Year 8 n 4-19 damage, D i, for the i sea-state, is given by the following relation: Fig. 3 - Finite Element Model of Ecubier and Chain Stopper where a and m are factors of S/N curve (C curve has been considered for fatigue verification of Ecubier and Chain Stopper), while σ s is the standard deviation of S distribution. Finally, based on Miner-Palmgreen relation, the total damage, D, due to the summation of damages of each seastate, D i, is: Enrico Miorin, Fabiano Maggio, Livio Furlan EnginSoft Fig. 4 - S/N Curves in sea-water with cathodic protection For more information: Livio Furlan, EnginSoft Design and FEM Analyses in Offshore and Oil&Gas Industry Besides competencies in Automotive, Aerospace and Industrial Engineering Simulations, EnginSoft has knowledge also in the Design and Analyses voted to the Oil&Gas and Offshore Industry. Many consultancy activities have been performed via collaborations with the most important Italian players in this sector: ENI, Saipem, Tecnomare, MIB Italiana, Petrolvaves, Cameron, FBM, Officine Resta, Nuovo Pignone, ATB, Foster Wheeler. EnginSoft can supply a full range of services covering projects entire design route, from the earliest conceptual studies passing through FEED and basic design up to detailed design and installation engineering. The following list reports some of the Oil&Gas Business Unit competences: Conceptual and detailed design and structural analysis of fixed offshore platforms (jacket, top-sides, buoyancy tanks, stiffened structures) Design and analysis of subsea foundation templates Design and analysis of pressure vessels, valves, piping, rack, etc. Design and analysis of subsea manifold (even for installation, repairing and retrieval operations) Detailed structural analysis of structural parts (Hulls, Deck, etc.) of Semi-Submersible Vessels Detailed structural assessment of steel Gravity Based Structures (GBS) including stiffened plate code checks Detailed design and structural analysis of risers and FPSO's mooring connectors Revamping of fixed offshore platforms (assessment of structural reliability- re-certification and life extension), fracture and fatigue assessment of installed jacket structures (risk analysis) Motion Analysis of Floating Vessels (even for Marine Pipeline Installations) The BU, which is located in EnginSoft Padova Office and is coordinated by Livio Furlan, has high skills also in the field of structural and mechanical applications in general (as an example the design and analysis of Roller Coaster structures and cars or the design of large valves for hydroelectric power plants). For more information: Livio Furlan, EnginSoft -

20 20 - Newsletter EnginSoft Year 8 n 4 Numerical Analysis of a Micro Gas Turbine Combustor Fed by Liquid Fuel This work presents a CFD analysis of the combustion chamber of a 50 kwel nominal power micro gas turbine. The purpose of the analysis is to investigate the combustion process and performance of the combustion chamber fed by liquid fuels, through 3D numerical simulations performed with ANSYS CFX Firstly, a sensitivity analysis was carried out in order to determine the parameters for the correct modeling of the liquid injection. Then, a simulation campaign was conducted to investigate the case of Jet A feeding and the supply with different liquid fuels deriving from biomass. Introduction Nowadays micro gas turbine (MGT) are one of the more flexible and effective system for the distributed and residential micro cogeneration, due to their compact size, the low operating and maintenance costs, their greater overall conversion efficiency and reduced environmental impact. The continuous flow operation of this system offers a greater flexibility with respect to the unsteady process of internal combustion engines that imposes constraints on fuel characteristics. In particular, MGTs can be supplied with fuel (both gaseous and liquid), characterized by a higher level of contamination thanks to their greater adaptability to different fuel supply. Among the renewable sources, an increasing interest has been shown in fuels derived from biomass since they are a predictable source, allowing the distributed grid-connected generation without causing discontinuities in the electric grid and frequency instabilities. At the same time, vegetable oils have gained attention since they can be low-cost fuels and allow to implement systems for the distributed energy production. MGTs are not well-established systems for straight vegetable oil feeding, yet, because the combustion of these oils had to be investigated due to the opposite physical and chemical characteristics, such as the chemical composition, the lower heating value (LHV), the molecular mass, the density and the viscosity, compared to diesel, biodiesel, dieselvegetable oils and their mixtures. In fact, the combustion performance depends on the atomization process and spray characteristics, which are directly related to the fuel composition and its physical properties, in particular the high viscosity of vegetable oils. The study presented below regards the preliminary analyses performed on a MGT combustion chamber fed by conventional fuel (Jet A), in order to find the correct settings for the simulation of biofuel feeding. Computational domain and numerical models Geometry. The numerical analysis have been conducted on the combustion chamber of Solar T62-T32, a micro gas turbine of 50 kwel nominal power, fed by diesel fuel. The combustion chamber (Figure 1a) is a reverse-flow annular type combustor, with six fuel injectors, 24 dilution holes and a series of holes for the cooling of the liner wall. The air from the compressor enters the combustion chamber in counter-current with respect to the combustion gases, passing through the space between the external wall and the liner s wall. The solid domain of the combustion chamber (Figure 1b) was obtained from the direct measurement of the real geometry (Fig. 1a). Thanks to the periodicity of the number of fuel nozzles, dilution holes and wall cooling holes, the fluid domain was reduced to a 60 annular sector of the combustor (Figure 1c). Figure 1 - (a) real combustor geometry, (b) solid domain, (c) grid of the fluid domain.

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