Laboratory Virtual Product and Process Development (VPP)

Student at a computer simulation.
  • Support the training in mechanical engineering design
  • Application of CAD and FEM in the CAE process
  • Design studies with 3D CAD
  • Computer-aided dimensioning of machine parts
  • Finite Element analyses for the simulation of the component behaviour under mechanical and thermal loads
  • Dimensioning of components in relation to fatigue strength
  • Numerical simulation and visualisation of dynamic processes
  • Represent Esslingen University of Applied Sciences in working groups for design and CAD at the Baden-Württemberg universities of applied sciences.

 

Hardware

  • 18 x 64Bit Fujitsu-Workstations, Intel® Core™ i7 mit 2.20 GHz
  • 1 x DELL PRECISION TOWER T7910. XEON® E5-2623 v3, 4 cores, 3 GHz, 8 GB DDR4-RDIMM memory (2 x 4 GB)
  • DIMENSION ELITE 3D-printer (from Stratasys)
  • Ultimaker 3D-printer 3 Extended
  • Single-mass oscillator, Double-mass oscillator
  • Testbench to visualise rotational oscillations
  • Device to investigate lateral critical speeds

Software

CAD

  • PTC Creo with additional application Startup Tools
  • Rendering with KeyShot
  • Creo - Ansys Geometry interface

 FEM

  • ANSYS
  • Creo Simulate

Machine elements

  •   KISSsoft

Miscellaneous

  •   MATLAB

  •   FlexPro

  •   CD-Adapco  STAR-CCM+

  •   LabVIEW

Other

Various types of software for project planning, database searches, collection of electronic catalogues, statistics software, use of and responsibility for mechanical engineering software used in the computer centre on 100 PC-Workstations.

Laboratory exercises

Introduction to the application of the PTC Creo CAD system

CAE (engineering design, Finite Element Method)

Machine dynamics

Important for students: laboratory exercises, dates and documents can be found at W:\Faculty-MS\2 Lehr- und Forschungsfabrik Maschinenbau\LKS\CAD-Kurs or in the Moodle-Kurs "CAD 1"

 

Introduction to the application of the PTC Creo CAD system

2 Dimensional drawing of a shaft
2D drawing of a shaft
  • Teaching the necessary knowledge and basic rules for modeling components and assemblies of simple to medium complexity, deriving 2D drawings from these components and assemblies.
  • 3D geometry: profiles and rotated forms, tension members and parallel composite elements, material cross-sections, sketching tools, boreholes, edge bevels, edge filleting, models of machine elements, use of standard parts
  • Insertion, deletion, suppression and modification of assemblies
  • 2D drawing: create drawing, add and edit drawing views, sections, dimensioning, dimension, shape and position tolerancing, symbols for surface symbols, welding symbols, drawing frames, title block, parts list

 

CAE (engineering design)

Cutter head (3D model)
Shower head (analysis with PTC Creo Parametric)
  • Application of a parametric 3D CAD system and integration into the development and design process
  • User-specific adaptation and use in project groups
  • Assembly management: skeleton models and layouts as basis of parametric assemblies,
    user-specific adaptation family tables and UDFs as user-defined adaptations / extensions
  • Modelling and organisation of special geometry for complex modelling problems, model organisation with films
  • Interfacing problem Creo - ANSYS (CAD - FEM), Creo - KISSsoft

 

CAE (Finite Element Method)

3D modelling and FE analysis of a gear housing
Total deformation of the model (scaled 30x) [Source: ANSYS Workbench]
Total deformation of the model (30x magnification) [source: Ansys Workbench]
Equivalent stress in the lower notch radius [source: Ansys Workbench]
Equivalent stress in the lower notch radius [source: Ansys Workbench]
  • Introduction to the application of the finite element method with a professional FEM system using simple, linear, structural mechanics problems.
  • From the product model to the computational model
  • Boundary conditions: fixtures, forces and pressures
  • Representation of strains and stresses with the aid of contour plots, path plots, tables, interpretation of results
  • Theory: numerical analysis of a simple 2D rigid frame

User support

The VPP supports users in the use of hardware and software in the exercises to the lectures in design theory, machine elements, drive systems, machine dynamics and projects 1 and 2.

Machine dynamics

Test vehicle torsional mass oscillator
Test bench torsional mass oscillator

Presentation of oscillation phenomena with the aid of different experimental test benches. A single-mass oscillator, a double-mass oscillator, a testbench for the visualisation of torsional oscillations, and an experimental platform for the illustration of the lateral critical speed are available for this purpose.

 

The Virtual Product and Process Development Laboratory collaborates with industry and other universities. The collaboration focuses on the use of computers in design and calculation.

Projects carried out (excerpt)

  • Development of a new model of the hip muscles
  • Bone remodelling processes for hip replacements
  • Determination of the resonant angular frequencies of a rotor
  • Geometry transfer CT-FEM

Two doctorates have been successfully completed in the field of biomechanical engineering.

Project partners (selection)

CADFEM GmbH, Grafing
inno-shape/CFK, Kriftel/Taunus
Orthopädische Universitätsklinik Frankfurt
AQ Implants GmbH, Ahrensburg

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