News 2016

Motion Analysis - Pontoon "Offshore BHV 1" with Topside "NOR OSS"


On behalf of BVT Bremen GmbH & Co. KG, MET GmbH successfully carried out an examination of the movements of the substation NOR OSS during the transport process. The model consisted of the floating pontoon "Offshore BHV 1" and the topside, which was placed on the pontoon. The sea behavior of the pontoon with the platform was simulated on the transport route from Bremerhaven to the wind farm Nordergründe, taking into account the site-specific environmental conditions (wind, wave, depth of water). The nonlinear interactions of ship, sea and wind were calculated transiently in ANSYS-AQWA.

With the calculated results the customer received a prediction of movement (position, speed and acceleration) in the most important components of the substation and the possibility to compare them with the allowed values. The simulation also enabled the definition of the most unfavorable weather conditions (wind & wave), in which a safe transport operation of the substation is still possible.

 

Simulation-based development of friction-welded high-performance pistons

friction welded piston

friction welded piston


Within the scope of the "INKOV" research project funded by the BMWI, the task for MET GmbH was the simulation-based development of a friction welded high-performance piston. The simulation itself included casting simulation, first time simulation of the complete friction welding process, durability proof and shape curve calculation for the test pistons. The highly efficient production technology required for this piston was developed by SECO GmbH in Quedlinburg and successfully applied to test pistons. The measuring equipment and testing in a 1-cylinder test engine was carried out by the project partner WTZ Roßlau GmbH. With the successful completion of research project INKOV, the engine industry will be provided with new development results for future highly efficient and competitive pistons for maritime use.

 

New research project started

Calculation

Calculation


Final product

Final product


In July 2016, the project "Model Development for the Simulation of Shaker Cooling of Gas Engine Pistons for Marine Engines and Evaluation of Calculation Results in a One-Cylinder Research Engine", funded by the BMWi / PTJ, was started together with Caterpillar Energy Solutions GmbH.

This joint project aims to develop an innovative piston cooling system for new, low-emission maritime gas engines with the objective of performance increase and meeting the high environmental standards of the IMO.

For this purpose, an accurate, simulation-based prediction method and new measurement and transmission technique will be developed, which describe and evaluate the complicated heat transfer process of the shaker cooling.

 

Simulation solutions for new aqua parks on luxury liners


The boom in large luxury liners leads to the implementation of special features such as new attractions in the aqua parks on the ships, taking into account the minimization of investment costs (e g. lightweight construction) at a favorable operating cost level.

Therefore the research project "Model development for novel aqua parks on luxury liners for the sustainable increase of passenger comfort" (funded by the German Federal Ministry of Economics and Energy,FKZ: EP140661) provided new realistic models and powerful calculation / simulation tools for dimensioning, design and construction of aqua parks on board of luxury liners.

With the developed simulation methodology and the powerful calculation and simulation tools MET can meet the high comfort requirements of luxury liner aqua parks by different ship movements under all sea conditions. For realistic results the complex interaction of fluidic, thermodynamic and structural mechanical lightweight design have to be taken into account.

The MET GmbH offers modern design and simulation for aqua parks, which

  • significantly reduce the development time of cruise liners
  • make the design process of a cruise liner more efficient
  • reduce the costs of production and operation

After successful completion, MET GmbH offers engineering services for:

  • design of aqua parks for different sea conditions
  • optimization of the energy input (operating costs)
  • use of lightweight construction
  • increasing the aqua parks comfort

Aqua parks on land can of course also benefit from our new methods. The proven calculation methodology can be applied to other applications and new business fields, such as:

  • large buildings with complex architecture as well as for high-resolution interior flows,
  • offshore facilities, in order to simulate the exhaust gas emissions and wind loads, to determine the environmental impact and potential risks
  • on ships and offshore facilities with helicopter landing to predict at an early project stage the wind conditions on the landing deck as a result of the interaction with ship bodies and superstructures
  • on industrial plants, for example to determine wind resistance and exhaust gas spread

For more information, see: Fun parks

 

MET GmbH at the status seminar of the PTJ


The INKOV joint project (Development of Innovative Piston and Valve Solutions with Material Combinations in Marine Engines) was successfully completed after 3 years.

The success was based on the close cooperation between the following partners:

  • Gesenkschmiede Schneider GmbH Aalen,
  • IWU Fraunhofer Institute for Machine Tools and Forming Technology,
  • WTZ Roßlau gGmbH

and MET Motoren- und Energietechnik GmbH, which was specifically responsible for the processing of subproject 3 "New Design, Dimensioning Methods and Manufacturing Technologies for Marine Motors with Hybrid Material Combinations" (FKZ: 03SX364C).

The novelty in the processing of the mentioned subproject is the continuous simulation-based development process.

The simulation included the calculation of the stresses and deformations of the new friction welded bimetallic piston consisting of a piston lower part with a large linear thermal expansion coefficient and a piston upper part consisting of a newly developed heat-resistant material with a smaller linear thermal expansion coefficient. This material combination minimizes the strain due to the thermal expansion of the upper piston part and the lower piston part and thus increases the durability of the frictionally welded piston. For this purpose a simulation tool has been developed for the prediction of the complete friction welding process, which also analyses the influence of the selected different weld connecting positions and welding seam formation on the durability of the piston when considering the different material properties.

All developed partial models were subjected to a practical evaluation before the next modelling task was started. This enabled us to achieve a close approximation to reality. The technology demonstrator is available for the propagation of this new development technology and for future market advertising for this innovative product. The joint project was published during the PTJ Statute seminar on 08.12.2016. The article can be found at: http://juser.fz-juelich.de/record/825956/files/PTJ_08.pdf

We would like to thank the Federal Ministry of Economics and Energy, who provided the funding and the project executing organization Jülich.

 

MET GmbH at the Lightweight Construction Competence Center of the BMWi

CFD Simulation of Autoclave

CFD Simulation of Autoclave


CFD Simulation of Autoclave

CFD Simulation of Autoclave


From now on, you can find MET GmbH and further information about our competences in lightweight construction in the interactive web portal with the company database at www.leichtbauatlas.de. The Competence Center for Lightweight Construction is an internet site, which represents all players from light weight construction industrial sectors. A significant aspect here is in particular the cross- sector and cross-material view of the industry. As a result, in our projects we have the opportunity to access a network of all relevant companies and research facilities in the lightweight construction sector. The portal was prepared by the Fraunhofer Institute for Operational Stability and System Reliability (LBF) in cooperation with the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) and Brimatech Services GmbH from Austria.

 
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