According to our experiences, the main application range of FE analysis is shifting from failure analysis to design resp. construction with increasing acceptance. Nevertheless, cases of damage still remain the typical FEM application and the main business of Merkle & Partner.
In case of component failures within the agreed service life, costs are often high due the substitution of the component itself, secondary damages as well as production downtimes resp. product recalls. A great many of these damages could have been identified by the early application of numerical simulations alreday in the design resp. construction phase. Therefore, failure prevention is to be preferred according to the proverb: “Prevention is better than cure”.
Despite all possible precautions taken in the development process of structures and components, the occurrence of damage cannot always be excluded. Often the effects are the cause, which were not even considered in the design phase.
The analysis of damage is often a long process, which on the one hand requires knowledge of the basic physical processes, but also a great deal of experience in the field of damage analysis and a targeted approach.
Merkle & Partner, with its almost 30 years of experience in damage analysis of various assemblies and components will gladly support you in the very demanding topic of damage analysis.
With future-oriented methods of optimization combined with modern CAE tools of FEM and CFD, we are, in the long run, trying not only to determine the cause of damage by means of appropriate simulations, but also to offer suggestions for optimization with subsequent verification from one source.
Your advantage – we monitor the entire process!
Avoid further and unnecessary costs in case of damage claims by a professional approach with MERKLE & PARTNER,
a very experienced and efficient partner, and win back the trust of your customers!
In the case of a dryer, the weld seams on the drum floor are torn at regular intervals and have been elaborately re-welded. This was caused by high thermo-mechanical stresses during start-up of the plant. The calculated proof showed that the permissible stresses were exceeded by a factor of 3. Repair concepts using gusset plates were evaluated. The drum floor was completely redesigned and optimised by MERKLE & PARTNER so that the permissible stresses in the weld seam could be maintained.
A dryer caused cracks in the axle connection. A mathematical explanation, which corresponded to the crack pattern, could only lie in the circular bending. However, the stresses here were within the permissible range. After corresponding enquiries with the operator, we found out that the dryer was completely filled with water for cleaning purposes and ran for several days. This load case was never considered and showed unacceptably high stresses. By avoiding the critical operating condition, the repaired condition could continue to be operated until a new dryer was manufactured.
Grounding contacts of rail vehicles were broken. This was caused by natural resonances of the fastening. Design measures could be taken so that the natural frequencies were within an uncritical range.
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