Static Structural Analysis

Reducing IC Package Warping

The semiconductor manufacturing sector is currently facing an issue with warpage brought on by thermal pressures in IC packaging. In this recent project conducted by SimuTech Group engineers, warpage in an IC package was reduced using FEM in conjunction with a direct optimization. An active metal brazed (AMB) ceramic substrate composite material’s warpage during heat cycling during production was predicted by the ANSYS Static Structural module.

The Direct Optimization module of Design Explorer was then connected with it.  Within established parameters, the DO modifies the composite material’s dimensions and characteristics in an effort to find the optimal arrangements that will prevent warpage. The findings demonstrate that mirroring the channel patterns on the opposite side of the package lowers warpage caused by channels or cuts on the AMB face by over 90%.

• Most Recent FEA Project: Investigation into curing and chemical aging effects during molding (Electronics).

Sub-Sea Pipeline

Over the past ten years, subsea gathering and pipeline system complexity has grown significantly. An effective subsea pipeline structure is essential given that more processing steps are being carried out on the seabed and that fields have production and injection wells that are scattered more widely. The most typical layouts are ring flow-lines or hub-and-spoke designs.

The proper dimensioning of the entire system, including the pipes, manifolds, risers, and umbilicals, calls for knowledge and expertise from a variety of engineering specialties.

When constructing an offshore subsea umbilicals, risers, and flowlines system, factors such process dimensioning and predicted product composition, pipe deployment and installation, material selection, erosion and corrosion, and multi-phase fluid dynamics should all be taken into account.

• Most Recent FEA Project:  Estimation of collapse pressure on nanolaminated metal alloy pipeline (Oil & Gas).

Rubber Gasket

One of the key components of a high-pressure hydrogen storage vessel is the sealing structures. The experts at SimuTech Group periodically examine the sealing effectiveness of the combination wedge-ring and rubber sealing structure used in high-pressure hydrogen storage containers. This is frequently done by explaining the mechanisms of swelling brought on by dissolved hydrogen.

Additionally, internal testing of sealing ability comparing ring types (such as D-ring vs. O-ring) compares the effects of key elements including the wedge-ring, hydrogen pressure, and swelling. Based on the matching swelling impact, plasticity, and mesh adaptivity observed in the early research stages, our engineers may use these exams to estimate the best wedge angle, peak contact stress, and ideal seal groove design.

• Most Recent FEA Project:  Sealing analysis using hyperelasticity, plasticity, mesh nonlinear adaptivity and fluid penetration (Industrial Products).

FEA for Riser Stakes

Riser mechanical and stress calculations have also seen an increase in the use of finite element analysis.

In addition to significant static loads like self-weight, steady current drag, or buoyancy forces, riser attachments, connections to the seafloor, and fasteners on floating rigs/platforms may also be subject to potentially more harmful dynamic/oscillating loads like those caused by vortex-induced vibration (VIV), wave-induced motion, or even transient in-line pressure fluctuations.

The intricate interactions between these static and dynamic loads have the potential to cause severe fatigue damage. Predicting fatigue life/damage utilizing FEA tools in compliance with pertinent industry Standards, SimuTech Group has a strong experience in stress and fatigue calculations for a variety of riser and flow-line configurations.

• Most Recent FEA Project: Investigation into cracking due to 5,000-ton force (Industrial Products) & Dynamic Loading Analysis

PBGA

The plastic ball grid array (PBGA) package size is decreasing, and packaging delamination is becoming a bigger issue. In order to investigate the delamination in the packaging components, SimuTech Group is actively working with its customer to enhance the packaging process through finite element analysis (FEA).

First, using the universal design method (UDM), Kriging model, and response surface approach, the sealing and lamination model is constructed (RSM).

The mold pressures are between a predetermined MPa, with temperatures set similarly within a parallel threshold, and UDM and RSM obtain the best parameters.

The RSM is often more accurate depending on process parameters like sealing and lamination interaction. As a result, the outcome of RSM will direct the subsequent optimization process.

• Most Recent FEA Project:  Moisture absorption and desorption prediction during reflow (Electronics).

Traveling-Wave Reactor (TWR)

In situ breeding is used in the traveling wave reactor (TWR), a once-through reactor, to significantly reduce the requirement for enrichment and reprocessing. Breeding transforms incoming subcritical reload fuel into fresh critical fuel, enabling the propagation of a breed-burn wave. As a result, in relation to the observer who is immobile, either the fuel or the waves may move. The most practical TWR designs keep the nuclear reactions stationary while moving the fuel around.

A uranium derivative or used light water reactor (LWR) fuel can then be used to create TWR reload fuel. Without the need for reprocessing, each of these scenarios achieves exceptionally efficient fuel consumption and significant waste volume reduction. The TWR’s biggest advantages apply when the reload fuel is depleted uranium since, after the startup phase, no enrichment facilities are needed to maintain the first reactor and a series of consecutive reactors.

• Most Recent FEA Project: Analysis of fuel assemble irradiation creep and swelling (power generation).

Amusement Park Waterslide

Unexpected equipment breakdown involving slides, tubes, swings, metal bars, and climbing frames can result in serious accidents. Our FEA simulation software enables realistic 3-D models for slides, tubes, and ramps found in amusement parks.

These models show the stress distribution of the frame, allowing us to assess whether the corresponding equipment is strong enough to support the weight of multiple riders and whether the material design is appropriate for the anticipated velocity given rider journeys under various conditions like weight, water pressure, and temperature.

• Most Recent FEA Project:  Verification of primary structure to customer design requirements including operations, environmental and seismic.

Land Grid Array (LGA) Socket

One of the most developed and commonly utilized central processing unit (CPU) packages is the land grid array (LGA).

With the necessity for retention force growing, LGA loading mechanism has become more crucial to achieve mechanical, thermal, and electrical functions.

Some of the major structural hazards while developing the loading mechanisms for LGA packages and sockets include load deterioration, solder joint durability under shock loads, socket pin fretting under vibration, and socket pin contact to LGA pad under retention loads.

• Most Recent FEA Project:  Investigation into 3D IC packaging requirements (Electronics) via static analysis.

FEA Stent Insertion

Stent design is very important; if there is any fault, the stent may fail inside the blood vessel. Because it has good accuracy and is a relatively inexpensive experiment, finite element analysis is very successful for testing stents. Recent internal experimental research has demonstrated that coupling boundary conditions on the tip of a diamond-shaped stent makes the product simulation more accurate than an uncoupled simulation.

Additionally, the opening area ratio of a human autopsy sample, a pig cardiac model, manufacturer data, and finite element analysis all show good similarities in bifurcation stenting (though, at a significantly reduced cost).

• Most Recent FEA Project: Nonlinear analysis of stent insertion process for biotechnology manufacturer.

Once Through Steam Generator

Structural validation of finned tubes, tubesheets and supports for standard operating conditions as well as shipping and seismic. Analyses are performed using ASME guidelines (Power Generation).

Aircraft FLIR Turret Airworthiness

Structural validation of Forward-Looking Infrared Radar (FLIR) for airworthiness requirements (Aerospace). A thermal imaging inspection involves using a FLIR (Forward Looking Infrared) camera to check for water and moisture.

Tracked Construction Equipment Suspension System

Verification of tracked suspension system to customer’s requirements. Aspects investigated include standard operating and extreme utilization (Industrial Products).

Rail Car Wheel

• Most Recent FEA Project: Delamination and crack growth analysis for operational loading (Industrial Products).

Bone Implant

• Most Recent FEA Project:  Non-linear analysis investigating implant insertion to join a fractured bone (Healthcare).

Automotive Assembly

Recent static structural analyses include stress level evaluation in a flanged autoclave connection, and optimizing thermal headlight assemblies.