Case Study: Advanced FEA for Industrial & Offshore Components
Industry: Heavy Industrial, Offshore
Services: Finite Element Analysis (FEA), Design Optimization
Standards: ASME, DNV
The Challenge
Ensuring the safety, longevity, and structural integrity of high-stress components is paramount in heavy industrial and offshore applications. Clients required validation for HUB Bearing Units (HBU3) under variable vehicle loads and for critical offshore lifting equipment and pressure vessels, which must perform flawlessly under immense pressure and dynamic lifting forces while complying with strict international standards.
Our Solution
5D Nexus performed multi-domain Finite Element Analysis to assess operational life and performance, focusing on detailed simulations and design optimization.
- Multi-Domain FEA on HUB Units: We conducted a comprehensive analysis of HBU3 components, including static stress analysis for peak loads, fatigue life prediction over 45 distinct load cycles, and stiffness and displacement analysis to ensure functional performance under dynamic conditions.
- Validation of Offshore Equipment: For offshore lifting equipment and pressurized containers, we created detailed 3D models and simulated complex load cases, including lifting and internal pressure scenarios. The analysis ensured full compliance with critical standards like ASME and DNV.
- Design Optimization: In both cases, the FEA results were used not just for validation but to actively drive design improvements. We identified high-stress areas for reinforcement and over-engineered areas where material could be safely removed to reduce weight and cost without compromising safety or capacity.
The Results
Our rigorous FEA services provided our clients with the critical assurance needed for deploying high-stakes equipment:
- Extended Service Life: For the HUB units, our insight-driven design changes based on fatigue analysis demonstrably extended the operational service life of the components.
- Validated Product Safety: The analyses confirmed that all components could operate safely under the specified dynamic and peak loads, meeting all required safety factors.
- Compliance and Certification: We delivered comprehensive engineering documentation and detailed FEA reports that enabled safe, certified deployment of offshore and heavy industrial equipment.
- Increased Load Capacity & Reduced Weight: Design optimization for the offshore equipment successfully increased load capacity while simultaneously reducing component weight, improving operational efficiency.