Altair > Case Studies > Eaton's Aerospace Group's Efficiency and Accuracy Enhancement in Hydraulic Systems Analysis with HyperWorks

Eaton's Aerospace Group's Efficiency and Accuracy Enhancement in Hydraulic Systems Analysis with HyperWorks

Technology Category

Actuators - Hydraulic Actuators
Sensors - Level Sensors

Applicable Industries

Aerospace
Automotive

Applicable Functions

Product Research & Development
Quality Assurance

Use Cases

Experimentation Automation
Virtual Prototyping & Product Testing

Services

Testing & Certification

About The Customer

Eaton's Aerospace Group is a leading provider of hydraulic components and systems for many of the world’s military and commercial aircraft. The Hydraulic Systems Division, based in Jackson, Mississippi, is particularly focused on the design and testing of hydraulic pumps, actuators, motors, and related components. The division conducts a range of tests, including stress analysis, computational fluid dynamics, and dynamic simulation, to ensure the components work as expected. The division is especially focused on fatigue analysis and pressure analysis. The division's Analysis Group is at the forefront of the product-development process, analyzing parts or assemblies for a variety of aircraft to determine whether components meet loading requirements.

The Challenge

The Hydraulic Systems Division of Eaton’s Aerospace Group, based in Jackson, Mississippi, is responsible for designing hydraulic components and systems for many of the world’s military and commercial aircraft. The division conducts virtual testing of many of its designs, including stress analysis, computational fluid dynamics, and dynamic simulation for hydraulic pumps, actuators, motors, and related components. However, the division faced a significant challenge in improving efficiency in meshing. Before 2002, the Analysis Group used a process built into a solver for use on finite-element models. This process was not designed for finite-element analysis and often failed to provide the quality mesh needed when dealing with complex hydraulic components. Meshing complex hydraulic component geometry required a great deal of effort and time, making the process inefficient and cumbersome.

The Solution

To address the challenge, the Eaton team turned to HyperMesh, part of Altair Engineering’s HyperWorks suite. HyperMesh was introduced to the team by Ahmad Sereshteh, Eaton’s Senior Stress Analyst, who had used the tool for 20 years in Eaton’s automotive division. HyperMesh was used to analyze complex internal fluid passages, determining the proper angle at which they should intersect and the appropriate positioning of their centerlines. The tool was demonstrated using an Engine Driven Pump (EDP) cylinder block with a fairly complex geometry. With the previous process, creating a finite-element model for that component was challenging and would take three to four days to complete. However, with HyperMesh, the process was significantly improved in terms of speed, accuracy, and confidence.

Operational Impact

The implementation of HyperMesh has resulted in significant improvements in the efficiency, accuracy, and reliability of Eaton's Analysis Group. The tool has enabled the team to analyze complex internal fluid passages with greater precision and confidence. The process of creating a finite-element model, which previously took three to four days, has been significantly streamlined. The group has also seen a significant efficiency improvement since it started using HyperMesh. Looking ahead, the Analysis Group plans to put increasing emphasis on using its HyperWorks suite to optimize designs, reducing product weight while meeting all load requirements. The group has also started using OptiStruct, an optimization tool within HyperWorks, in the development of future components.

Quantitative Benefit