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In an effort to increase their manufacturing efficiency, an industry leading supplier of aerospace control systems has undertaken an effort to reprocess legacy components to be manufactured on modern multi-axis machining centers. In order to this, a 3D CAD model of the component must first be created and from this model, a manufacturing program is created using advanced CAM software.

The latest part to be reprocessed had an error in the CAD model that resulted in a thin wall condition in one of the manifold pressure ports. The company turned to Endesin in order to verify that the parts that were machined with the thin wall condition would meet the performance requirements for the component.



The steps used to perform the analysis were as follows

  • The CAD model was reduced to the extent that only the relevant port remained.
  • This port was then simplified to remove any features that did not contribute to the structural integrity of the port or were too small to be meshed reliably.
  • The port was then meshed making extensive use of mesh transitions to keep the elements as small as possible in the area of the thin wall condition while keeping the size of the mesh relatively small.
  • The edges of the outside square face of the port were constrained to prevent rigid body motion while still allowing the port to displace.
  • The required pressure load was applied to the inside faces of the port and the thin wall area was checked for stresses.



The analysis was completed using NX Advanced Simulation for pre and post processing and the solver was NX Nastran.



A leading aerospace controls systems supplier needed to verify the performance of their parts to avoid losing the time and money invested to manufacture them. By turning to Endesin for a finite element analysis, they were able to ship their parts with the confidence that they would perform as needed.