INNOVATIVE CONTROL TECHNOLOGY

Simulation Services

SIMULATION SERVICESSTRUCTURAL
To provide highly accurate and reliable results, a wide variety offeatures is applied when performing static structural analyses.
The optimization of CAD models, materials modeling, linear andnonlinear contact modeling, meshing of complex geometrical structures and scripting for customization purposes are only a few ofthe tasks that can be completed while performing static structuralanalyses.
Typical applications of this specific type of analysis cover staticlinear and nonlinear stress-strain analyses as well as the dynamicassessment of structures. The latter covers various analyses, such as
FKM analysis using an FKM extension in the FEA tool.
In case the simulation focuses on the structural behavior of a specific area, using the submodeling approach increases the accuracy of
the results while maintaining a reasonable calculation time.

Representative structural
analysis focusing on weld
seam stress

FATIGUE ASSESSMENT
Fatigue assessments are used to analyze structures that are exposed to cyclic loads considering individual material properties.
To evaluate a structure regarding its lifetime, two approaches are
generally used:
Based on a static structural analysis, a fatigue extension in the FEA
tool evaluates results, such as life, damage or the safety factor,
against fatigue of a component. This first approach takes into account different mean stress theories and the materials S/N curve as
well as pulsating or alternating loads.
S/N curves are mainly available for standard materials, whichmakes the second approach very attractive. This second approach
follows the FKM guideline and covers a wide variety of materials.
It additionally enables the analysis of the entire structure as well as
local areas, such as weld seams. Results are based on analyticalformulas that serve to determine the structure’s lifetime.

2Fatigue assessment ofa structure exposed toalternating load using thefatigue extension in the FEA
tool. Areas susceptible tofatigue are highlighted. In
this case, the weld seam
represents the critical area of
this structure.

THERMAL
To ensure the proper functioning of our components under thermal
influence, simulations of thermal behavior (steady state/transient)considering convection, radiation and thermal interaction between
components are carried out.
We are able to investigate the heat transfer for various applications,
including valves for cryogenic and high-temperature service, whileconsidering environmental boundary conditions, such as insulation,
cold boxes or higher ambient temperatures.
Our library contains standard engineering materials, including metals,
polymers and various fluids.

Temperature profile

DESIGN BY ANALYSIS (DBA)
Usually, we verify pressure equipment using Design by Formulae(DBF) according to the EN 12516-2, ASME B16.34 and ASME BPVCstandards. In case of special designs where the standards do notprovide formulas, we can verify these parts using Design by Analysis (DBA) according to EN 13445-3 Annex B.
DBA includes the following:

Stress profile– Elastic analysis– Plastic analysis– Creep– Fatigue

BUCKLING
Valve stems are exposed to high axial forces. Especially long stems
in valves with insulating sections are vulnerable to buckling. In addition to calculations based on the formulas provided by Euler etc.,
we use FEA to determine the maximum allowable actuator force
before the onset of buckling for individual valve designs.

Equivalent stress in a valve
with insulating section.

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SIMULATION SERVICESSEISMICFor machines or equipment installed in earthquake hot zones, seismic evaluation according to the ASCE/SEI 7 or DIN EN 1998/EC8standards for example, provides a numerical assessment of theirseismic response. The response spectrum analysis method is applied to calculate the stress-displacement response of the equipment
under seismic load (seismic spectrum) and check its compliancewith a given standard. This analysis also has the following features:– Superposition of seismic loads in different directions– Mode analysis

TOPOLOGY
Topology optimization gives us an opportunity to achieve a similar
outcome (e.g. strength) but with minimum material usage and low
cost of production for a part. The optimization objectives can be:

Structural displacement due
to seismic loads with different
excitation frequencies

Original  optimized (raw) optimized (ready formanufacture)– Minimize part weight– Minimize part volume– Minimize global/local stress on the part
– Minimize part displacement– Minimize reaction force of the part

STATIONARY FLOW
Numerical solving of the fundamental flow equations enables us togain an insight into the pressure, velocity and temperature distributions inside a valve. In addition to pressure loss and flow characteristics, flow-induced forces and torques can be evaluated. The
pressure distribution can be used as input data for further structural
calculations, fatigue analysis or fluid-structure interaction (FSI).
With certain boundary conditions, the evaluation of valve-specificvalues (e.g. KV, xFz and xT) is also possible. They are essential tovalve sizing. Dead space analyses can be performed if special
requirements have to be met. In general, simulations can be performed either turbulent or laminar flow regimes.

4Simulated valve characteristic(left) and corresponding CFD
result (right)

FLOW OPTIMIZATIONThe results of a flow simulation can be used to improve the geometry to achieve certain optimization goals. They can be, for example
maximize the flow rate, minimize dead spaces or eliminate potential sources of noise. Lower noise emissions can be achieved byimproving the xFz value by delaying the onset of cavitation.
Unwanted flow conditions (e.g. large vortices) can induce additional vibration, noise sources and reduce the flow rate due to additional pressure losses. These flow conditions can be eliminated bya targeted manipulation of the valve geometry.
A parameter study can be used, e.g. to optimize certain parts of theassembly. Through calculation of targeted parameter combinations
in a design of experiments (DoE), a qualitative statement can bemade for all possible combinations in the chosen parameter space.

Response surface of a DoE(bottom) and dead space
optimization of a valve inlet
without reducing the flowrate (top)MULTI-PHASE FLOW
When the pressure falls below the vapor pressure at the vena contracta, vapor bubbles start to form, which can cause serious damage to the valve body or piping when they implode in regionsof higher pressure. Targeted multi-phase simulations enable us totrack the origin and path to the implosion region. Early on in thedevelopment process, potential weak spots can be identified andeliminated. An evaluation of the liquid pressure recovery factor FLof valves is also possible.

PLUG

SEAT

PLUG

SEAT

Cavitation bubble in a small gap
between plug and seat (left) and free
jet of water in air-filled domain (right)

IMPINGEMENT ANALYSISACCORDING TO EIGA 13/20
Oxygen applications, in particular with oxygen gas, have to beevaluated critically due to the risk of ignition. With impingement
analyses, surfaces along the flow path are rated based on pressure
and temperature values according to EIGA 13/20. Based on thisworst-case assessment, some materials can be ruled out or cleared.
In addition, non-impingement sites (surfaces with low ignition probability due to particle impact) can be identified so that additional
materials can be applied safely.

Impingement curve (left) andCFD simulation (right - green:on curve, blue: below curve,red: above curve)

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SIMULATION SERVICESPARTICLE
Based on flow simulation results, particle simulations can predict
the trajectories of particles with different shapes, sizes and masses.
The computational effort is notably lower compared to the initial
flow simulation. Typical particles can be welding residue, metalchips or other fluid contaminants. Through particle simulations, wecan gain insights into impact angle, velocity and frequency. With
this information, an assessment of vulnerable parts (e.g. bellows)
can be made and general safety limits for particle impact can bechecked.
Particle tracks (left) andcorresponding erosion rates
on the valve body surface(right)TRANSIENT FLOW
Time-dependent simulations provide additional information on theflow, especially turbulence. Along with fluctuations in pressure andvelocity, time-dependent boundary conditions (e.g. pressure loss atthe inlet) can be implemented. Virtual probes enable us to gather
time-dependent process data at different positions. These positions
may be impossible to probe on the physical test specimen. These
data can be used, for example as the basis for a digital twin or tobuild a reduced order model (ROM).
Frequency-dependent analyses can determine characteristic frequencies from longer time spans of periodic flow separation, forexample. Time-dependent forces or torques can be used as boundary conditions for fatigue analysis.

6Transient results plottedin time domain (left) andfrequency domain (right)

IMPROVING INJECTION MOLDING PROCESS AND QUALITY
Injection molding simulations support the new development and re-engineering of injection-molded plastic parts to optimize product design
and manufacturability. Therefore, they help cut cost for development
testing and shorten the time-to-market. The outcome strongly depends
on the chosen type of plastics. A database with a wide range of plastic
materials, including fiber-reinforced types, is available and secures ahigh reality grade in results. How much the process can be improved
mainly depends on the filling behavior and ability, cooling state andwarpage.

Filling time of an injectionmolded parta) Filling problems and low-pressure regions are detectible at
an early stage of designing. Injection molding simulations provide individual reality-inspired melt delivery and cooling systems, including sprues, runners, gates, coolant channels andmold base. Real machine data from different injection molding machine models ensure a realistic process simulation.
b) Cooling mode enables us to make exact predictions of the cooling behavior of injection-molded parts to save energy and reducethe cycle time to establish a high level of production efficiency.
The cost-intensive cycle time for production depends to a great
extent on the time required for the cool-down until demolding of
the single injection-molded part. Otherwise, too fast or unequalcooling may cause quality problems. Such problems are solvable by making design changes to the in-mold cooling channels
and ensuring a suitable temperature control of cooling media.
3D numerical simulations tackle complex injection-molded parts
with high reliability and deliver their results in colored figures and animations. Engineers are enabled to detect potential
heat spots from comprehensive analyses and iterate on designchanges to optimize the later process time at the early stages.
c) The warp analysis allows users to validate the part-deforming
ratio of shrinkage effects and to identify warpage causes at anearly stage. For fiber-reinforced materials, the warp module incorporates fiber composite theories and fiber orientation results
to predict how anisotropic shrinkage, residual stress effects andmaterial viscoelasticity will affect warpage and flatness of theready-produced part. The results are existential for an exact fitting
and tightness forecast in further applications.

Part temperature after adefined cooling timeHighly exaggerated
warpage result

Did a task immediately come to your mind or would you like more
information? Please feel free to contact us.
Our simulation experts look forward to discussing any issues with you
to develop customized solutions that meet your specific needs.

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SAMSON AT A GLANCE

STAFF

PRODUCTION SITES– Worldwide 4,500– Europe 3,700– Asia 600– Americas 200– Frankfurt am Main, Germany 2,000– SAMSON Germany, Frankfurt, established in 1916
Total plot and production area: 150,000 m²

INDUSTRIES AND APPLICATIONS– Chemicals and petrochemicals– Food and beverages– Pharmaceuticals and biotechnology– Oil and gas– Liquefied Natural Gas (LNG)– Marine equipment– Power and energy– Industrial gases– Cryogenic applications– District energy and building automation– Metallurgy and mining– Pulp and paper– Water technology– Other industries

PRODUCTS– Valves– Self-operated regulators– Actuators– Positioners and valve accessories– Signal converters– Controllers and automation systems– Sensors and thermostats– Digital solutions

SALES SITES– More than 50 subsidiaries
in over 40 countries– More than 200 representatives– SAMSON France, Lyon, established in 1962
Total plot and production area: 23,400 m²– SAMSON Turkey, Istanbul established in 1984
Total plot and production area: 11,100 m²– SAMSON USA, Baytown, TX, established in 1992
Total plot and production area: 20,000 m²– SAMSON China, Beijing, established in 1998
Total plot and production area: 47,000 m²– SAMSON India, Pune district, established in 1999
Total plot and production area: 28,000 m²– SAMSON Russia, Rostov-on-Don, established in 2015
Total plot and production area: 24,000 m²– SAMSON AIR TORQUE, Bergamo, Italy
Total plot and production area: 27,000 m²– SAMSON CERA SYSTEM, Hermsdorf, Germany
Total plot and production area: 14,700 m²– SAMSON KT-ELEKTRONIK, Berlin, Germany
Total plot and production area: 1,100 m²– SAMSON LEUSCH, Neuss, Germany
Total plot and production area: 18,400 m²– SAMSON PFEIFFER, Kempen, Germany
Total plot and production area: 20,300 m²– SAMSON RINGO, Zaragoza, Spain
Total plot and production area: 19,000 m²– SAMSON SED, Bad Rappenau, Germany
Total plot and production area: 10,400 m²– SAMSON STARLINE, Bergamo, Italy
Total plot and production area: 27,000 m²– SAMSON VDH PRODUCTS, the Netherlands
Total plot and production area: 12,000 m²– SAMSON VETEC, Speyer, Germany
Total plot and production area: 27,100 m²

Weismuellerstrasse 3 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
E-mail: samson@samsongroup.com
Internet: www.samsongroup.com

2022-01 · WA 450 EN

SAMSON AKTIENGESELLSCHAFT