Engineering Code Review & Numerical Solver Improvement
Project Overview
PDL was engaged to investigate persistent convergence issues within a proprietary engineering calculation tool used to predict bending moments in flexible pipe systems. The numerical script formed a critical part of the client's engineering workflows, yet recurring failures and unpredictable behaviour were impacting engineering efficiency and confidence in the tool's outputs.
Our Solution
Our engineers deployed a comprehensive suite of simulation tools, including ANSYS Mechanical for structural analysis and ANSYS Fluent for thermal-fluid interaction. We developed a detailed 3D model of the component, applying realistic boundary conditions and material properties. Key aspects of our solution included:
Material Characterization : Incorporating advanced material models to accurately represent behavior under irradiation and high temperatures
Topology Optimization : Identifying optimal material distribution to reduce weight while maintaining structural integrity.
Thermal-Structural Coupling : Simulating the interaction between temperature fields and structural deformation.
Fatigue Life Prediction : Performing high-cycle and low-cycle fatigue analysis to predict component lifespan.
The root causes of the convergence issues were successfully identified and eliminated. The revised code delivered stable and reliable results across all tested scenarios, significantly improving confidence in the software and increasing the efficiency of the engineering team. The project also improved long-term maintainability through enhanced documentation and understanding of the underlying methodology.
Client: Undisclosed
Sector: Other
Service Provided: Software Assurance, Code Review, Numerical Methods Verification
Challenge: Unreliable convergence behaviour in critical engineering software
Outcome: Stable, validated code with improved engineering confidence and productivity
