Development and Design
Finite-Elemente-Methode
We guide you from the initial sketch to the finished product. Our hydraulic cylinders are therefore not just any component, but an integral part of your machine.
Using advanced calculation and simulation methods, we create the optimal solution for you.
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At MBS-Hydraulik, innovation begins with development. Our engineers and technicians combine years of experience with state-of-the-art simulation software—such as ANSYS—to develop custom hydraulic cylinders for the most demanding applications.
Whether in traditional mechanical engineering or in highly dynamic lightweight construction applications, we know the key factors for durable and cost-effective designs. Especially when designing components made of high-strength aluminum alloys, it is often the seemingly insignificant details that determine service life and reliability.
Through FEM analyses, topology optimization, and material-appropriate design, we develop solutions that are not only lightweight but also safe and efficient. In doing so, we don’t think in terms of standard solutions—but in terms of possibilities.
In addition to the finite element method, we naturally also use traditional analytical approaches.
These include:
• Bolt design calculations according to VDI 2230, which are also used in combination with the FEM
• Strength verifications according to the FKM guideline or DIN 13001
• Buckling analyses, both analytical and using the FEM
• Simulation of end-position damping using a custom-developed calculation program
// FAQS
Questions About FEM
FEM (Finite Element Method) is used in hydraulic design to efficiently simulate and develop products. This enables a more precise analysis of structures and their behavior under pressure loads.
The finite element method (FEM) offers several key advantages over traditional experiments:
1. Cost savings
FEM reduces the need for expensive physical prototypes and tests, which lowers development and production costs.
2. Time savings
Simulations can be performed faster than physical tests, which shortens development time.
3. Flexibility
FEM allows for the investigation of various designs and operating conditions without the need for additional physical models.
4. Precision
Highly accurate analyses of stresses, deformations, and other physical properties provide deeper insights into the behavior of systems.
5. Safety
Risks can be identified and addressed during the simulation phase before physical prototypes are tested.
6. Complexity
FEM can account for complex geometries and material behavior that are difficult to replicate in physical experiments.
When applying the finite element method (FEM) to hydraulic systems, various challenges may arise:
1. Complex Geometries
Modeling: Accurately modeling complex geometries can be time-consuming and difficult. Inaccurate models can lead to erroneous results.
2. Nonlinear Material Behavior
Material Properties: Hydraulic components can exhibit nonlinear behavior (e.g., plastic deformation), which can complicate the analysis and require specialized solution methods.
3. Dynamic Loads
Time-dependent analyses: Accounting for dynamic and time-dependent loads (e.g., pressure fluctuations) requires more complex models and longer computation times.
4. Boundary Conditions and Contact Issues
Constraints: Correctly defining boundary conditions and accounting for contact between different components can be challenging and lead to instabilities.
5. Mesh Quality
Discretization: Insufficient mesh quality (e.g., elements that are too coarse) can compromise the accuracy of the results. However, fine mesh refinement can significantly increase computation time.
6. Computational Intensity
Computational Effort: FEM analyses, especially for complex systems, require significant computational resources and time, making it difficult to perform multiple simulations.
7. Validation of Results
Comparison with Experiments: Validating FEM results against experimental data can be difficult
1. Conceptual Phase
Preliminary Analyses: FEM can be used to evaluate initial design concepts and identify potential weaknesses or opportunities for improvement early on.
2. Design Phase
Detailed Analysis: In this phase, the design is developed in detail. FEM is used to simulate the behavior of the design under various loads and conditions.
Optimization: The design can be optimized based on the FEM results to improve weight, cost, and performance.
3. Prototyping Phase
Validation: FEM analyses help predict and validate the results of physical prototype tests. This allows potential problems to be identified before prototypes are manufactured.
4. Testing Phase
Comparison with Experimental Results: During the testing phase, the FEM results are compared with the results of physical tests to verify the accuracy of the simulations and calibrate the model.
5. Production Phase
Process Optimization: FEM can also be used to optimize manufacturing processes, such as analyzing forming processes or predicting deformations during production.
6. Lifecycle Management
Lifespan Analyses: FEM is used to evaluate the lifespan and reliability of products, particularly when analyzing fatigue and wear over the entire lifecycle.
7. Failure Analysis
Root Cause Analysis: In the event of problems or failures following de
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