Latest News September 2023
Welcome to the Frewer Engineering latest news September 2023.
As the seasons change, so too does the landscape of Frewer Engineering.
This issue is brimming with updates that underline our commitment to excellence, innovation, and growth.
Our Lightweight Composite Structures Team Deliver
Our specialist team of composite structure designers completed the design of a complex executive jet gas turbine intake.
The intake is used for investigating the effects of cross wind on the air presentation to the fan. This can be a problem especially when the effect of a cross wind running over the fuselage interrupts the air flow being drawn into the intake that is currently under test!
- Addressing Real-world Challenges: Designing a gas turbine intake to investigate the effects of crosswind is vital. Crosswinds can significantly impact the performance of aircraft engines, especially during critical phases like take-off and landing. Addressing these challenges head-on can lead to safer and more efficient aircraft operations.
- Incorporating Advanced Techniques: The use of particle image velocimetry (PIV) via laser windows demonstrates a cutting-edge approach. PIV is a powerful and sophisticated flow visualization technique that can offer valuable insights into flow dynamics. Understanding potential crosswind effects and mitigating fan flutter is critical for aircraft safety.
- Material Selection and Optimization: Choosing an epoxy/carbon lay-up is indicative of prioritizing weight reduction without compromising strength – a fundamental principle in aerospace design. Lightweight structures directly contribute to improved fuel efficiency and overall aircraft performance.
- Innovative Integration: Integrating laser windows, which span 50% of the circumference, along with a suite of aerodynamic instruments, showcases an intricate and holistic design approach. This enables comprehensive data collection, ensuring a thorough understanding of the engine’s response to various conditions.
- Investment in Future Capabilities: Our team is currently investing in new capabilities and forming partnerships with composite manufacturing specialists suggests a forward-thinking approach. Offering a turn-key service, from design to production, can be a game-changer in the industry, ensuring streamlined processes, reduced lead times, and potentially lower costs.
- Potential Impact: With advancements in engine intake design and a clearer understanding of airflow dynamics, aircraft manufacturers and operators can enhance the reliability and efficiency of their systems. This could have positive ramifications for the entire aviation industry in terms of safety, performance, and operational costs.
Thermal Analysis Update
Frewer Engineering’s Advanced Analysis team is involved in some highly specialized and technical work, especially concerning thermal analysis of complex systems. Thermal analysis, particularly with coupled FEA (Finite Element Analysis) and CFD (Computational Fluid Dynamics), is an advanced and intricate task, often vital for ensuring the reliability and efficiency of high-performance systems, especially in industries like aerospace, automotive, and energy.
- Coupled Analysis Mode: This approach, which integrates both structural (from FEA) and fluidic (from CFD) phenomena, is crucial when studying systems where the structural behaviour affects fluid flow, and vice versa. This can be seen in applications such as jet engine turbines, where the heat from combustion affects both the metal components and the flow of exhaust gases.
- Bespoke Code Creation with Python: As generic tools often have limitations, especially for unique systems, creating custom scripts or modifying the existing solver’s behaviour using Python (or similar) can be essential. This bespoke approach allows for a more tailored analysis that can capture intricate system behaviour’s more accurately.
- Thermal Transient Analysis: Analysing the behaviour of systems during transient events, such as start-up, shutdown, or failure, is of paramount importance. These are often the most critical phases for many systems, where the risks of failure or damage are highest. For example, an aerospace component might experience very different thermal stresses during take-off compared to cruising altitude, and it’s vital to understand these differences
Our Gas Turbine Test Facility achieves successful completion of customer review CDR/FDR
Last week we achieved successful completion of the critical design review & final design review of the facility test equipment for the new Whittle Laboratory at Cambridge University.
- Historical Significance: The fact that the ground-breaking ceremony for this new facility was one of the first engagements the King attended post-coronation highlights the national and perhaps even international importance of this project.
- Innovative Design: Designing a test facility that allows for swift changes of test shapes is an innovative approach. Rapid prototyping and testing in the aerospace industry is essential for staying competitive and meeting the fast-evolving demands of technology, efficiency, and environmental considerations.
- Environmental Considerations: With growing global concern about environmental issues, creating technologies that reduce environmental impact is not only beneficial for business but also for the planet. Your project’s focus on this aspect is commendable and very timely.
- Potential Impact: Given that the Whittle Laboratory is affiliated with Cambridge University, one of the world’s premier research institutions, the research and breakthroughs that come from this facility could set new standards and influence the aerospace and energy industries worldwide.
- Collaborative Efforts: Projects of this scale require collaboration between various stakeholders. The successful completion of the critical and final design review shows the effectiveness of our team and its ability to work together towards a shared vision.
Our team’s efforts in designing a state-of-the-art test facility will undoubtedly play a pivotal role in advancing research in this area. The ability to swiftly test new ideas will expedite innovation, paving the way for more efficient and environmentally friendly propulsion systems in the future.
Marine Defence Update
Our analytical proficiencies, ranging from Computational Fluid Dynamics to Fluid-Structure Interaction analysis, mean we can tackle a diverse set of challenges, offering our clients comprehensive solutions tailored to their needs.
Rest assured, with our emphasis on robust security controls, a team comprised entirely of UK Nationals, and credentials such as JOSCAR and Cyber Essential Plus, we ensure not just top-tier engineering solutions but also seamless, secure communications.
For bespoke solutions that prioritize performance, safety, and longevity, do consider partnering with us. Reach out today to learn how we can assist with your specific requirements.
Computational Fluid Dynamics (CFD) Team Update
At Frewer Engineering, our CFD team has been at the forefront of advancing internal airflow optimization for gas turbine testing rigs. With our arsenal of top-tier tools like Star CCM & SC Flow, we’ve been unraveling complex challenges posed by our esteemed clients.
Understanding the ever-evolving demands of the industry, we’ve augmented our capabilities with two state-of-the-art high-spec workstations. This translates to faster computations, allowing us to tackle larger and more intricate problems at an accelerated pace.
Under the visionary leadership of our CFD team head, Martha Cooper, we’re on a trajectory of growth, expanding our resources to cater to emerging client needs.
If you’re seeking a partner who doesn’t just keep up with the industry but paves the way forward, let’s discuss how we can redefine the boundaries of fluid dynamics together.
High Temperature Combustion Test Equipment Design
Our Advanced Gas Turbine Team brings with it a rich legacy of expertise in the design of high-temperature equipment. These designs are crafted to operate under the most extreme temperature conditions.
Leveraging advanced technologies, we’re proud to have the capability to produce intricate and highly accurate 3D full thermo-mechanical models. These models allow us to simulate a vast array of transients and operating conditions. Through them, we can effectively verify displacements, estimate equipment life, and more to ensure flawless in-service operation.
Of special note is our in-depth knowledge in water cooling and insulation – a crucial aspect that bolsters the efficacy and reliability of our equipment.
Pioneering the Future of Fuel Cell Test Stands
At Frewer Engineering, our engineers are not just keeping pace with the evolving world of fuel cell technology; they’re shaping its future. Our recent endeavors in designing next-generation fuel cell test stands underscore our commitment to innovation.
From the development of custom thermo-fluid analysis tools to a comprehensive design approach encompassing every mechanical aspect, our team has showcased unparalleled expertise. Our proactive use of thermal structural analysis ensures the longevity and reliability of our designs.
What sets us apart is our integrated approach. Our adept team, skilled in a myriad of design and analysis disciplines, has concurrently managed three interlinked projects, ensuring cohesive and timely outcomes.
For a seamless fusion of innovation, expertise, and efficiency, look no further.
New Addition to our Advanced Analysis Team: Welcome Michael Chapman!
We’re excited to announce the newest member of our team, Michael Chapman, who comes to us with an MSc in Aerodynamics & Computation from Southampton University. Michael’s academic background, combined with his keen interest in aerodynamics, makes him a valuable addition to our advanced analysis team.
As we’re currently engaged in several aerodynamic design optimization projects, Michael’s expertise will play a pivotal role. He will be one of the primary users of our comprehensive suite of CFD tools, delving deep into simulations of air and gas flows across various equipment, from gas turbines to fuel cell test apparatuses.
We believe that with Michael on board, we’ll be better poised to deliver even more precise and optimized solutions to our esteemed clientele. Please join us in welcoming him to our team and wishing him a successful journey ahead!
Harnessing the Power of Advanced Technology for Efficient Engineering Solutions
At Frewer Engineering, we constantly strive for innovation, not just in our engineering solutions but also in the tools and technologies we utilize. In line with this commitment, we’re thrilled to announce the latest advancements in our technological capabilities:
- High-speed Intranet: Our new 10 GPS intranet infrastructure has paved the way for lightning-fast data transfers, ensuring efficient computational processes and enhanced collaboration.
- State-of-the-art Workstations: We’ve onboarded high-specification workstations that have demonstrated reductions in run times for large models by a staggering 50% or even more in specific scenarios.
- Remote Accessibility & Flexibility: With the integration of our VPN, our dedicated engineering team can now remotely access these workstations. This ensures continuity in operations, with models in CFD and FEA running seamlessly over weekends and nighttime.
The outcome? Our clients benefit from accelerated solutions and a refined design process, thanks to quicker design iterations. As we move forward, you can expect even more agile, precise, and efficient solutions, making your visions a reality in record time.
