Fuel tank, 3D simulation, method FEA

Fuel tank for 39 tons and FEA (Finite element analysis) – computerized method of prediction model reaction.

This fuel tank transports 39 tons of fuel for your car or another vehicle. Customer wanted to check weak zones and improve construction. After discussion, we decided to make a FEA analysis and check welding connections.

Troubles

3D model with big gaps between the details because of a sheet metal bending requirements.
Unable to check welds because of gaps between the corners.
Complicated force distribution because of pressure difference between the top and the bottom of fuel volume.

Solutions

I transformed all sheet metal bodies to a surface bodies and repaired gaps. I saved directions of all surfaces, outer sides were outside, inner – inside. (Otherwise, I would have trouble with model preparing for simulation.)
Thanks to repaired surfaces connection, I created welds plots on intersection of planes.
According to transportation requirements, fuel tank must be filled for 90-95% of total volume. This condition created two zones of inner surfaces: under pressure and non pressure. Zone under pressure has complicated pressure pattern because of Pascal's paradox. This pressure can be applied on model by using mathematical formula or by CFD simulation. I used CFD simulation of fuel on the tank and export results to a model for FEA simulation.

Results

1 – Simulated safe factor, found out weak zones and checked welding plots.
2 – Recommendations for improving weak zones.
3 – Overall report of CFD and FEA simulations.


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