The challenge
Established in 1988, Crossland Tankers transitioned from a tanker repair and servicing company to a manufacturer, producing one new tanker daily across two 80,000 square-foot facilities.
Bulk liquid transport is integral to the UK’s supply chain, with approximately 300 terminals dedicated to import, export, and distribution. Specialising in bulk-load road tankers in Northern Ireland, Crossland manufactures vehicles capable of transporting up to 40,000 litres of liquid over long distances. The sloshing of liquids within the tanks significantly impacts driveability and lifespan.
In response to competitive pressures and weight restrictions, Crossland engaged in a Knowledge Transfer Partnership with Queen’s University Belfast to enhance their research and development capabilities. The goal was to simplify the tanker design process using Ansys LS-DYNA simulations, focusing on three main components: SPH (Smoothed Particle Hydrodynamics) tank model, structural chassis model, and truck/suspension elements. Utilising the Oasys LS-DYNA Environment products and expertise, the team including R&D Engineer Conor Robb aimed to streamline design iterations and adapt to market demands effectively.
Software used on this project
The solution
This project aimed to develop a versatile road tanker model that captured road, tire, and suspension dynamics along with chassis effects.
The purpose-built Oasys Suite enabled efficient navigation of Ansys LS-DYNA’s extensive features and tools, with intuitive menu options for creating connections like welding and bolts. Oasys PRIMER’s model checking features further streamlined the process, and a simplified model featuring a rigid tank filled with water was constructed.
This project simulated the full tanker and chassis under diverse loading conditions including braking, turning, and NVH (noise, vibration, and harshness). SPH capabilities were employed to simulate sloshing effects within the tanker.
Crossland validated the model by completing real world testing in house, fitting acceleration and strain gauges to the tanker and performed various road manoeuvres.
After the real-world testing was performed, the recorded acceleration was applied to the Finite Element Analysis (FEA) model in three different load cases. Using Oasys D3PLOT, the team could extract the Stress/Time data from the shells corresponding to the location of the real strain gauges. Then using Oasys T/HIS they plotted the test data against the FEA results to determine the validity of the model.
The Oasys team provided continuous support throughout, guiding the project from academic modelling to commercial application. They assisted in defining the problem and determining optimal approaches using Ansys LS-DYNA and Oasys tools and techniques.
The result
By creating a "worst case scenario" load case of the tanker undergoing an emergency braking manoeuvre, the team were able to identify areas of weakness. The comprehensive model of the tanker provided opportunities for incremental and substantial modifications throughout the tanker design to reduce weight and improve market competitiveness. The design process has been enhanced by informing and evaluating design decisions with simulation data. “Using LS-DYNA and the Oasys Suite has enabled us to streamline our design process and deliver innovative and high-quality solutions for our customers. The software has given us the flexibility and accuracy to model complex features and interactions, and the support from the Oasys team has been invaluable. We are confident that this partnership will help us achieve our goals and maintain our competitive edge in the market." – Pearse McKeefry, Managing Director of Crossland Tankers Crossland can now design with efficiency in mind as they reduce weight and increase strength while still maintaining a factor of safety. This process will support them to pass all relevant compliance tests first time and save valuable time and money building multiple test rigs. With an effective workflow setup in Oasys PRIMER, this allows them to rapidly update models with new designs. This plays a key role in the new process at Crossland where designs are tested and evaluated with significant accuracy.