CAD geometry of the generator housing was idealized into a quad-dominate shell FEA model. The housing is a space-frame structure composed of structural steel tubing. This frame is then covered with lightweight metallic panels that are attached via self-taping screws. The frame and panels were all modeled with shells with the screws as beam elements connected node-to-node. Contact was enforced between all components to capture the interaction of the panels slamming against the ribs and other internal components.
The first pass through the work was to meet the CSA S850-12 and PDC-TR 06-08 Protective Design standards and once these requirements were met, the structure could be optimized to improve its manufacturability. Upon the final simulation, the survivability of the housing was shown to pass and that improvements in manufacturing and weight reduction essentially paid for the consulting engineering work.