Get There Faster

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Nov 18, 2013 (3 years and 8 months ago)

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Get There Faster


CAE Overview

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Company Founded


1st Modal Analysis Package


1st Graphical FE Package


1st NURBS Solid Modeler


Automatic Mesh Generation


1st Commercial Enterprise Data Management System


Architecture for Hardware Independence


Relational Engineering Database


Adaptive Analysis / Optimization


Variational Design


I
-
DEAS Master Series Introduced


Dynamic Navigator





Concurrent Associativity





Non
-
Manifold Topology





Generative Machining





Metaphase Series Introduced





Variational Equations






Advanced Surfacing





Hybrid Modeling






VGX



Technology Leadership

1967

1970

1980

1985

1990

1993

1994

1996

1995

1997

1998

Metaphase Enterprise


Solution Series


Imageware Acquired


1st Variational Analysis


Capability

Imageware Surfacer

Top Award

EuroMold

98, Dec 1998

1997
Product of the Year

Design News Magazine, Mar 1998

1999

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Product Development Process


Time to Market controlled by Product Development
Process

Customer

Requirement

Product

Concept

Product

Design

Design

Evaluation

Part &

Product Detailing

Manufacturing

Tools & Plans

Production

Product Recycling

/

Performance

Certification

Total process time is the only TTM metric

Design

Evaluation

Manufacturing

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Product Evaluation Process

Prototype

Construction

Data Acquisition

Analyze Results

Physical Test

&
Measurement

Low Cost

“Low” Fidelity

Easy to Explore/Re
-
use

High Cost

“High” Fidelity

Difficult to Explore/Re
-
use

Model Creation

Solution

Analyze Results


Virtual”

Computer

Simulation

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Analysis Process & Tools

Design Geometry

Pre
-

Processor

Finite Element
Geometry

Visualized
Result

Finite Element
Results

[

]

x
1

x
2

x
3

y
1
y
2

y
3

z
1
z
2

z
3

Post
-
Processor

FE Data

Translator

IF

External Solver

Solver

IF

Integrated Solver

CAD Data

Translator

IF

Foreign CAD

IF

Integrated CAD

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Objective of the Analysis


Increased understanding of the design.

-
Deflection/stiffness


strength and feel

-
Load capacity


efficient use of material

-
Life and durability


field failures

-
Manufacturability


plastic fill analysis



Quickly pass through the model construction
phase

-
engineering begins after the results are available

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Geometric Sources for CAE


Imported CAD Geometry

-
Direct Interfaces


PTC, CATIA, UG, ICEM and PDGS

-
Industry Standards


IGES, SET, VDA, and STEP



Native I
-
deas Master Series

-
Model files

-
Library Access

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A complete set of tools for creating finite element models...

Powerful modeling technology


Master Model used directly for
simulation

-
feature suppression

-
partitioning

-
mid
-
surface extraction


Comprehensive meshing tools

-
free, mapped, manual methods

-
associative with design geometry


Boundary conditions can be
applied directly to geometry


Material data system

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Design Geometry Abstraction


Acknowledges CAD Geometry
is Almost Never Perfect

-
Small edges & surfaces

-
Poor surface parameterization

-
Odd surface shapes


Users Need More Control

for Better Quality

-
Improved interaction

-
Edge proximity


Meshing Improvements

-
Parity

-
Smoother

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Abstraction of Geometry


Section meshing

-
logical meshing areas, gathering of surfaces

-
interactive construction and modification

-
captures analysis intent



Topological features

-
curve and surface tangency recognition

-
edge adjacency or gap distance

-
removal of internal surface trim holes



Feature suppression

-
dependent upon constructors technique

-
not available with imported geometry

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Typical Design Geometry


Topology Issues

-
small edges

-
compound edges

-
sliver surfaces

-
high aspect ratio

-
missing surfaces

-
topology too detailed

-
reconstruction

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Meshing issues


Topology Suppression


History Supported


Automatic / Manual Modes


Loop Collapsed to Point


Curve Collapsed to Point


Ignores Small Edges

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Creation Options




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Augmentation of Geometry


Geometric information; physical representation

-
Additional structure.

-
Calculation surface to measure energy propagation.

-
Contact regions, FEM or geometry based.

-
Weld attachments, reference series of locations



Non
-
geometric information; non
-
physical
representation

-
interpolated surfaces.

-
lumped masses, springs, or beams.

-
gaps, coupled dofs, or constraint equations.

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Adaptation of the FEM


Associative to design definition

-
geometry change

-
abstraction change

-
boundary conditions

-
loading conditions

-
surface mapping



Surface mapping/compare parts.

-
domestic or imported



Parameter studies

-
explore influence of a design feature

-
explore influence of fem properties/materials

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Management of FE Models.


Each Design can have multiple FE models.

-
dependent upon the analysis requirements



Each FE model can have multiple solutions.

-
Loadcases or configurations

-
mechanical, thermal, dynamic or process



Attachment to a Design can be maintained or
released.

-
reference or spawn a copy of the design data



A FEM can also reference a system’s hierarchy.

-
assemble multiple FEMs

-
append models as an option


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Complete Element Library


Over 87 different kinds of elements can be
created

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Beam Element


The most extensive beam element support
in industry for over 20 years

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Beam Element


Beam elements are the simplest elements
geometrically


Most complex to formulate for 3D behavior



-

eccentricity



-

shear area



-

warping restraint factor



-

stress recovery



-

AISC, ANSI, piping code checking



-

standard shape library



-

general shape properties via mesh
discretization

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Physical Properties User Interface



User Interface

-
Fully forms based

-
Display of all properties on one form
for create/edit

-
Ability to display/group associated
elements

-
Active units displayed for property
values

-
Multiple selection of tables

-
Graphical selection of coordinate
systems and nodes



Solver Support

-
Update analysis program mask menu

-
Use native nomenclature for 3rd Party
properties

-
Generic physical properties
capabilities for external use

Phys. Prop. UI for Model Solution

above and MSC.Nastran below

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Composite Shell Elements

Laminate definition


-

support convenient layup



-

repeat



-

symmetric



-

anti
-
symmetric


-

groups of plies can be


replicated


45
°

90
°

0
°

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Composite Shell Element

Material orientations almost never matches element CS


-

stationary curve tangent


-

dynamic curve tangent


-

s,t surface directions,

Curve rotated about

axis of dome

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Communication of Findings


The analyst must effectively communicate
investigative findings in a language and a forum
that will affect robustness of the design in a timely
manner.


Formats

-
Beam Sections

-
Report

-
VRML

-
Picture files

-
XY, XYZ

-
Contours

-
Animations

-
Cross Section


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Thickness on Midsurfaced shell model


New Midsurface extraction


Thickness of elements are retained from midsurface
operation


Plot of thickness on midsurfaced model can be verified


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Process Efficiencies.


The analyst must apply various disciplines in order
to fully investigate the robustness of the
developing design.



Solutions

-
linear and nonlinear deflections

-
free and forced vibration

-
electronic system cooling

-
transmission and emission of noise

-
steady state linear or nonlinear thermal

-
static and dynamic stress evaluation

-
durability, strength and life evaluation

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FEM from Assembly


Flexible mapping of FEMs to System
Instances.

-
Direct access to orientation data

-
Flexible mapping of FEM to instance(s)

-
Node and element label control

-
Supports updates


instance hierarchy


configuration


FEM

-
Automatic creation of groups for each FEM


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Augmentation of Geometry


Other elements (Geometry based as well)

-
Rigid


Weld attachments, reference series of locations

-
Lumped masses, Springs


Gaps, Coupled dofs, or Constraint equations

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Assembly FEM from Renault


Four parts


48 Spot
welds defined


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Auto generate connections at spot welds

Using point data in separate

part


Associative connection between

a section entity (boundary or inside)

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Solution Depth


I
-
deas Master Series

-
h or p element formulations

-
non
-
linear directly from the linear model

-
structural dynamics response/random

-
experimental data analysis



Bi
-
directional

-
ABAQUS, ANSYS, NASTRAN

-
Moldflow

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Model Solution Enhancements


New Version of Sparse Matrix Solver

-
10% to 20% reduction in run time for models which require
no

memory paging

-
2x
-
3x reduction in run time for models which require memory paging


New Version of Iterative Solver

-
Max DOF = 10 million (parabolic tetrahedral)

-
2x
-
3x reduction in solve time (in memory)


Modal Damping Calculations


Strain Energy Table


Miscellaneous Solver Performance
Enhancements

-
2x improvement in “Physical Properties and Offset tables formed” step in solving a
geometry based mesh

-
5x improvement in the “Materials Tables Formed” step in solving a geometry based
mesh

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I
-
DEAS Response Analysis


Packaging & Positioning

-
New task in Simulation Application based
on extraction of “Dynamics” part of MS7
Durability & Dynamics

-
Pre
-
req’s include Simulation Modeling Set
or MasterFEM

-
Add
-
on potential for existing I
-
DEAS users
with NASTRAN


New & Enhanced Functionality

-
New
-

Random Vibration

-
New
-

Shock Response

-
New
-

Distributed Loads

-
Steady
-
State Analysis Enhancements

-
Transient Analysis Enhancements

-
Drop Test Simulation

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Response Spectrum


Standard modal response
combinations supported
including

-
ABS

-
SRSS

-
CQC

-
NRL

-
NRC


These techniques support a
wide range of industries

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Understanding Design Variation using I
-
DEAS
Variational Analysis

Variational
Geometry

Variational FE
Mesh

Variational Result

Criteria = F(Design
Variables)


Example:

Stress =
F(width,height)

Same result as
“constant”
analysis

Design Variable
Sensitivity

Design Curves

+

+

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Variational Analysis


New Mechanical Simulation Solver

-
Automatically solves FE model over entire range of design
variable variation
-
> produces design handbook results


Design Variables can include geometric, material
property, or elemental quantities

-
Provides a number of possible solutions to a given design
problem (not just a single solution)

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Variational Analysis


Integration with Model Solution

-
Access to Matrix Solver

-
Same Element Formulations (with some
exceptions)

-
Consistent User Interface


New Boundary Condition Type:
Linear Statics
-

Variational


New Solution Set Form

-
defines variational analysis type
(Baseline, Sensitivity, Parametric) and
parameters


Solve initiated using Model Solution
solve icon


Post processing sub
-
panel

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We were extremely pleased that
we were able to come up with a
rather unusual design that would
not have been possible without the
extensive use of design simulation.
Using I
-
DEAS Master Series™, we
even managed to reduce the weight
of the component by 18%.”


Thomas Kunze

Senior Design Engineer/Analyst

Lucas Varity
-

Heavy Vehicle
Braking Systems



Situation

-
Supplies brake systems for all but
one of Europe’s truck manufacturers

-
Needed to quickly design and
evaluate new disk brake system for a
new range of trucks

Get There Faster



We were extremely pleased that
we were able to come up with a
rather unusual design that would
not have been possible without the
extensive use of design simulation.
Using I
-
DEAS Master Series™, we
even managed to reduce the weight
of the component by 18%.”


Thomas Kunze

Senior Design Engineer/Analyst

Lucas Varity
-

Heavy Vehicle
Braking Systems



Situation


Goals

-
Leverage geometry created by
manufacturer

-
Increase evaluation accuracy


Demanded by critical safety
factors

Get There Faster



We were extremely pleased that
we were able to come up with a
rather unusual design that would
not have been possible without the
extensive use of design simulation.
Using I
-
DEAS Master Series™, we
even managed to reduce the weight
of the component by 18%.”


Thomas Kunze

Senior Design Engineer/Analyst

Lucas Varity
-

Heavy Vehicle
Braking Systems



Situation


Goals


Results

-
50% lower stress & 18% lower
weight in the redesigned carrier

-
Not a single carrier failed prematurely
in prototype testing

Get There Faster



Integrated
CAD/CAM/CAE
technology lets us
provide all services our
customers require.

It gives us a better way of
doing business.”

Industrial Packaging Systems


Situation

-
Provides custom containers used by
auto makers to ship parts

Dave Wahl,

President

Get There Faster



Integrated
CAD/CAM/CAE
technology lets us
provide all services our
customers require.

It gives us a better way of
doing business.”

Industrial Packaging Systems


Situation


Goals

-
Quickly build and evaluate complex
assembly models.

-
Bring analysis up
-
front in the design
process

-
Use advanced engineering technology
to differentiate the company

Dave Wahl,

President

Get There Faster



Integrated
CAD/CAM/CAE
technology lets us
provide all services our
customers require.

It gives us a better way of
doing business.”

Industrial Packaging Systems


Situation


Goals


Results

-
Reduced evaluation cycle time by
40%

-
Decreased packaging system costs
anywhere from 10% to 200%

Dave Wahl,

President

Get There Faster



The particular challenge on
this project was managing the
thermal and stress aspects of
an extremely dense electronic
product weighing more than 50
lbs. SDRC I
-
DEAS
®

software
enabled us to meet the exacting
specification and get to first
prototype within a demanding
deadline of nine months.”


Geoff Hardman, Engineering
Team Leader, BASE

British Aerospace


Situation

-
Established supplier of high
-
tech
aerospace and defense engineering to
the Aerospace/ Defense market

-
Design the power supply for a new
system to protect aircraft from the latest
generation of infrared missiles

Get There Faster



The particular challenge on
this project was managing the
thermal and stress aspects of
an extremely dense electronic
product weighing more than 50
lbs. SDRC I
-
DEAS
®

software
enabled us to meet the exacting
specification and get to first
prototype within a demanding
deadline of nine months.”


Geoff Hardman, Engineering
Team Leader, BASE

British Aerospace


Situation


Goals

-
Easily evaluate thermal and structural
performance of new power supply

-
Reduce/eliminate iterative stages of
physical prototyping

Get There Faster



The particular challenge on
this project was managing the
thermal and stress aspects of
an extremely dense electronic
product weighing more than 50
lbs. SDRC I
-
DEAS
®

software
enabled us to meet the exacting
specification and get to first
prototype within a demanding
deadline of nine months.”


Geoff Hardman, Engineering
Team Leader, BASE

British Aerospace


Situation


Goals


Results

-
Thermal & Structural evaluations
completed 40% earlier in development

-
From concept to working prototype took
only nine months, a 50% savings in time

Get There Faster



While it’s still early in our
implementation, I
-
DEAS
software has already helped us
reduce the weight of a brake
pedal by 26%. We can now
generalize the integrated
development and analysis
methodology we used on this
component to a whole calls of
brake pedals.”


Michel Dittlo, Design Systems
Manager

Sollac


Situation

-
Consulting firm that assists automotive
companies in developing new steel
components.

-
Design a new brake pedal for large
Automotive supplier.

Get There Faster



While it’s still early in our
implementation, I
-
DEAS
software has already helped us
reduce the weight of a brake
pedal by 26%. We can now
generalize the integrated
development and analysis
methodology we used on this
component to a whole calls of
brake pedals.”


Michel Dittlo, Design Systems
Manager

Sollac


Situation


Goals

-
Meet the safety and performance
requirements and a weight target set by a
competitive plastic part.

-
Base the new brake pedal on past
designs.

Get There Faster



While it’s still early in our
implementation, I
-
DEAS
software has already helped us
reduce the weight of a brake
pedal by 26%. We can now
generalize the integrated
development and analysis
methodology we used on this
component to a whole calls of
brake pedals.”


Michel Dittlo, Design Systems
Manager

Sollac


Situation


Goals


Results

-
Weight reduced by 26%, while maintaining
the required stiffness and durability.

-
Reduced the time to evaluate and arrive at
the final design by 90%.