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I-DEAS Variational Analysis

I-DEAS Variational Analysis. The Next Generation of CAE software. Overview. Review the past promises and realities of the CAE products throughout the market Review of past trends and current demands on CAE in the product development process Product demonstration: I-DEAS Variational Analysis

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I-DEAS Variational Analysis

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  1. I-DEAS Variational Analysis The Next Generation of CAE software

  2. Overview • Review the past promises and realities of the CAE products throughout the market • Review of past trends and current demands on CAE in the product development process • Product demonstration: I-DEAS Variational Analysis • VGX for Analysis: The technology behind the I-DEAS Variational Analysis • The future of VGX for Analysis Technology

  3. The Product Development Process • Every Company has a different process... Launch Ready Production Start Customer Wants Package Program Approval Styling Powertrain Analysis Sign-off Prototype Sign-off Vehicle System Sub-system Component Production Readiness Production Start Transfer Proposal Definition Design Stability Deployment Readiness Market & Product Strategy Define Market Attack Plan & Technology Define Product & Deliver Technology Design Product Demonstrate Product Deliver Product Delight Customers

  4. What is effective use of CAE technology? • “Effective firms appear to have people who can translate the simulation results at the production stage more accurately. To the extent that the simulation models are not perfectly representative, casual human knowledge (i.e. interpretation of the results) that supplements physical and virtual simulation models is still important.” • Takahiro Fujimoto Harvard Business School, 3/97

  5. How Evaluation gets done today % of sites • “... the data strongly indicates that respondents prefer that engineers perform simulation in a collaborative design effort” • - DH Brown, Jan 1997.

  6. Requirements for Evaluation Technology Three biggest gaps • Managers Require: - DH Brown, Jan. 1997

  7. Requirements for Evaluation Technology • Designers and design engineers require: • Design guidance from analysis results, not raw analysis results(stress contours, mode shapes, response spectra) • Design parameter influence vs. design performance relationship in order to ensure design robustness. • CAE Experts require: • Design intent & modeling guidance from the 3-D design geometry- not all the complex design geometry • A high degree of confidence in the accuracy of their CAE modeling and simulation tools.

  8. In the Beginning, there was FEA…. • Promise : • Verify design performance without physical prototypes • Application : • Given to experts to be used to predict performance before prototype or production stage. • Result : 3 options • Prediction not finished in time • Prediction is completed in time and shows design will not perform correctly • Fix problem = Production delay • Ignore problem = Wasted effort • Prediction is completed in time and shows design will perform correctly • Raises comfort level prior to product release • However, there is little business benefit • Barrier to success : Time to complete analysis

  9. Then, there was CAD-Integrated FEA... • Promise : • Verify design performance earlier in product development cycle. • Application : • Given to experts to create FEA models directly from Design geometry. • Result: • Performance was predicted in time, saving one (or many) prototype(s) • Then the market saw an opportunity for Analysis to not only verify design, but provide design direction for “optimum” performance • The designer is given the engineering results directly • Not in a “language” they can interpret • The engineer interprets the results and makes a design decision • No knowledge of design constraints • Barrier to Success : Communication between • Design and Engineering

  10. Now, there is “Designer” FEA” …. • Promise : • Provide analysis-based design guidance to designers (remove the communication problem). • Application : • Given to designers to be used early in cycle to get performance evaluation results faster. • Result : • Designers find they don’t have enough time to use even with the easy-to-use, streamlined tools. • When they do have enough time, they still get engineering results, not design guidance. • Managers have doubts about quality of the results obtained from designers doing engineering work. • Barrier to Success: Designers don’t have enough time • to perform evaluations and can’t use the results

  11. How to improve Communication? • If there was a way to remove the communication problem and continue to front-load product evaluation such that: • Experts had access to complex 3-D design data in a format useful to performing CAE activities • CAE specialists could team with designers to provide “domain expertise” for a given industry/company/product • Designers had access to accurate analysis results in a format directly understandable by design engineers • Then, SDRC could provide a truly integrated CAE suite that provides designguidance as well as design verification. • That integrated CAD/CAE tool could also be positioned within the I-DEAS framework of “Collaborative Evaluation”.

  12. The Product Development Process • …but the basic tasks that must be accomplished are the same: Specification Development & Planning Concept Design Product Design Certification • The process goal is to produce a product that meets customers demands, is profitable and is delivered to market early enough to compete. Production

  13. Cost of Change Product Definition Product Knowledge Product Evaluation Specification Development & Planning Concept Design Product Design Prototype Production Cost vs. Knowledge

  14. What is Product Evaluation? • The process of assigning numerical values to a right to market attribute for the purpose of comparison or improvement.

  15. Test Article Drawing Prototype Mfg. Test Data Data Acquisition Visualized Result Data Analysis Prototype Testing Process & Tools

  16. Drawing Pre- Processor Finite Element Geometry Finite Element Results Solver Visualized Result Post-Processor FEA Process & Tools

  17. Design Geometry CAD Data Translator IF Foreign CAD Finite Element Geometry ] [ x1 x2 x3 y1 y2 y3 z1 z2 z3 Pre- Processor IF Integrated CAD FE Data Translator IF External Solver Finite Element Results Solver IF Integrated Solver Visualized Result Post-Processor CAD-Integrated FEA Process & Tools

  18. Design Geometry Pre- Processor Solver Visualized Result Post-Processor Designer FEA Process & Tools

  19. Cost of Change Product Definition Product Knowledge Specification Development & Planning Concept Design Product Design Prototype Production The Product Definition “Wall”

  20. r = 3 F = 1 x r = 2 r = 1 r = ? x = .05 L=? x=.05 L F Dealing with Unknowns • How is a design problem posed? • Design Curves • Display a functional relationship between design variables (r and L) and performance criteria (x)

  21. r = 2 r = 3 x x L L r = ? 3 r r 15 .017 15 x = .05 x x x x x .025 20 20 15 L = ? 20 L L 25 .07 25 25 F = 1 F x 2 r = 2 Target: x = .05 3 r = 3 r = 3 r = 3 r = 2 r = 2 15 20 25 L Design Curves - Traditional Analysis .025 .032 .058

  22. Fixed Analysis Variational Design Space Traditional CAE Analysis Point VGX for Analysis • The Need: • The focus of Digital Evaluation activities has shifted: • Away from reducing the number of prototypes by providing digital design verification. • Towards reducing the number engineering change orders by providing digital design guidance. • The Challenge: • You must decide on a design before you can evaluate performance = no guidance !

  23. Variational Analysis Analysis Space VGX VGX for Analysis • The Answer: • I-DEAS VGX for Analysis Technology leverages the full power of the Variational CAD Model • Understand which parameters impact performance • Make design decisions fully aware of their impact on performance. Design Space

  24. Variational Finite Element Geometry Variational Design Geometry Pre- Processor Solver Variational Finite Element Results ] [ Post-Processor x1(a,b) x2(a,b) x3(a,b) y1(a,b)y2(a,b) y3(a,b) z1(a,b) z2(a,b) z3(a,b) Variational Analysis

  25. Product Definition Product Knowledge Communication Solution • - Provide more insight to the product = product knowledge • - Information is in a format which communicates the design behavior in an understandable way in which no contour, arrow, animation, . . . can ever do • - For the first time the product knowledge curve breaks through the product definition wall!

  26. r = 3 x r = 2 r = 1 r r x x L L F F L Target: x = .05 Design Curves - Variational Analysis • Design Curves • Display a functional relationship between design variables (r and L) and performance criteria (x) • Variational Analysis • Creates the same functional relationship • Design curves for any geometry !

  27. Variational Analysis • First Introduced in I-DEAS Master Series 6A • Linear Structural Static Solutions • In I-DEAS Master Series 7 • Linear Structural Statics and Normal Mode Dynamics

  28. Variational Analysis • Sensitivity Analysis • How important is each design variable in determining a particular performance criteria? • Design Parameter Studies • When I change these design variables what will the value of my performance criteria be? • Generation of Design Curves • Complete results for Particular Configurations • Contour Plots / Animations • Optimization with respect to multiple design variables • Automatically find the combination of design variables that will create a design that has a certain performance.

  29. VGX for Analysis How is Variational Analysis different from Traditional CAE? • What’s not different: • Type of results • Modeling / solution process from the user standpoint • What is different: • One solution run for full variational design space • Usable in production environment • “Design Handbook” results

  30. Variational Analysis Demonstration

  31. Model: Holder • Boundary Conditions • supported by springs • radial and axial force

  32. Model: Holder

  33. Model: Holder

  34. Model: Crankcase • Boundary Conditions • Clamped along cylinder head • Intensity force on 2 nodes

  35. Model: Crankcase

  36. Model: Wheel Disk • Boundary Conditions • Clamped on inner edge (with symmetry conditions) • Pressure load on the face

  37. Model: Wheel Disc

  38. Model: Oil Pan • Boundary Conditions • 6 bolts (clamped condition) • Surface pressure

  39. Model: Oil Pan

  40. Model: Oil Pan

  41. The Approach

  42. Ro x x x F R1 R1 Ro x F F F Uo= U(Ro) U1=U(R1) Functional relationship Solve Uo Solve U1 R1=Ro+DR U(R+DR) = ?

  43. U R Ro U R Ro U R Ro The Taylor Series Expansion • Now the question becomes:

  44. Derivatives of U • Using these equations we can calculate any order derivative of U. • Now the question becomes: . .

  45. Standard FEM Variational FEM Derivatives of K • The Variational Analysis elements contain the necessary functions to calculate the higher order B, J and D matrices given the required input.

  46. Validity range of R for 1st order with 1% error Validity range of R for 2nd order with 1% error Validity range of R for 4th order with 1% error Accuracy of the Taylor Series Imag Order Error 4 3 1 2 3 4 . . 10 10% 5% 2% 1% . . 0.01% 2 1 R1 Rmax R0 Real

  47. The Applications of the method • Design by Analysis • Optimization • Matching / Correlation • Tolerancing • Real-Time review of results • Multi-Discipline Application (future)

  48. The future of Variational Analysis • Element Library • Wide library of elements • Solvers • Iterative solver • Sparse Matrix Solver • Results Viewer • I-DEAS independent results viewer • Create design curves/surfaces directly from VA results • Client/Server architechture

  49. The VisionMulti-disciplines Structural Analysis Normal modes C. Fluids D. Electromagnetic Compatibility Acoustics Inverse Problem : Multi-discipline approach

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