Interface Software Development for Patran/Thermal, Esarad and Thermica

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1 Interface Software Development for Patran/Thermal, Esarad and Thermica 19th European Workshop an Thermal and ECLS Software Dr. Cosmas Heller EADS ASTIUM GmbH, Friedrichshafen - Germany All the space you need Contents I. The Goal for Thermal Distortion II. III. IV. Current Status Thermal Distortion Work Flow First Interface Approaches V. Second Interface Approach VI. Summary 1

2 I. The Goal for Thermal Distortion Approach for an Ideal Thermal Distortion Process: GMM creation with the aid of the CAD and FEM mesh data ay tracing, flexible and reliable orbit analysis Semi/Fully-automated capacity and conductor calculation Direct creation of TMM (skeleton file) with user coding Post-processing (incl. stochastic tool) to identify worst cases Transfer of geometry and worst case temperatures Automated temperature mapping from FDM to FEM nodes If possible: avoid black box analysis functions to simplify model check use existing tools to provide reliable results and minimize user reluctance 2 II. Current Status FDM Thermal Analysis: Esarad, Thermica, Esatan - Slower GMM creation without CAD/FEM interface Dedicated ray tracing and orbit analysis functions - Limited support for C & GL-calculation But transparent and simple check of C & GL-calculation Flexible user coding in TMM - Temperatures must be transferred for FEM distortion analysis FEM Thermal Analysis : Patran/Thermal Very efficient GMM creation with aid of CAD input - Limited to TIs, QUADs and Wedges - Lack of ray-tracing and orbital analysis capabilities Tools for automated C & GL-calculation available - C & GL-calculation difficult to check Temperature mapping functions implemented 3

3 IV. Thermal Distortion Work Flow FDM Tools FEM Tools CAD Input GMM Creation - No CAD interface - Text based modeller Several primitives CAD interface 3D GUI-Modeller - TI, QUAD & wedge only adiative Analysis Specular and diffuse - Diffuse reflection only Conduction & Cap. - Manual (future: automatic) Easy to check Partially automatic - Difficult to check Thermal Analysis Flexible user coding - Limited user coding Post-Processing - Mainly coded by user Future: Esatap Plotting implemented Mapping on geometry Temp.Mapping - Only for post-pro Mapping onto FE mesh FEM Analysis Standard Application IV. First Interface Approach FDM Tools FEM Tools CAD Input GMM Creation - No CAD interface - Text based modeller Several primitives CAD interface 3D GUI-Modeller - TI, QUAD & wedge only adiative Analysis Specular and diffuse - Diffuse reflection only Conduction & Cap. - Manual (future: automatic) Easy to check Partially automatic - Difficult to check Thermal Analysis Flexible user coding - Limited user coding Post-Processing - Mainly coded by user Future: Esatap Plotting implemented Mapping on geometry Temp.Mapping - Only for post-pro Mapping onto FE mesh FEM Analysis Standard Application

4 IV. First Interface Approach Data Transfer Scheme Patran/T Model Creation PatQ Controller View Factor Form Factor Calculation QTran Thermal Solver vfin.dat (Geometry) template.dat (Opticals) vfres.txt (esistors) qmacro.dat (Transient Loads) micro.dat (Transient Loads) qbase.dat (Steady State Loads) I/F Program I/F Program model.erg (Esarad Input) model.d (Esarad Output) Esarad/Thermica Heat fluxes calculated in Esarad: Q IV. First Interface Approach Theoretical Verification of adiative Approach Three triangles of same size with same normal vector Surface Indices: p, q = I, II, IV Edge Indices: i, j = 1, 2, Number of edges: EF of similar triangles: = Q Q = σ [ G ( T T ) G ( T T )] TOT, ESAAD I, III II, III I, III I III II, III II III n I = II III I, III = GII, III, GI, II = G 3, n = 3, n = 3 0 Heat fluxes calculated in Patran: 1 1, Q TOT, PATAN = σ 3 ( T T ) ( T T ) 3, Heat flux values are identical for: 1 3 1, 3, 1 3 1, 3, 2 i, j 2,, 2 n = p G n 2, q p, q p, q, 2 2,, Two TIs in FEM / FDM

IV. First Interface Approach Geometry Transfer Test Geometry built in

thermo-optical properties transferred correctly Interface software supports

First Interface Approach adiative and Orbital Test K C Temperatures calculated

check radiative couplings Small temperature deviation between Patran/T and

5 IV. First Interface Approach Geometry Transfer Test Geometry built in Patran/Thermal Geometry after transfer to Esarad Point, TIs, QUADs and thermo-optical properties transferred correctly Interface software supports single and double sided surfaces 8 IV. First Interface Approach adiative and Orbital Test K C Temperatures calculated with Patran/Thermal Temperatures calculated with Esarad/Esatan Test model to check radiative couplings Small temperature deviation between Patran/T and Esarad (next slide) Algorithm for distribution and transfer of radiative couplings is correct Transient orbit loads transferred correctly 9

IV. First Interface Approach Comparison of Temperature esults Esatan Node No.: Equivalent Patran Temp.* [ C]: Esatan Temp. [ C]: Deviation [ C]: 1 13.00 13.90 0.31 2 13.3 13.990-0.33 3 1.393 1.00-0.

6 IV. First Interface Approach Comparison of Temperature esults Esatan Node No.: Equivalent Patran Temp.* [ C]: Esatan Temp. [ C]: Deviation [ C]: *Equivalent Patran temperatures are calculated as average edge temperatures of surfaces. Esarad double-active nodes, corresponding to 12 single active Patran nodes. Deviation excluding these nodes: 0.11 C 10 IV. First Interface Approach Linear Conductance and Capacitance in Patran User friendly definition of properties for each element with GUI: Thermo-optical properties Thermal conductivity Specific heat Thickness Automated capacity and conductor calculation supported by GUI Possibility to add linear conductors (e.g. for contact conduction) For rectangular elements: conductors between FEM nodes are in the form λ A/d Conductor calculation for other element shapes is difficult to check No documentation for linear conductor calculation available 11

V. Second Interface Approach FDM Tools FEM Tools CAD Input GMM Creation - No CAD interface - Text based modeller Several primitives CAD interface 3D GUI-Modeller - TI, QUAD & wedge only adiative

7 V. Second Interface Approach FDM Tools FEM Tools CAD Input GMM Creation - No CAD interface - Text based modeller Several primitives CAD interface 3D GUI-Modeller - TI, QUAD & wedge only adiative Analysis Specular and diffuse - Diffuse reflection only Conduction & Cap. - Manual (future: automatic) Easy to check Partially automatic - Difficult to check Thermal Analysis Flexible user coding - Limited user coding Post-Processing - Mainly coded by user Future: Esatap Plotting implemented Mapping on geometry Temp.Mapping - Only for post-pro Mapping onto FE mesh FEM Analysis Standard Application 12 V. Second Interface Approach 1. Step: GMM Creation in Patran/Thermal Geometry in Patran/Thermal Finite element definition (TIs, QUADs and wedges) Efficient due to semi-automated meshing and CAD data import Assignment of thermo-opticals and element activity Grouping of elements: Improves overview/transparency Enables simple assignment of group thicknesses and properties Output: geometry and thermoopticals 13

displayed in interface S/W Geometry and thermo-optical check for each group Definition of

Include file providing group properties 1 V. Second Interface Approach 3.

conversion of point coordinates, surfaces and thermo-optical properties Automatic group

8 V. Second Interface Approach 2. Step: Group Property Definition with I/F I/F file defining group properties Geometry displayed in interface S/W Geometry and thermo-optical check for each group Definition of properties for each group: Thermal conductivity Specific heat Thickness Output: Esatan Include file providing group properties 1 V. Second Interface Approach 3. Step: GMM Conversion with I/F Esarad Geometry provided by Interface S/W Automatic conversion of point coordinates, surfaces and thermo-optical properties Automatic group colouring Creation of Thermica Sysbas file using TASverter (batch) Geometry file can by directly used by Esarad or Thermica Output: Esarad (*.erg) and Thermica (*.sysbas) files 1

displayed and can be modified by user Use of group properties Specific heat Thickness Output: Esatan Include file defining element thermal capacities 1 Step: Linear Conductor Calculation with I/F

9 V. Second Interface Approach. Step: Capacitance Calculation with I/F GUI of Interface S/W for capacitance calculation Valid for TIs and QUADs Semi-automated process Automated capacitance calculation for each element Formula is displayed and can be modified by user Use of group properties Specific heat Thickness Output: Esatan Include file defining element thermal capacities 1 V. Second Interface Approach. Step: Linear Conductor Calculation with I/F GUI of Interface S/W for linear conductor calculation Valid for TIs an QUADs Use of group properties Semi-automated process Automated linear conductor calculation for neighbouring elements Formula is displayed and can be modified by user (e.g. contact for insertion of conductance) Output: Esatan Include file defining linear conductors 1

(e.g. for heat sources, heat pipes) Esatan output: Node (or element) temperatures I/F output: Patran BDF file and Patran

10 V. Second Interface Approach. Step: TMM Creation and Thermal Analysis Esatan TMM with Include files generated before Esatan skeleton file created automatically (e.g. by Esarad) Insertion of Include files created beforehand: Linear conductors Capacities Additional user coding (e.g. for heat sources, heat pipes) Esatan output: Node (or element) temperatures I/F output: Patran BDF file and Patran temperature input file 18 V. Second Interface Approach. Step: Temperature Mapping Transferred geometry and temperatures Temperature map on FEM mesh Model geometry transferred with I/F to Patran (BDF file) Element data transferred with I/F to Patran (temperature input file) Interpolation of FEM element temperatures in Patran Finally: structural FEM distortion analysis 19

11 VI. Summary I/F software created to link Patran with Esarad/Thermica Favourite application: thermal distortion problems I/F Approach 1: GMM and TMM defined in Patran/T CAD and FEM structural model interface available Automated linear conductor calculation - No documentation for linear conductor calculation available - Limitations on TIs and QUADs adiative couplings calculated in Esarad/Thermica - Esatan input data transferred to Patran/T (TMM user coding restricted) Patran/T results verified (theoretically and by simple test cases) 20 VI. Summary (cont d) I/F Approach 2: GMM defined in Patran/T CAD and FEM model interface - Limitations on TIs and QUADs Semi-automated linear conductor and capacitance calculations adiative couplings calculated in Esarad/Thermica Esarad/Thermica surfaces can be added (e.g. cylinders, discs ) Esatan TMM using Include files for conductance and capacitance esults transferred to Patran via BDF and temperature data files Mapping onto FEM mesh and thermal distortion analysis in Patran Process already used in recent projects (early design phases) 21

James Etchells (TEC-MCV) 19 th European Workshop on Thermal and ECLS Software 11 th 12 th October 2005

James Etchells (TEC-MCV) 19 th European Workshop on Thermal and ECLS Software 11 th 12 th October 2005 James Etchells (TE-MV) 19 th European Workshop on and ELS Software 11 th 12 th October 2005 1. Introduction and discussion of background and important issues 2. omparison of TLP and FEA for S/ thermal