Simcenter 3D What s New in Mark Donley: Simcenter Structures Product Manager

Transcription

1 Simcenter 3D What s New in Mark Donley: Simcenter Structures Product Manager Realize innovation.

2 Simcenter 3D Highlights of Enhancements Desktop Meshing Selection Recipes Universal Connections Post-Processing Nonlinear Solutions Multi-Physics FSI Solutions Acoustic Solutions Thermal/Flow Solutions Motion Solutions Aerostructures Solutions Page 2

3 Engineering Desktop Highlights: Mesh Quality and robustness: get meshes right first time Workflow support: improving support for specialist applications Automation support: selection recipes to reduce manual steps Connections: supporting more industrial applications Post-Processing: More queries and controls

4 Quality and Robustness Improved Aesthetics of Surface Meshes Provide surface meshing tools that meet the demands of Automotive OEMs Challenge: Meet mesh quality objectives while still honoring feature details Current approach tends to blur features and excessively merge faces. Meet the user s eye test Current approach leaves unwanted pinching Version Version 12 Capture bead ridge line Capture stamped depressions Solution: Better recognition of CAD feature details Better mesh on specific features Preserve feature edges during abstraction, especially with significant face angle differences. Capture fillet chains Page 4

5 Quality and Robustness Element Quality Thresholds Reduce mesh quality failures for element quality parameters. Version Version 12 Challenge: Lower number of element quality for 2D Quad meshing. Failures related to key user defined parameters, such as: min and max element length, min and max angle, jacobian, warp, skew, aspect ratio Solution: Improved adherence to quality parameters User must input value within acceptable range of quality parameters Will happen automatically, no change to UI Page 5

6 Workflow Support 2D Meshing from Facets Enable meshing of convergent models to provide end-to-end free design workflows Challenge: Design freedom considerably increases with Additive Manufacturing Growing usage of facet data or mix facet/nurbs-based data (Convergent),.e.g. from Topology Optimization Challenges are adressed jointly by Modeling, CAM and CAE teams to provide seamlesss handling of Convergents in NX/Simcenter Convergent bodies are often too complex to be meshed with algorithms based on surface flattening or require heavy manual work on the geometry Solution: New approach: apply remeshing to the model facets New mesh recipe «2D Meshing from Facets» Triangles (linear, parabolic) Tets with «3D Tetrahedral» Leveraging the STAR-CCM+ remesher Robustness, performance Page 7

7 Workflow Support Lattice Meshing Enhanced workflows for Additive Manufacturing components Octet Challenge: Lattice structures are commonly used in AM components NX CAD Lattice command creates a faceted Convergent Body It is not practical to create a solid FE mesh on the lattice Solution: Lattice Convergent Body is instead converted to an orphan beam mesh; the lattice rods are represented by beam elements Meta data stored with the Lattice Convergent Body is used to construct the beam mesh and create a new Physical Property Connecting to the surrounding solid meshes is handled with an extension to the 1D Connection; 1D Mesh to Face Page 8

8 Selection Recipe Input Filter Enable more flexible workflows for automation Challenge: For automation of workflows involving complex models, it can be challenging to automatically select the desired entities in a repeatable way Solution: Extension of Selection Recipes to include an Input Filter to limit the initial selection to specific Polygon Bodies or FEM Components In the example shown, the Attribute method is now limited to a selected FEM Component Page 9

9 Selection Recipe Stacking Strategies Enable more flexible workflows for automation Challenge: For automation of workflows involving complex models, it can be challenging to automatically select the desired entities in a repeatable way Solution: Extension of Selection Recipes to include the ability to stack multiple strategies In the example shown, the following strategies are stacked: Bounding Volume by two points generates an initial selection of 69 Polygon Faces An Attribute strategy is added to re-select only those Polygon Faces with a certain name Page 10

10 Automation Support Selection Recipes in Meshing Improve automation of meshing tasks to reduce CAE model build times Challenge: Robust support of CAD driven automation of CAE analyses Assignment of geometry to mesh objects via CAD attributes Solution: Add selection recipes as selectable objects for meshing commands After CAD changes, meshes update according to what their selection recipes find Permit mesh object definitions that resolve to no geometry This leads to template FEMs now having template meshes with best practice settings shared among an entire estate Create FEM becomes a batch model build process Produce complete FEMs in a single step Create FEM Page 11

11 Bolted Connection Modeling Example Page 12

12 Connections Universal Connection for BIW Extend Universal Connections for full coverage of automotive Body-In-White assembly Challenge: Time consuming manual assembly of BIW Frequent CAE updates required in line with design changes Multiple models required for different attributes and solvers Improvements: Connection type to represent crimp connection used to join panels Connection type to represent clinch connections formed using a punch and die and are an alternative to spot welds for joining automotive body panels Connection type to represent non-modelled lumped masses ( trimming ), which are important for accurate NVH analysis Page 13

13 Connections Universal Kinematic Joints Extend Simcenter Nastran Sol402 with kinematic capabilities for the design and verification of mechanical systems with moving components Challenge: Extend the Finite Element analysis of single components to large assemblies in working conditions, i.e., take into account relative displacements of the different parts. Solution: Offers a toolbox of mechanical components and assembly conditions, such as: Kinematical joints Contact-friction conditions Pre-stressed structural assemblies Nonlinear material models including composites Page 14

14 Automotive BIW Example Page 15

15 Usability Postprocessing Measure Distance Quick interrogation of structural results Challenge: Methods are already available to find distances between deformed nodes in Post, but they require relatively complex user input. A solution is needed for users who wish to quickly measure distances interactively Solution: Implementation of the Simple Distance command in Postprocessing Interactive node pick or specified node number Use undeformed or deformed coordinates Output to graphics and list information Page 16

16 Usability Legend Color Bar Level Control Accurately define the required level boundaries for increased display control Challenge: Previously the level values in the color bar could be automatically calculated (default), or each set manually by the user. It could therefore be time consuming to arrive at the desired display Solution: New options for level spacing: Level Increment Increment and maximum number of levels Software calculates number levels Round Off Minimum number of levels Software calculates round values Page 17

17 Nonlinear Solution Highlights: Contact: Improved robustness Restart: Restart solutions from previous solutions Nonlinear Kinematics: Addition of kinematic joints and drives Material Extensions: Gasket and Strain Rate dependency

18 Evolution of the Simcenter Nastran Nonlinear Solutions The Twins Industry standard for over 50 years Complete suite of FE solvers Shared technologies : Element formulations Material library Numerical Strategy Capability Speed Usability Simcenter Nastran Multistep Nonlinear The Twins : SOL 401 / SOL 402 Page 19 Spin-off of Liege University (1965) European Aerospace industries footprint Complete suite of FE solver

19 Simcenter Nastran Multistep Nonlinear Simcenter Nastran Multistep Nonlinear One License Two Solutions SOL 401 SOL 402 New solution based on Nastran architecture Initial targeted for aero-engine applications Expanding into general purpose nonlinear New solution based on Samcef solver Samcef is well known among European aerospace companies Embedded in Simcenter Nastran paradigm to provide easy access to Nastran users Perform all your structural solutions using Simcenter Nastran Page 20

20 Contact Robustness Improvements Extend contact algorithms and controls to make convergence more robust Challenge: In some cases it is difficult to get convergence of nonlinear solution with contact boundary conditions Solutions: Adaptive Penalty Stiffness: automatic adjustment of penalty stiffness helps converge for light or hard contact Penalty stiffness update for temperature dependent material Gap / Penetration Adjustment: more options when initial gaps or penetrations exist Move nodes/adjust penetration within tolerance Specify delta time to eliminate initial interference Page 22

21 Nonlinear Workflows Restart Support Allow restart of nonlinear solutions Challenge: In some cases it is difficult to get convergence of nonlinear solution Users want to run different solution variations from a nonlinear state Solutions: Restart a nonlinear analysis from any converged state in a prior run From the end of any solved subcase From the last convergence of a subcase In restart solution can: Adjust solution parameters Change load and BCs Use cases: Restart from last converged time and change parameters to progress solution Multiple restarts from a converged preload condition so that preload step does not have to be repeated Page 23

22 Nonlinear Solutions Nonlinear with Kinematic Behavior Facilitate nonlinear solutions that have flexible and kinematic displacements Challenge: Some structures experience nonlinear displacements as a result of deformations as well as kinematic motion Solutions: Robust algorithms that support large displacement and rotational behavior in combination with flexure Kinematic joints: Hinge Prismatic Cylindrical Sliders Twister Spherical Removable link Drivers and time constraints Page 24

23 Industrial Robot Example Page 25

24 Nonlinear Materials Gasket and Strain-Rate Dependency Nonlinear material behaviors for non-metals Challenge: Gaskets need to be designed to prevent leakage and rupture Many plastics have different stress-strain behavior that are dependent on the rate of strain Solutions: Gasket materials Nonlinear backbone curve Multiple unload curves Gasket state as output result: open, closed, sealed, leaking Strain-rate dependent materials. Options: Analytical Cowper-Symonds law General tables Pressure (MPa) Gasket Bead Gasket Closure Page 26

25 Multi-Physics Highlights: FSI: Cosimulation with Simcenter STAR-CCM+ and Simcenter Nastran

26 Need for Multiphysics Simulations Real Physical Systems Real things respond to multiple physical conditions at the same time Mechanical loads, thermal loads, fluid loads, electromagnetic loads. Single physics simulation Mathematical simplification used to isolate the response to a single type of physicals Satisfactory for many systems for understanding system behavior and supporting product development Multi-physics simulation In some cases, multiple physics are needed to accurately simulate more complex system behavior Basic multi-physics (One way coupling) Response to a single physics gives rise to loads for another set of physics Advanced multi-physics (Two way coupling) Response to a single physics gives rise to loads for another set of physics and vice-versa Page 28

27 Simcenter Multi-Physics Solutions Thermal/Flow Thermal/Mechanical Vibro-Acoustic Predict temperature in electronic equipment Gain understanding of air flow paths Predict distortion from thermal loads Predict PCB temperatures Account for thermal and structural Determine fan size requirements contact coupling Design flow system to prevent Predict interior noise from external Predict creep strain from thermal loads overheating structural excitations Account for temperature dependent materials Predict loss of bolt preload from thermal loads Predict noise radiated off vibrating surfaces Fluid/Structure Predict how flow paths deform a structure Design structures to control the flow path New in Simcenter STAR-CCM+ and Nastran Cosimulation Page 29

28 Applicable Industries/Applications for FSI Industry Applications Marine Oil & Gas Ship maneuvers, slamming/green seas, whipping/springing, appendages Ship propeller stresses/singing Offshore platforms, rigs Riser/jumper pipes Automotive Airframe Aerospace Consumer Energy & Power Biomedical Valves, hydro-mounts, airbags, fuel tanks, shock absorbers, spoilers Engine header, transmission thermal stresses Vehicle wading BIW stresses/buckling in dipping process Flutter, wings, airfoils Rocket engines, fuel tanks Packaging, manufacturing Gas turbine blades, combustors, compressors Pumps, valves, hydro turbines Nuclear fuel rods Wind turbines Heat exchangers Heart valves, catheters, stents Page 30

29 New in Simcenter STAR CCM+/Nastran FSI Co-Simulation Description Cosimulation between best-in-class structural and CFD solver Implementation Steady or unsteady flow // Static or dynamic mechanical analyses Tight Cosimulation Nastran passes displacements to STAR-CCM+ STAR-CCM+ passes fluid tractions to Nastran STAR-CCM+ fluid mesh is morphed to the deformed wetted structural mesh Environment Structural analyst builds Nastran model in Simcenter 3D CFD analyst works in Simcenter STAR-CCM+ Imports Nastran model and launches/monitors cosimulation Page 31

30 FSI Example using Simcenter STAR-CCM+ and Simcenter Nastran Page 32

31 Acoustic Solution Highlights: Aerovibroacoustics: Flow induced vibration on structures cause noise Aeroacoustics: Turbulences within the flow emit noise Powertrain: Radiated noise from powertrain systems

32 SC3D Acoustics Aerovibroacoustics applications CFD based loads (aerodynamic/aeroacoustic) SC Nastran SOL108 / 111 Standard VA response Structural and acoustic response OR TBL Model loads (Turbulent Boundary Layer) OR SC Nastran SOL108 VATV based response Contribution Analysis Page 34

33 SC3D Acoustics Aerovibroacoustics applications Aircraft Flow Induced Noise Train Flow Induced Noise Sonar Self Noise Pump Noise Page 35

34 Vehicle Wind Noise Example Page 36

35 SC3D Acoustics Aeroacoustics applications HVAC / ECS Noise Fan Noise Aeroacoustic analogies to convert CFD flow results into equivalent acoustic sources Noise propagation including effect of environment (cabin) in acoustic (SC Nastran) solver tonal and broadband fan noise using aeroacoustic FWH analogy For cooling fans, ship and aircraft propellers Propagate aeroacoustic noise including effects of environment (encapsulations, ship hull, aircraft fuselage,..) Page 37

36 SC3D Acoustics Powertrain applications Powertrain Radiation Component-based or Full Vehicle Level FEMAO is now SOL111 enabled: for acoustic radiation Structural Modal DOFs and Fluid Pressure DOFs ERP is supported on 2D PLOT elements For powertrain or other rotating machinery + encapsulation Intake/Exhaust (beta) Acoustics Duct Modes allow for easy and accurate excitation and anechoic termination Good for small and large section ducts: trucks, industrial mufflers for building cooling systems, generator sets Temperature gradients in eg exhaust lines are accounted for Page 38

37 Thermal/Flow Solution Highlights: Multiphysics: Coupling with structural solution Workflow: Internal fans on disjoint meshes

38 Simcenter 3D Multiphysics Thermal-Flow-Structural Solutions Easily perform coupled thermal-flow-structural analyses in the Multiphysics environment. Challenge: Flow solution was previously not available in the Multiphysics environment. Pressure from CFD had to be mapped to the structural model. The process was disjointed and potentially error-prone, particularly in transient analyses. Required multiple models and meshes. Heat load Fixed translation Solution: All flow functionalities available in Multiphysics. Easy setup of thermal-flow-structural analysis on the same model. The thermal, flow, and structural solvers operate seamlessly and results can be post processed. Lays foundation for two-way FSI in future releases. Inlet flow Valve subject to fluid, and thermal stresses. Page 40

39 Valve Flow and Deformation Example Page 41

40 Simcenter 3D Flow and Electronics Systems Cooling Internal fans on disjoint meshes Define internal fans on surfaces with disjoint meshes to streamline flow simulation workflows in complex systems. Challenge: Prior to SC2019.1, internal fans had to be defined on mesh-mated surfaces. Mesh mating is not available in the AFEM context. Fluid domains had to be extracted at the modeling level. Idealized parts not accessible at the part level. Fluid domain extraction for complex assemblies with internal fans is challenging. Solution: Fluid domains can remain within their respective component idealized parts. Can be combined with surface wrapping workflows. Allows analyst to follow the Simcenter iprt paradigm more closely. Page 42

41 Simcenter 3D Flow and Electronics Systems Cooling Internal fans on disjoint meshes Page 43

42 Motion Solution Highlights: Transmission Builder Motion Time Waveform Replication (TWR) Flexible Bodies: Automatic Flex

43 Simcenter 3D Transmission Builder Efficient model creation and simulation of gear and transmissions Automated Creation of Multibody Models of Transmissions Based on Industry Standards Challenge: High effort to create and parameterize Transmission simulation models Inefficient processes for model updating Solution: New gearbox-centric application (on top of Simcenter 3D) to create Multibody Models automatically Adhering to Industry standard parameters. Supports the advanced solver methods. Simulation of gear forces as accurate as non-linear Finite Element Analysis, but orders of magnitude faster. Page 45

44 Simcenter 3D Motion TWR Time Waveform Replication Accurate Loads Prediction for Durability Analysis Challenge: Getting accurate loads of new parts early in development cycle when no physical prototype is available only test data from predecessor vehicle is available. High fidelity Multi-Body model and Tire model data is not yet available. Solution: Simcenter 3D Motion TWR Predict the loads on system, sub-system & components from any set of measured data. Capture Test conditions through Hybrid road approach, without the need for high fidelity tire models. Measurement (Red) Simulation (Blue) Page 46

45 Simcenter 3D Motion Flexible Body Enhancements Automatic Flex New flexible bodies with few mouse clicks Challenge: Currently several modeling steps are required to make a body flexible, also involving other Simcenter 3D applications (Pre/Post) Solution: A dedicated interface guiding any Motion users to make a body flexible through a full automatic process Making a body flexible has never been easier and quicker Page 47

46 Aerostructure Solution Highlights: Margin of Safety: Extension of Applications

47 Simcenter 3D Aerostructures Integrated end-to-end process As is typical process Disconnected systems The Siemens solution Integrated end-to-end solution Page 49

48 Simcenter 3D Aerostructure What s new focus: Laminates composite Allow to calculate margins of safety on composite structures Benefits Associative link to the FE model laminate composite definition Embed ready-to-use composite laminate methods Provide dedicated services embed company-specific knowhow for laminate composite assessment Enable what-if scenarios independently from existing model using local detailed definition of laminate Page 50

49 Simcenter 3D Aerostructure What s new focus: 1D Profile section properties Associativity between margin of safety calculation and 1D profile sections Benefits Use any profile section property (dimension, area, inertia ) for margin of safety calculations Full associativity with 1D model definition Available for all ready-to-use methods as well as all customer-specific methods Page 51

50 Simcenter 3D Aerostructure What s new focus: Load extraction with free-bodies Assessment of neglected structures Benefits Assess the local behavior of neglected parts (ex: bolt) directly by using the equivalent passing-through loads thanks to free-body, defined at post-processing step Perform stressing activities on any mesh (coarse or refined) Available for all ready-to-use methods as well as all customer-specific methods Page 52

51 Thank You Realize innovation.

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