Overview. simulation situation and trends. Martin Eerme

Transcription

1 Overview Engineering calculations and simulation situation and trends

2 History Grow up from aircraft industry. Need for licht structures Need for strenght calculations Development of computer technology

3 History Hrennikoff [1941] - model of 1D trusses Courant [1943] Ritz methods application Levy [1947, 1953] - Flexibility & strenght Argyris and Kelsey [1954] Statics and dynamics prob. matrix based formulation Turner, Clough, Martin and Topp [1956] - 2D elements (Hrennikov evolution) Clough [1960] - Termin Finite Elements

4 History John Argyris Stuttgardi Ülikooli õhu- ja ruumisõidukite staatika ja dünaamika emeriitprofessor. TTÜ audoktor aastast, tunnustamaks tema väljapaistvaid teeneid lõplike elementide meetodi uurimisel ning Saksamaa ja Eesti teaduskoostöö arendamisel.

5 Development and implementation of CAD/CAM/CAE systems is one of the most important result in 20th century in technical sciences and technology. National Academy of Engineering American Society of Mechanical Engineering i

6 FEM - field of usage time Process simulation Biology/ physics medicine, geophysics Electronics/ micromechanics 1970 Chemistry, machinery 1960 Car industry, Ship industry, civil eng, Aircraft industry Field of usage

7 Multiphysics A general purpose analysis tool allowing a user to combine the effects of two or more different, yet interrelated physics, within one, unified simulation environment. Electromagnetic Magnetic Thermal Fluid Electrostatic Electrical Structural

8 Machinery A general purpose analysis tool allowing a user to to combine the effects of two or more different, yet interrelated physics, within one, unified simulation environment Thermal Optimisation Interdistsiplinary Fluid Fatigue Dynamic Static Processes

9 Simulation Products Processis Forming Welding Contact problems

10 Applications Food industry T t t P t Spagetties drying process = a11 T + a12 U + a13 P + U 2 2 = a T a U a P = a31 T + a32 U + a33 P P a 14 Q P pressure T Temperature U - humidity

11 Applications Process simulation welding

12 Applications Process simulation welding

13 FSI Remeshing Examples Coupled fluid-solid (FSI) meshing capability can handle applications with large boundary/domain changes. This feature addresses a broader range of FSI market applications, as the solid can undergo large deformation or even complete rotations. E.g.. Pumps or stirrers. Detached solid object can also move through the fluid. Example: Rigid body rotation, a flap valve in a tube:

14 FSI Detached, Moving Solid Example Cylinder passing through a channel:

15 Applications Process simulation Deep drawing

16 Applications Process simulation bending

17 Structural-Radiation Heat Transfer Coupling Radiation heat transfer to plate (temperature) Heated roller displacement versus time

18 Conjugate Heat Transfer Vertical heat sink

19 Thermal Structural Example BGA IC Package differential thermal expansion Image courtesy of MCR.

20 Applications Optimisation (topology and geometry) Applying simulation technology to industrial design accelerates the generation of design concepts that are exciting, feasible, desirable and profitable. Dave Simmon Altair Engineering, product innovation

21 Lokale Optimalitätskriterien Mattheck s Computer-Aided Optimization CAO Claus Mattheck leitet aus Beobachtungen des Wachstums von Bäumen, speziell ihrer Anpassung an unterschiedliche Belastungen, Optimierungsmethoden für grösste Belastbarkeit ab. Die Steigerung der Belastbarkeit folgt aus dem Abbau von lokalen Kerbwirkungen. Claus Mattheck, Design in der Natur, Rombach Wissenschaft, 1993

22 Optimisation

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24 Probabilistic Design Random input parameters Material Properties Finite-Element Model Random output parameters Critical Stress Critical Strain Critical Temperature Lifetime... Probabilistic Results Loads Thermal Structural Geometry/ Tolerances equency Histogram Rel. Fre Histogram LN_LCF Scatter Plot ANSYS Probability Cumulative Distribution Function 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% ANSYS LN_LCF ANSYS Sensitivities of LN_LCF AN SYS Geometry Thermal BC Boundary 10 Conditions 5 Gaps 0 Restraints LN_LCF LN_STRESS Material

25 Applications Process simulation (hydroforming) Alcan Technology & Management AG

26 Applications Medizinstechnik Verbreiten den Blutgefäße StentFomMovie.mpeg

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28 Applications Biomechanik (biologische trägestrukturen)

29 Applications Herz contact

30 Applications Fatigue Crack propagation area Kolben high temperature fatigue analysis Calculated life contours

31 Applications Scheibenbremse: Temperaturen Einfluss und Materialien Festigkeit

32 Auf die Felgen auftretende Lasten Applications

33 Applications

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36 LF Electromagnetic Cyclic Symmetry

37 Rotating Machine Examples Picture: CAD-FEM GmbH.

38 Acoustics Example Response of axisymmetric disc in tube to plane wave.

39 Fluid dynamics Pressure Iso lines Temperature

40 Applications Process in car engine

41 Applications Aerodynamics

42 Applications Crash elements elements elements

43 3D Lagrange Interactions - External Gap Boing 747 Impact into a Reinforced Concrete Wall 3m thick wall 1m thick wall Courtesy of CRC Solutions, Tokyo, Japan

44 3D Lagrange Interactions - External Gap Phantom Jet Impact On Concrete Sandia Test, 1988 Courtesy Sandia National Lab.

45 3D Lagrange Interactions - External Gap Train Crash on thr JR- West s Fukuchiyama Line (Japan 2005) Condominium Building Impacted Column Impact Direction 90 Front = 45 Rear 2nd Car Courtesy of CRC Solutions, Tokyo, Japan

46 Applications

47 Applications

48 Applications Penetrations simulation /products /p_app_plate -impact.html

49 Applications Nonlinear analysis: Deformations in Rubber

50 Applications Acustics: Soundpressure inside car

51 Rechnerische Ziele Reducing time for Simulations: Modeling, Meshing & Analysis time (John Swanson, 1997) Ansys Inc Months 1994 Days 1996 Hours 2000 Minutes Ziel - 10 M DOF während 1Std

52 Computig time versus number of CPU AMG Performance (0.8 M DOF) Time (Sec c) Number of Processors

53 You ve spent three days building a model, a day applying boundary conditions, and, after an overnight solution, you re ready to postprocess the results and move on to your next analysis. What s wrong with this picture? The problem is that we often don t spend enough time reviewing the answers and gaining insight into the problem to offer an enlightened interpretation of what the results really mean. John Crawford Consulting Analyst

54 Ein kleines Beispiel: Ein junger Ingenieur hat ein schönes FE-Modell erstellt. Er hat die Lastfälle und die Randbedingungen eingeben und das ganze laufen lassen. Wunderschöne farbige Bilder mit Spannungen sind herausgekommen. Es gab auch kritische Stellen welche sofort näher untersucht wurden. Sind sie wirklich kritisch oder liegt ein Modellierproblem vor? Irgendwann haben wir dann die Ergebnisse gemeinsam angeschaut. Seltsamerweise waren die Spannung etwas asymmetrisch obwohl ein symmetrischer Lastfall vorlag. Er konnte sich das auch nicht erklären und hat auch keinen Fehler im Modell gefunden. Als wir dann ein paar einfache Grundüberprüfungen machten, welcher er bisher nicht kannte, mussten wir feststellen, dass irgend eine horizontale Kraft auftrat, welche er aber nirgends aufbrachte. Eine weitere Untersuchung führte dann den Fehler zum Vorschein. Er hat im Modell die Erdanziehung mitrechnen lassen, nur leider war sein Modell um 90 gegenüber der Erdanziehung gedreht.

55 Engineers can t do a better job designing products just by working harder or longer hours, they need the right tools to leverage their expertise, and that demands investment in the latest software technology. David Weisberg Chief Industry Strategist Cyon Research Corp

56 Trends Better algorithms Better computers Bigger models (number of DOF) Assembly based (product) simulation Virtual Reality

57 Kvant computer RSA kood murtakse 5 minutit peale esimese suure kvantarvuti käivitamist David Deutsch (kvantarvutite guru) RSA Tuntuim avaliku võtmega krüptoalgoritm, mida loetakse turvaliseks alates 768 või 1024 biti pikkusest võtmest. Töötasid välja Rivest, Shamir ja Adleman 1978.a.

58 Virtual reality Physical based Simulation and Visualization of Flexible Materials for Design and Assembly Virtual Environments Research, Bonn; Fraunhofer IMK, Sankt Augustin

59 Assambly based analysis

60 Testing (CAT) There is need for testing for different products according to EU directives (lifters, Seat Frame with 3-point Safety Belt,...) Can rise the speed of investigation in some cases (incremental forming)

61 Testing

62 Testing

63 Thank You!!!