Introduction to (CAD CAM CAE)

Transcription

1 ANSYS, Inc. April 14, 2015 Introduction to (CAD CAM CAE) Uzman Yaser ALAIWI Mechanical Engineering Department İstanbul University

2 CAD CAM CAE Computer-Aided Design (CAD) Computer-Aided Manufacturing (CAM) Computer-Aided Engineering g (CAE)

3 COMPUTER-AIDED DESIGN (CAD) Computer-Aided Design (CAD) and drafting (CADD), is a technology for design and technical documentation, which replaces manual drafting with an automated process.

4 SolidWorks USER INTERFACE Part: Single body or Multibody of one Function Part: Single body or Multibody of one Function. Assembly: Combination of Multiple Parts Drawing: Technical Drawing of Part or Assembly

5 SolidWorks 2018

6 ASSEMBLY DESIGN: EXPLODED VIEW Napco Rotary Gear Pump

7 JET ENGINE A jet engine is a reaction engine discharging a fast-moving jet that generates thrust by jet propulsion.

8 SHEET METAL PRODUCTS

9 SOLIDWORKS COMPATIBILITY

10 SOLIDWORKS COURSE Part and Assembly Essentials Sketching- Basics - Symmetry- Patterning- Revolved Features Shelling Configurations of Parts Design Tables and Equations Advanced Features Bottom-Up Assembly Modeling Assembly Editing Large Assemblies Drawings Sheets Bill of Materials Technical Drawing Applications MKMU nd Year students

11 SOLIDWORKS COURSE Advanced Part Modeling Multibody Solids Sweeps- Lofts Advanced Surfaces Modelling Plastic Molds: Core and Cavity Modeling Sheet Metal Parts Structures & Weldments Computer Aided Design MKMU th Year students 1 st Semester Advanced Assembly Modeling Top-Down Assembly Modeling SolidWorks Animation introduction to Simulation

12 COMPUTER-AIDED MANUFACTURING (CAM) Computer aided manufacturing (CAM) is the use of software to control Computer-aided manufacturing (CAM) is the use of software to control machine tools and related ones in the manufacturing of workpieces.

13 CNC MACHINE

14 CNC MACHINE

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16 Introduction to FEA Analysis

17 Introductionto to FEAAnalysisAnalysis The Finite Element Analysis (FEA) is a numerical method for solving problems of engineering and mathematical physics. It is also referred to as Finite Element Method (FEM).

18 ANSYS 18

19 ANSYS COURSE 1. ANSYS Mechanical Basics 2. General Preprocessing, 3. contact and Mesh Computer Aided Engineering 4. Static Structural ral Analysis MKMU Vibration Analysis 4 th Year students 6. Thermal Analysis 2 nd Semester 7. Linear Buckling Analysis 8. Results Post processing 9. Nonlinear Overview 10.Basic Contact simulation 11.Advanced Contact simulation 12.Metal Plasticity 13.Hyperelasticity 14.Nonlinear Diagnostics

20 THE FINITE ELEMENT METHOD DEFINITION The finite element method is a numerical method for solving problems of engineering and mathematical physics. Useful for problems with complicated geometries, loadings, g, and material properties p where analytical solutions can not be obtained.

21 SIMPLE CONCEPTS OF FEA The finite element method (FEM) is a computer technique for solving partial differential equations. We use it to predict the deformation and stress fields within solid bodies subjected to external forces, involving fluid flow, heat transfer, electromagnetic fields, diffusion, and many other phenomena.

22 BRIEF HISTORY OF FEM Hrennikoff [1941] - Lattice of 1D bars to McHenry [1943] - Model 3D solids Courant [1943] - interpolation functions (shape functions) Levy [1947, 1953] - Flexibility & Stiffness Early 1950s developmemt of digital computers Argryis and Kelsey [1954] - matrix structural analysis using Energy principles Turner et al. (1956) stiffness matrices of truss elements, beam elements, 2-D plane stress elements [direct stiffness method] Clough (1960) (a) the first use of the phrase finite element (b) triangular and retangular elements in plane stress problems Zienkiewicz The Finite Element Method. 1967,1971, 1977, FEM software: ANSYS 1970 Nonlinear FEM software: MARC 1971 Today (a) High-speed computers and PC s (b) FEM theory and applications (c) CAD/CAE

23 Linear behavior? Recall, in the 1600s, Robert Hooke discovered a simple linear relationship between force (F) and displacement (u), known as Hooke s Law: F=Ku The constant K represents structural stiffness. A linear structure obeys this linear relationship. A common example is a simple spring: K u F F K Linear structures are well suited to finite element analysis, which is based on linear matrix algebra.

24 FEA PROCEDURES

25 ELEMENTS TYPES

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28 Engineering design: CAD

29 EXAMPLE: Questions: 1. What is the bending moment at section AA? 2. What is the deflection at the pin?

30 Difficult to solve by hand!

31 Engineering design Solidworks Sketch

32 Solidworks 3D Model

33 SolidWorks Stress Analysis: Solidworks 3D Model

34 Ansys Stress Analysis:

35 SolidWorks Deflection: Solidworks 3D Model

36 ANSYS Deflection

37 ANSYS Crack Simulation

38 intensity or K1c stress fact 3E+09 2,5E+09 2E+09 1,5E+09 1E ,5 1 a/(r0-ri) Seri 1 The stress intensity factor, K is used in fracture mechanics to predict the stress state ("stress intensity") near the tip of a crack caused by aremote load or residual stresses.

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40 OPTIMIZATION IN ANSYS

41 AUV DESIGN SEMBIO AUV

42 TECHNICAL DRAWING

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44 ANSYS: MESH PREPARATION

45 ANSYS: BOUNDARY CONDITIONS

46 SOLUTION AND POST PROCESSING

47 ANSYS: RESULTS

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49 WHY YOU SHOULD CARE ABOUT SIMULATION? Of course, design iterations and physical testing cannot (and should not) be entirely eliminated from the product design process. However, with Computer-Aided Engineering (CAE) the days, weeks or months of physical testing are replaced with hours or sometimes even minutes of a simulation run.

50 COMPUTER-AIDED ENGINEERING (CAE) Computer-aided engineering (CAE) is the broad usage of computer software to aid in engineering analysis tasks. It includes finite element analysis (FEA), computational fluid dynamics (CFD), multibody dynamics (MBD), and optimization. This includes simulation, validation, and optimization i of products, processes, and manufacturing tools.

51 COMPUTER AIDED ENGINEERING G

52 COMPUTER-AIDED ENGINEERING (CAE) CAE areas covered include: Stress analysis on components and assemblies using Finite Element Analysis (FEA); Thermal and fluid flow analysis Computational fluid dynamics (CFD); Multibody M l d dynamics (MBD) and Kinematics; i Analysis tools for process simulation for operations such as casting, molding, and die press forming. Optimization of the product or process.

53 COMPUTER-AIDED ENGINEERING (CAE) In general, there are three phases in any computer-aided engineering task: Pre-processing : defining the model and environmental e factors to be applied to it. Solving: by submitting the prepared model to a solver (usually performed on high powered computers) so we can perform the analysis Post-processing of results (using visualization tools) This cycle is iterated, often many times, either manually or with the use of commercial iloptimization i i software.

54 BENEFITS OF CAE: The benefits of CAE include reduced product development cost and time, with improved product quality and durability: Design decisions can be made based on their impact on performance. Designs can be evaluated and refined using computer simulations rather than physical prototype testing, saving money and time. CAE can provide performance insights earlier in the development process, when design changes are less expensive to make. CAE helps engineering teams manage risk and understand the performance implications of their designs. Warranty exposure is reduced by identifying and eliminating potential problems. When properly integrated into product and manufacturing development, CAE can enable earlier problem resolution, which can dramatically reduce the costs associated with the product lifecycle. We will use ANSYS software for Mechanical Structural Linear and Nonlinear Analysis in our course which its license is available at İstanbul University. And the language which will be used in this course is English language.

55 COMPUTATIONAL FLUID DYNAMICS

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58 Role of simulation in design: Boeing 777 (

59 Another success..in failure: Airbus A /

60 Drag Force Analysis of Aircraft Question What is the drag force distribution on the aircraft? Solve Navier-Stokes Partial Differential Equations. Recent Developments Multigrid Methods for Unstructured Grids

61 COMPUTATIONAL FLUID DYNAMICS DELTA WING

62 WHY YOU SHOULD CARE ABOUT SIMULATION? The design of any product is a highly complex process, and designing refrigeration units is a good example of that. In order to keep the cold chain uninterrupted, the insulated shipping box design needs to satisfy multiple objectives, requirements, and constraints. In the traditional design process, the only way to ensure the durability of such a product is to perform a high number of design iterations until all criteria are met. That means a high number of physical prototypes and a time-consuming and expensive physical testing process. In addition to the number of design iterations, the stage at which design changes need to be implemented is equally important; the earlier in the overall process, the cheaper a design change can be realized. This drastically narrows down the scope of possible design changes, making only small, incremental design modifications possible at a later stage.

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65 Types of Nonlinearities Rubber Boot Seal An example of nonlinear geometry (large strain and large deformation), nonlinear material (rubber), and changing gstatus nonlinearities (contact).

66 ELECTRO-HYDRAULICALLY DRIVEN SHEET METAL TESTING MACHINE WITH AUTOMATIC CONTROLS Test: ERICHSEN cupping test Drawing force: max. 120 kn Blank holder force: max. 45 kn Sheet thickness: mm Blanking force: max. 200 kn Deep-drawing cup test t Drawing punch ø: max. 33 mm Sheet thickness: mm Blank ø: max. 80 mm Bore expanding test Sheet thickness: mm

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68 ABAQUS SIMULATION

69 ABAQUS SIMULATION

70 TITAN SUPERCOMPUTER A Supercomputer is a computer with a high level of computing performance compared to a general- purpose computer. Performance of a supercomputer is measured in floating-point operations per second (FLOPS) instead of million instructions per second (MIPS). Titan is a system capable of churning through more than 20,000 trillion calculations each second oror 20 petafl ops by employing a family of processors, called graphics processing units (GPUs), The system contains 18,688 nodes, with each holding a 16-core AMD Opteron 6274 processor and an NVIDIA Tesla K20 GPU accelerator. Titan also has more than 700 terabytes of memory.

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72 Supercomputer Uses SCIENTIFIC RESEARCH NUCLEAR ENERGY MATERIALS SCIENCE WEATHER FORECASTING INTELLIGENCE AGENCIES DATA MINING

73 Nuclear Reactor Core Simulation: A DETAILED 3-DIMENSIONAL CAD GEOMETRY MODEL IS UTILIZED TO DEVELOP COMPUTATIONAL MESH FOR LARGE SCALE FLOW SIMULATIONS. THE INFORMATION DERIVED FROM THE THERMAL-HYDRAULICS SIMULATION IS USED TO FORMULATE INPUTS AND BOUNDARY CONDITIONS FOR OTHER SIMULATIONS SUCH AS FUEL PERFORMANCE, GTRF, CRUD, AND STRUCTURAL CALCULATIONS. MANY FACTORS AFFECT CORE OPERATING CHARACTERISTICS (E.G., TEMPERATURE, PRESSURE, POWER DENSITY GRADIENTS, THERMAL HYDRAULICS, NEUTRON TRANSPORT BEHAVIOR, FUEL PERFORMANCE, STRUCTURAL GEOMETRIES, AND COOLANT CHEMISTRY). THE CFD MESH USED FOR THE SIMULATION ILLUSTRATED CONTAINS 1.2 BILLION COMPUTATIONAL CELLS AND WAS SOLVED USING THE TITAN SUPERCOMPUTER. THE HIGH FIDELITY SIMULATION ILLUSTRATES COMBINED PHYSICS EFFECTS AT LEVELS OF DETAIL NEVER BEFORE AVAILABLE TO NUCLEAR SCIENTISTS AND ENGINEERS. THIS PARTICULAR SIMULATION WAS MESHED AND SOLVED USING CD-ADAPCO S STAR-CCM+ SOFTWARE. IMAGES COURTESY OF ZESES KAROUTAS AND JIN YAN (WEC)

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76 ILLUSTRATION OF A NUCLEAR REACTOR CORE: A QUARTER VIEW OF THE CAD GEOMETRY (ALL BUT ONE FUEL ASSEMBLY REMOVED FOR CLARITY) (LEFT); A QUARTER VIEW OF THE COOLANT TEMPERATURE DISTRIBUTION DURING NORMAL OPERATION (CENTER); AND A HALF VIEW OF THE REACTOR COOLANT PRESSURE DISTRIBUTION (RIGHT).

77 I wish you all the best in your career