NX and LMS Test.Lab Integration at AAM. NX CAE Symposium Title

Transcription

1 Title 11/5/ 1

2 Introduction: About AAM NX and LMS Test.Lab Integration at AAM Company Background Europe North America Asia South America World Headquarters Key Facts $2.93 Billion USD Sales (2012) 33 Locations in 13 Countries 11,000 Associates 20 Manufacturing Facilities 11 Business, Technical and Engineering Centers 2 Joint Venture Operations Technical Center 11/5/ 2

3 AAM s products NX and LMS Test.Lab Integration at AAM Passenger Car & Crossover Vehicle Company Background Light Truck and SUV Multi-piece Propeller shaft Rear Drive Module w/ Torque Transfer Device Transfer Case Rear Beam Axle Power Transfer Unit eaam electric AWD Front Axle (Independent & Steerable) Other Chassis Components 1.6% Front & Rear Propeller shafts Rear Beam Axle Propeller Shafts 8.0% 11.5% Metal Formed Products 6.3% 55.8% 11/5/ Front Axle Commercial Vehicle Driveshafts Front Axles 16.8% Rear Axle Systems (Includes Rear Drive Modules) 3

4 AAM s Customers NX and LMS Test.Lab Integration at AAM Company Background Light Truck / SUV Driveshafts Transfer Cases Rear Axles Front Axles Passenger Car / Crossover Independent Rear Drive Axles (IRDAs) Multi-Piece Driveshafts Transmission Differentials Independent Front Drive Axles (IFDAs) Torque Transfer Devices (TTDs) Power Transfer Units (PTUs) Commercial Vehicle Front Axles Rear Axles Metal Formed Products Ring / Pinion Gears Transmission Components Bus Axles (Rear Engine) Tandem Axle / Output Shafts Differential Gears 11/5/ 4

5 NVH Background Typical Automotive Driveline System NVH Problems Gear Whine Driveshaft critical speed Engine torque fluctuation Gear Rattle Shudder / Moan / Chatter Clunk AAM NVH CAE Responsibilities 1. Early upfront analysis and optimization to minimize NVH risks 2. Model correlation and physical validation during product development 1. Product behavior with different boundary conditions (Dyno vs Vehicle etc.) 2. Model methodology and database improvement 3. Problem troubleshooting and identification 3. Assist with Production and Field NVH Issues Driveline 1st order (imbalance and pitch line run-out) Driveline 2nd order (Cardan joint kinematics) Propshaft instability Chain noise Wheel imbalance Engine idle shake NVH CAE Team resides in NVH Product Engineering Department Test, Project Management, CAE 11/5/ 5

6 CAE Test NX and LMS Test.Lab Integration at AAM AAM Software History Timeline 1990s LMS Cada-X LMS Test.Lab I-DEAS I-DEAS I-DEAS Siemens NX 8.5 Windows 7 Upgrade Siemens LMS Acquisition LMS Cada-X No CAE functionality Few individuals could use the software efficiently I-DEAS Thoroughly integrated Test and CAE functionality Entire group used the software efficiently through use of scripts LMS Test.Lab No CAE functionality Very easy user interface Entire group has learned how to use the software effectively Used by CAE for Function Math and Plotting Siemens NX Mature CAE Environment Easy transition from I-DEAS Entire CAE group is very capable within the software 11/5/ 6

7 CAE Analysis Process Generating correlated CAE results involves a fairly standard iterative loop consisting of : 1. Model Construction 2. Model Solution 3. Calculating Responses 4. Comparison/Correlation to Test Data 5. Design Studies As with any iterative process, several repetitive software functions are used as each iteration requires a new calculation of results This is further complicated by the need to use Test.Lab for function math and powerful plotting tools NX 8.5 Journaling has saved significant effort as repetitive functions within NX can be replayed automatically 11/5/ 7

8 Log (...) NX and LMS Test.Lab Integration at AAM CAE Analysis Process Predictive Analysis is conducted in NX Advanced Simulation Module Models are solved using standard Sol 103 (Normal Modes) Response Simulation (FRF Calculator) is used to generate functions Front Axle Model in NX Iterative correlation activities occur often requiring the use of both Test.Lab and NX for analysis currently Test.Lab Functionality allows for more complex operations NX does not currently read Test.Lab data Test.Lab does read NX data Test.Lab has Advanced Function Math Tools Test.Lab plotting is very advanced m/s e-3 10e-3 3.0e-3 1.0e-3 Pinion Nose Vertical Response Test and CAE Data displayed in Test.Lab Test CAE 300e-6 100e Hz 11/5/ 8

9 CAE Analysis Process While the process could be conducted within NX, efficiency is improved dramatically when post processing is carried out within Test.Lab for the following reasons: Advanced function math, data manipulation and calculation scripting capability Very advanced plotting capabilities that enhance ability to review data Convenient comparison of Test data and model data (overlays) Rear Drive Module Model in NX For reporting purposes, calculated results are displayed in LMS Test.Lab NX data is in.afu format and is automatically saved externally LMS created a plugin for AAM that allows Test.Lab to read AFUs directly for comparison to Test data Pinion Nose Vertical Response Test and CAE Data displayed in Test.Lab Test CAE Frequnecy (Hz) 11/5/ 9

10 CAE Analysis Process - Correlation Inputs - CAD Models - Nastran Models - Gear Contact Info - Boundary Conditions (Dyno, Vehicle, etc.) NX 8.5 Advanced Simulation - FEM - Generate FEA Mesh (if necessary) - Auto-mesh most 2D and 3D components NX 8.5 Advanced Simulation - FEM - Manual Mesh 1D/0D components - Generate Gear Mesh Kinematics - Ensure proper connectivity between components (Springs, RBEs) NX 8.5 Advanced Simulation - SIM - Connect to appropriate Boundary Conditions - Add appropriate constraints (MPCs, SPCs, etc.) NX 8.5 Advanced Simulation - FEM - Manual remesh of 2D and 3D components (if necessary) Solve Strain Energy Table NX 8.5 Response Simulation - Apply appropriate damping treatment - Generate functions Test.Lab - Import calculated functions - Perform function math (scaling, multiplying, etc.) - Compare to Test Data - Evaluate Effectiveness Acceptable Correlation? NX 8.5 Advanced Simulation - FEM - Design Studies / Optimization Yes Report No 11/5/ 10

11 CAE Analysis Process Design Studies Inputs - CAD Models - Nastran Models - Gear Contact Info - Boundary Conditions (Dyno, Vehicle, etc.) NX 8.5 Advanced Simulation - FEM - Generate FEA Mesh (if necessary) - Auto-mesh most 2D and 3D components NX 8.5 Advanced Simulation - FEM - Manual Mesh 1D/0D components - Generate Gear Mesh Kinematics - Ensure proper connectivity between components (Springs, RBEs) NX 8.5 Advanced Simulation - SIM - Connect to appropriate Boundary Conditions - Add appropriate constraints (MPCs, SPCs, etc.) NX 8.5 Advanced Simulation - FEM - Manual remesh of 2D and 3D components (if necessary) Solve Strain Energy Table NX 8.5 Response Simulation - Apply appropriate damping treatment - Generate functions Test.Lab - Import calculated functions - Perform function math (scaling, multiplying, etc.) - Compare to Test Data - Evaluate Effectiveness Acceptable Correlation? NX 8.5 Advanced Simulation - FEM - Design Studies / Optimization Yes Report No 11/5/ 11

12 CAE Analysis Process The Strain Energy Tabulation allows the primary contributor to each mode to be clearly identified so that appropriate modifications to the mesh can be easily made to achieve the desired dynamic changes The table shows clearly that Modes #7 and #8 are Propshaft Bending Modes The Prop 2D (Tube modeled as shells) group contains more than 90% of the Strain Energy Mode #9 is Propshaft/Transmission Interface Torsion as the Prop 2D and Prop Joint Groups are the highest contributors Animation of the mode in conjunction with the Strain Energy table clearly identifies the controlling components in each mode Rear Axle Single Piece Propshaft Example Mode #9 Mode #8 11/5/ 12

13 CAE Analysis Process A great improvement to the NX user experience has been the addition of the Journaling Tool Works like Macros in Microsoft products Can Record and Playback actions as needed Very useful for repetitive actions Journal used to Calculate and Display Frequency Response Functions 11/5/ 13

14 CAE Analysis Process The calculated functions are easily read into Test.Lab by browsing to the files from the Navigator Functions are stored locally as.afu files LMS created an AFU reader plugin to easily access the data NX AFU files plotted within Test.Lab 11/5/ 14

15 CAE Analysis Process The functions are added to the Data Calculator and a previously used Formula Set is loaded For each iteration the FRFs and the necessary calculations are the same Functions are easily loaded for calculation 11/5/ 15

16 CAE Analysis Process The newly calculated Acceleration data is then displayed easily within Test.Lab The use of tabs in Test.Lab lets the user easily switch between the current plot window and a previously created plot Previous Plot Calculated CAE Surface Acceleration 11/5/ 16

17 Log NX and LMS Test.Lab Integration at AAM CAE Analysis Process The plots within LMS can then be copied to the MS Office suite and manipulated as the user sees fit Plot editing from within PowerPoint includes: X and Y-Axis modification Addition of cursors Curve Color and Line Thickness editing Statistical calculations (Max, Mean, RMS, etc) And much more CAE data is easily overlaid with Test Data for correlation m/s F FRF 60Y:+X/3000:+X 0 / F FRF 61Y:+X/3000:+X 0 / F FRF 62Y:+X/3000:+X 0 / F FRF 63Y:+X/3000:+X 0 / Hz /5/ 17

18 Summary The NVH CAE team at AAM has been using NX for almost 18 months The transition from IDEAS was smooth as old IDEAS models were easily imported into NX NX provides a very powerful environment for analysis The primary shortcomings on NX are with Function Math and Data Plotting Test.Lab serves very well as a supplement to complete the required analyses 11/5/ 18

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