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CAE OverviewCAE Overview

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Company Founded 1st Modal Analysis Package 1st Graphical FE Package 1st NURBS Solid Modeler Automatic Mesh Generation

1st Commercial Enterprise Data Management System Architecture for Hardware Independence Relational Engineering Database Adaptive Analysis / Optimization Variational Design I-DEAS Master Series Introduced Dynamic Navigator™

Concurrent Associativity™ Non-Manifold Topology

Generative Machining Metaphase Series Introduced Variational Equations

Advanced Surfacing Hybrid Modeling

VGX™

Technology Leadership1967

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1998

Metaphase Enterprise Solution Series Imageware Acquired 1st Variational Analysis Capability

Imageware SurfacerImageware SurfacerTop AwardTop Award

EuroMold ‘98, Dec 1998EuroMold ‘98, Dec 1998

Imageware SurfacerImageware SurfacerTop AwardTop Award

EuroMold ‘98, Dec 1998EuroMold ‘98, Dec 1998

1997 1997 Product of the YearProduct of the YearDesign News Magazine, Mar 1998Design News Magazine, Mar 1998

1997 1997 Product of the YearProduct of the YearDesign News Magazine, Mar 1998Design News Magazine, Mar 1998

1999

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Product Development ProcessProduct Development Process

• Time to Market controlled by Product Development Process

CustomerRequirement

CustomerRequirement

Product ConceptProduct Concept

ProductDesign

ProductDesign

DesignEvaluation

DesignEvaluation

Part &Product Detailing

Part &Product Detailing

ManufacturingTools & PlansManufacturingTools & Plans

ProductionProduction

Product RecyclingProduct Recycling

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PerformanceCertificationPerformanceCertification

Total process time is the only TTM metric

DesignDesign EvaluationEvaluation ManufacturingManufacturing

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Product Evaluation ProcessProduct Evaluation Process

Prototype Construction

Prototype Construction

Data AcquisitionData Acquisition

Analyze ResultsAnalyze Results

Physical Test & Measurement

Low Cost“Low” FidelityEasy to Explore/Re-use

High Cost“High” FidelityDifficult to Explore/Re-use

Model CreationModel Creation

SolutionSolution

Analyze ResultsAnalyze Results

“Virtual” Computer Simulation

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Analysis Process & ToolsAnalysis Process & Tools

Design Geometry

Pre-Processor

Finite Element Geometry

Visualized Result

Finite Element Results

[ ]x1 x2 x3

y1 y2 y3

z1 z2 z3Post-

Processor

FE DataTranslator

IF External Solver

SolverIF Integrated Solver

CAD DataTranslator

IF Foreign CAD

IF Integrated CAD

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Objective of the AnalysisObjective of the Analysis

• Increased understanding of the design.- Deflection/stiffness

• strength and feel- Load capacity

• efficient use of material- Life and durability

• field failures- Manufacturability

• plastic fill analysis

• Quickly pass through the model construction phase

- engineering begins after the results are available

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Geometric Sources for CAEGeometric Sources for CAE

• Imported CAD Geometry- Direct Interfaces

• PTC, CATIA, UG, ICEM and PDGS

- Industry Standards

• IGES, SET, VDA, and STEP

• Native I-deas Master Series- Model files

- Library Access

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A complete set of tools for creating finite element models...

Powerful modeling technologyPowerful modeling technology

• Master Model used directly for

simulation- feature suppression

- partitioning

- mid-surface extraction

• Comprehensive meshing tools- free, mapped, manual methods

- associative with design geometry

• Boundary conditions can be

applied directly to geometry

• Material data system

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Design Geometry Abstraction

• Acknowledges CAD Geometry is Almost Never Perfect

- Small edges & surfaces- Poor surface parameterization- Odd surface shapes

• Users Need More Controlfor Better Quality

- Improved interaction- Edge proximity

• Meshing Improvements- Parity - Smoother

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Abstraction of GeometryAbstraction of Geometry

• Section meshing- logical meshing areas, gathering of surfaces- interactive construction and modification- captures analysis intent

• Topological features- curve and surface tangency recognition- edge adjacency or gap distance - removal of internal surface trim holes

• Feature suppression- dependent upon constructors technique- not available with imported geometry

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Typical Design GeometryTypical Design Geometry

• Topology Issues- small edges

- compound edges

- sliver surfaces

- high aspect ratio

- missing surfaces

- topology too detailed

- reconstruction

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Meshing issues

• Topology Suppression

• History Supported

• Automatic / Manual Modes

• Loop Collapsed to Point

• Curve Collapsed to Point

• Ignores Small Edges

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Creation OptionsCreation Options

•

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Augmentation of GeometryAugmentation of Geometry

• Geometric information; physical representation- Additional structure.- Calculation surface to measure energy propagation.- Contact regions, FEM or geometry based.- Weld attachments, reference series of locations

• Non-geometric information; non-physical

representation- interpolated surfaces.- lumped masses, springs, or beams.- gaps, coupled dofs, or constraint equations.

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Adaptation of the FEMAdaptation of the FEM

• Associative to design definition- geometry change - abstraction change - boundary conditions- loading conditions- surface mapping

• Surface mapping/compare parts.- domestic or imported

• Parameter studies- explore influence of a design feature- explore influence of fem properties/materials

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Management of FE Models.Management of FE Models.

• Each Design can have multiple FE models.- dependent upon the analysis requirements

• Each FE model can have multiple solutions.- Loadcases or configurations- mechanical, thermal, dynamic or process

• Attachment to a Design can be maintained or released.

- reference or spawn a copy of the design data

• A FEM can also reference a system’s hierarchy.- assemble multiple FEMs- append models as an option

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Complete Element LibraryComplete Element Library

• Over 87 different kinds of elements can be

created

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Beam ElementBeam Element

• The most extensive beam element support

in industry for over 20 years

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Beam ElementBeam Element

• Beam elements are the simplest elements geometrically

• Most complex to formulate for 3D behavior

• - eccentricity

• - shear area

• - warping restraint factor

• - stress recovery

• - AISC, ANSI, piping code checking

• - standard shape library

• - general shape properties via mesh discretization

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Physical Properties User InterfacePhysical Properties User Interface

• User Interface - Fully forms based- Display of all properties on one form

for create/edit- Ability to display/group associated

elements- Active units displayed for property

values- Multiple selection of tables- Graphical selection of coordinate

systems and nodes

• Solver Support- Update analysis program mask menu- Use native nomenclature for 3rd Party

properties- Generic physical properties

capabilities for external use

Phys. Prop. UI for Model Solutionabove and MSC.Nastran below

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Composite Shell ElementsComposite Shell Elements

Laminate definition

- support convenient layup

- repeat

- symmetric

- anti-symmetric

- groups of plies can be

replicated

45°

90°

0°

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Composite Shell ElementComposite Shell Element

Material orientations almost never matches element CS- stationary curve tangent- dynamic curve tangent- s,t surface directions,

Curve rotated aboutaxis of dome

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Communication of FindingsCommunication of Findings

• The analyst must effectively communicate investigative findings in a language and a forum that will affect robustness of the design in a timely manner.

• Formats- Beam Sections- Report- VRML- Picture files- XY, XYZ- Contours- Animations- Cross Section

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Thickness on Midsurfaced shell modelThickness on Midsurfaced shell model

• New Midsurface extraction

• Thickness of elements are retained from midsurface

operation

• Plot of thickness on midsurfaced model can be verified

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Process Efficiencies.Process Efficiencies.

• The analyst must apply various disciplines in order

to fully investigate the robustness of the

developing design.

• Solutions- linear and nonlinear deflections- free and forced vibration- electronic system cooling- transmission and emission of noise- steady state linear or nonlinear thermal - static and dynamic stress evaluation- durability, strength and life evaluation

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FEM from AssemblyFEM from Assembly

• Flexible mapping of FEMs to System Instances.

- Direct access to orientation data - Flexible mapping of FEM to instance(s) - Node and element label control - Supports updates

• instance hierarchy • configuration • FEM

- Automatic creation of groups for each FEM

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Augmentation of GeometryAugmentation of Geometry

• Other elements (Geometry based as well)- Rigid

• Weld attachments, reference series of locations- Lumped masses, Springs

• Gaps, Coupled dofs, or Constraint equations

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Assembly FEM from RenaultAssembly FEM from Renault

• Four parts

• 48 Spot

welds defined

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Auto generate connections at spot weldsAuto generate connections at spot welds

Using point data in separate part•Associative connection betweena section entity (boundary or inside)

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Solution DepthSolution Depth

• I-deas Master Series- h or p element formulations

- non-linear directly from the linear model

- structural dynamics response/random

- experimental data analysis

• Bi-directional- ABAQUS, ANSYS, NASTRAN

- Moldflow

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Model Solution EnhancementsModel Solution Enhancements

• New Version of Sparse Matrix Solver- 10% to 20% reduction in run time for models which require no memory paging- 2x-3x reduction in run time for models which require memory paging

• New Version of Iterative Solver- Max DOF = 10 million (parabolic tetrahedral)- 2x-3x reduction in solve time (in memory)

• Modal Damping Calculations

• Strain Energy Table

• Miscellaneous Solver Performance Enhancements

- 2x improvement in “Physical Properties and Offset tables formed” step in solving a geometry based mesh

- 5x improvement in the “Materials Tables Formed” step in solving a geometry based mesh

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I-DEAS Response AnalysisI-DEAS Response Analysis

• Packaging & Positioning- New task in Simulation Application based

on extraction of “Dynamics” part of MS7 Durability & Dynamics

- Pre-req’s include Simulation Modeling Set or MasterFEM

- Add-on potential for existing I-DEAS users with NASTRAN

• New & Enhanced Functionality- New - Random Vibration- New - Shock Response- New - Distributed Loads- Steady-State Analysis Enhancements- Transient Analysis Enhancements- Drop Test Simulation

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Response SpectrumResponse Spectrum

• Standard modal response

combinations supported

including - ABS- SRSS- CQC- NRL- NRC

• These techniques support a

wide range of industries

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Understanding Design Variation using I-DEAS Variational AnalysisUnderstanding Design Variation using I-DEAS Variational Analysis

Variational Geometry

Variational FE Mesh

Variational Result

Criteria = F(Design Variables)

Example:Stress =

F(width,height)

Same result as “constant”

analysis

Design Variable Sensitivity

Design Curves+ +

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Variational AnalysisVariational Analysis

• New Mechanical Simulation Solver- Automatically solves FE model over entire range of design

variable variation -> produces design handbook results

• Design Variables can include geometric, material property, or elemental quantities

- Provides a number of possible solutions to a given design problem (not just a single solution)

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Variational AnalysisVariational Analysis

• Integration with Model Solution- Access to Matrix Solver- Same Element Formulations (with some

exceptions)- Consistent User Interface

• New Boundary Condition Type: Linear Statics - Variational

• New Solution Set Form- defines variational analysis type

(Baseline, Sensitivity, Parametric) and parameters

• Solve initiated using Model Solution solve icon

• Post processing sub-panel

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“We were extremely pleased that we were able to come up with a rather unusual design that would not have been possible without the extensive use of design simulation. Using I-DEAS Master Series™, we even managed to reduce the weight of the component by 18%.”

Thomas KunzeSenior Design Engineer/Analyst

Lucas Varity - Heavy Vehicle Braking SystemsLucas Varity - Heavy Vehicle Braking Systems

• Situation- Supplies brake systems for all but

one of Europe’s truck manufacturers- Needed to quickly design and

evaluate new disk brake system for a new range of trucks

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“We were extremely pleased that we were able to come up with a rather unusual design that would not have been possible without the extensive use of design simulation. Using I-DEAS Master Series™, we even managed to reduce the weight of the component by 18%.”

Thomas KunzeSenior Design Engineer/Analyst

Lucas Varity - Heavy Vehicle Braking SystemsLucas Varity - Heavy Vehicle Braking Systems

• Situation

• Goals- Leverage geometry created by

manufacturer- Increase evaluation accuracy

• Demanded by critical safety factors

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“We were extremely pleased that we were able to come up with a rather unusual design that would not have been possible without the extensive use of design simulation. Using I-DEAS Master Series™, we even managed to reduce the weight of the component by 18%.”

Thomas KunzeSenior Design Engineer/Analyst

Lucas Varity - Heavy Vehicle Braking SystemsLucas Varity - Heavy Vehicle Braking Systems

• Situation

• Goals

• Results- 50% lower stress & 18% lower weight

in the redesigned carrier- Not a single carrier failed prematurely

in prototype testing

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“Integrated CAD/CAM/CAE technology lets us provide all services our customers require.It gives us a better way of doing business.”

Industrial Packaging SystemsIndustrial Packaging Systems

• Situation- Provides custom containers used by

auto makers to ship parts

Dave Wahl,President

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“Integrated CAD/CAM/CAE technology lets us provide all services our customers require.It gives us a better way of doing business.”

Industrial Packaging SystemsIndustrial Packaging Systems

• Situation

• Goals- Quickly build and evaluate complex

assembly models.- Bring analysis up-front in the design

process- Use advanced engineering technology

to differentiate the company

Dave Wahl,President

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“Integrated CAD/CAM/CAE technology lets us provide all services our customers require.It gives us a better way of doing business.”

Industrial Packaging SystemsIndustrial Packaging Systems

• Situation

• Goals

• Results- Reduced evaluation cycle time by

40%- Decreased packaging system costs

anywhere from 10% to 200%

Dave Wahl,President

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“The particular challenge on this project was managing the thermal and stress aspects of an extremely dense electronic product weighing more than 50 lbs. SDRC I-DEAS® software enabled us to meet the exacting specification and get to first prototype within a demanding deadline of nine months.”

Geoff Hardman, Engineering Team Leader, BASE

British AerospaceBritish Aerospace

• Situation- Established supplier of high-tech

aerospace and defense engineering to the Aerospace/ Defense market

- Design the power supply for a new system to protect aircraft from the latest generation of infrared missiles

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“The particular challenge on this project was managing the thermal and stress aspects of an extremely dense electronic product weighing more than 50 lbs. SDRC I-DEAS® software enabled us to meet the exacting specification and get to first prototype within a demanding deadline of nine months.”

Geoff Hardman, Engineering Team Leader, BASE

British AerospaceBritish Aerospace

• Situation

• Goals- Easily evaluate thermal and structural

performance of new power supply- Reduce/eliminate iterative stages of

physical prototyping

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“The particular challenge on this project was managing the thermal and stress aspects of an extremely dense electronic product weighing more than 50 lbs. SDRC I-DEAS® software enabled us to meet the exacting specification and get to first prototype within a demanding deadline of nine months.”

Geoff Hardman, Engineering Team Leader, BASE

British AerospaceBritish Aerospace

• Situation

• Goals

• Results- Thermal & Structural evaluations

completed 40% earlier in development- From concept to working prototype took

only nine months, a 50% savings in time

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“While it’s still early in our implementation, I-DEAS software has already helped us reduce the weight of a brake pedal by 26%. We can now generalize the integrated development and analysis methodology we used on this component to a whole calls of brake pedals.”

Michel Dittlo, Design Systems Manager

SollacSollac

• Situation- Consulting firm that assists automotive

companies in developing new steel components.

- Design a new brake pedal for large Automotive supplier.

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“While it’s still early in our implementation, I-DEAS software has already helped us reduce the weight of a brake pedal by 26%. We can now generalize the integrated development and analysis methodology we used on this component to a whole calls of brake pedals.”

Michel Dittlo, Design Systems Manager

SollacSollac

• Situation• Goals

- Meet the safety and performance requirements and a weight target set by a competitive plastic part.

- Base the new brake pedal on past designs.

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“While it’s still early in our implementation, I-DEAS software has already helped us reduce the weight of a brake pedal by 26%. We can now generalize the integrated development and analysis methodology we used on this component to a whole calls of brake pedals.”

Michel Dittlo, Design Systems Manager

SollacSollac

• Situation• Goals• Results

- Weight reduced by 26%, while maintaining the required stiffness and durability.

- Reduced the time to evaluate and arrive at the final design by 90%.