Industry Collaborates on ISO standard

for integrating CAD, CAE, and PDM

Mike Stiteler, ATIKeith Hunten, P.E., Lockheed Martin Aeronautics

Overview

Mike Stiteler, ATISTEP and PDES, Inc.

Keith Hunten, P.E., Lockheed Martin AeronauticsEnterprise Integration with ISO 10303-209AP209 – Concepts and OverviewEngineering Analysis Pilot AP209 Validation EffortsConclusions

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An international standard (ISO 10303) for exchanging data between different systems (CAD, CAM, CAE, and PDM)

A computer interpretable definition of the physical and functional characteristics of a product throughout its life cycle

A proven way to ensure fast, reliable data exchange between partners and suppliers using different systems

What is STEP?

conceptdesign

fabricateassemble

test

supportdeliver

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What is PDES, Inc.?Mission: To be the world leader in accelerating the development,implementation, and use of STEP and related product data standards to deliver extraordinary business value to member organizations

Elements of the PDES, Inc. Long Term Vision:1. Modular STEP capability is being used easily by industry2. STEP-driven design and manufacturing are widespread3. STEP System Engineering capabilities are demonstrated in

development of complex systems4. STEP is proven as a mechanism for supporting Long Term Data

Retention5. Web-based STEP implementations are commonplace6. Significant cost reductions and shortened development times are

occurring7. STEP is widely accepted and PDES, Inc. membership remains

robust with effective collaboration around the world8. Entire supply chains are integrated through STEP

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PDES, Inc. Members Represent Many Industries

AerospaceAutomotiveElectronicsShipbuildingSoftware

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ATIATIHOST HOST CONTRACTORCONTRACTOR

BOEINGBOEING

LOCKHEEDLOCKHEEDMARTINMARTIN

IBMIBM

NISTNIST

NORTHROP NORTHROP GRUMMANGRUMMAN

ELECTRIC ELECTRIC BOATBOAT

UTC/P&WUTC/P&W

RAYTHEONRAYTHEON

GENERALGENERALMOTORSMOTORS

PTCPTC

ROCKWELL COLLINSROCKWELL COLLINS

NASANASA

U.S. U.S. ARMYARMY

PDES, Inc. MembersPDES, Inc. Members

http://pdesinc.aticorp.org/http://pdesinc.aticorp.org/

UKUK

BAE SYSTEMSBAE SYSTEMS

THEOREMTHEOREMSOLUTIONSSOLUTIONS

GEORGIAGEORGIATECHTECH

Copyright PDES, Inc. 2002PDES, Inc.®

FranceFrance

AIRBUSAIRBUS

EPMEPM

NorwayNorway

GermanyGermany

LKSOFTLKSOFT

U.S. DEPT. OFU.S. DEPT. OFENERGY/NNSAENERGY/NNSA

NARANARA

STEP use in Industry

STEP is being used in production for streamlined data exchange with suppliers

STEP adopted for all F-16 Military Fighter Aircraft production re-bid activitiesRecent major re-bid of F-16 machined parts:

Involved about 2300 part numbers and 50 potential suppliersSTEP provided 95% reduction in printing and reproduction costs and 52% reduction in labor by the prime contractor, not including similar savings by the suppliers

Lockheed Martin plans to implement STEP across all new aircraft programs which use CAD (F-22, F-2, T-50, JSF, etc.) and at all sites in the consolidated Lockheed Martin Aeronautics Company

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STEP is currently in production use for the exchange of solid model design data with many external customers including:

Allied Signal CaterpillarAtlas Casting U.S. Department of DefenseAvondale Industries Lunn IndustriesBath Iron Works (BIW) U.S. Navy LabsBF Goodrich Newport News ShipbuildingBoeing Northrop Grumman

Electric Boat uses STEP as their data exchange method of choice

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Boeing routinely uses STEP in every division of the companyCommercial AirplanesIntegrated Defense SystemsPhantom Works

“Use of STEP for production activities is so commonplace that wedon’t track it anymore.”

Dr. King YeeSenior Technical FellowThe Boeing Corporation

STEP is being used in production at Boeing today

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STEP comprises over 25% of IBM's globale-procurement design data exchange

Overview

Mike Stiteler, ATISTEP and PDES, Inc.

Keith Hunten, P.E., Lockheed Martin AeronauticsEnterprise Integration with ISO 10303-209AP209 – Concepts and OverviewEngineering Analysis Pilot AP209 Validation EffortsConclusions

PDM

CAD CAE

AP209

Enterprise Design and Analysis Information Integration with ISO 10303-209

Enables sharing of PDM controlled composite andmetallic design, analysis,material properties/specs information

Enables automated, electronic feedback of product shape, performance, and property analyses to CAD with respect to PDM product structure and versioningPlatform to extend engineering analysis STEP coverage into other analysis disciplines such as Fluid DynamicsProvides a long term, potentially growing, repository crucial to many industries and vendors

Neutral format for PDM/CAD/CAE

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Configuration Control, Approvals• Part, product definitions

• Finite element analysis model, controls, and results

Configuration Control, Approvals• Part, product definitions

• Finite element analysis model, controls, and results

Analysis Discipline Product Definitions

• Finite Element Analysis–Model (Nodes, Elements, Properties,...)–Controls (Loads, Boundary Constraints,...)

–Results (Displacements, Stresses,...)

• Analysis Report

Analysis Discipline Product Definitions

• Finite Element Analysis–Model (Nodes, Elements, Properties,...)–Controls (Loads, Boundary Constraints,...)

–Results (Displacements, Stresses,...)

• Analysis Report

Design Discipline Product Definition• Shape Representations

• Assemblies

Design Discipline Product Definition• Shape Representations

• Assemblies

Information Shared Between Analysis & Design

• 3D Shape Representations

• Composite Constituents

• Material Specifications & Properties

• Part Definitions

Information Shared Between Analysis & Design

• 3D Shape Representations

• Composite Constituents

• Material Specifications & Properties

• Part Definitions

Composite Constituents• Ply Boundaries, Surfaces

• Laminate Stacking Tables

• Reinforcement Orientation

Composite Constituents• Ply Boundaries, Surfaces

• Laminate Stacking Tables

• Reinforcement Orientation

Material Specifications & Properties

• Composites

• Homogeneous (metallics)

Material Specifications & Properties

• Composites

• Homogeneous (metallics)

3D Shape Representation• AP202/203 Commonality Plus Composite Specific

3D Shapes– Advanced B-Representation– Faceted B-Representation– Manifold Surfaces With Topology– Wireframe & Surface without Topology– Wireframe Geometry with Topology– Composite Constituent Shape Representation

3D Shape Representation• AP202/203 Commonality Plus Composite Specific

3D Shapes– Advanced B-Representation– Faceted B-Representation– Manifold Surfaces With Topology– Wireframe & Surface without Topology– Wireframe Geometry with Topology– Composite Constituent Shape Representation

AP209: Composite & Metallic Structural Analysis & Related Design

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STEP 10303 AP209 Components

One can use AP209 with any one or more of these pieces, but the real power lies with the assemblage of all these parts.

AP209 = CAD + CAE + FEM + FEA + PDM2

Nominal CAD Geometry

Idealized CAE “Simulation-Specific”

Geometry

Finite Element Model(s)

Finite Element Analysis

Controls & Results

Product Data Management Info

AP203 = CAD + PDM1

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Standard PDM Design Information Management

Indentured list of assemblies and componentsConfiguration and revision managementAssociated data management

Design shape model(s)Other related design information

Part / Version

Design Documents

Nominal Design Shape File

Next Higher Assembly / Version

Part / Version

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Critical AP209-Based PDM Concepts

Part / Version

Design Documents

Nominal Design Shape File

Idealized Analysis Shape File

Analysis Shape (FEM) and

Report File(s)

Analysis / Version

Analysis Design Version

RelationshipAnalysis

Documents

Next Higher Assembly / Version

Allow Analysis to Revise Independently of Related Design

Part / Version

Separate, Versioned Analysis

Three Classes of Shape

Same as AP203/214 Geometry

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AP209 Shares Shape and FE Model/Analysis InformationQuarter symmetry model of a drag racing supercharger rotorIdealized shape representation of a unit slice of the rotor profileLinear static structural analysis of steady state spinning loads

PDES, Inc. Engineering Analysis Pilot

Accelerating AP209 Deployment

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PDES, Inc. Engineering Analysis TeamObjectives

Accelerate the deployment of STEP support for EA applications in member companiesValidate AP209 capabilities in an industry setting

Extensive multi-company exchanges have been completed

Demonstrate the extended coverage of enterprise PDM exchanges that AP209 providesEstablish a pilot framework for extending STEP capabilities in EA leading to the CAx-IF testing forum

Initial CAx-IF testing underway

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UsersBoeingGD/Electric BoatLockheed MartinEADS/AirbusNAFEMS

Vendors/DevelopersMSC.SoftwareTheorem SolutionsOpenCASCADESoftInWay

SupportersNASANIST

PDES, Inc. Engineering Analysis TeamParticipants

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Extensive Multi-Company Exchanges have been Completed

PAS-C, TACOM, and PDES, Inc. demos 1995 -200412 Abstract Test Suite (ATS) files that cover minimum capabilitiesBig production files at GD/EB and LM AeroCATIA V4 test files ARA/NASA AP209-based NextGRADE large multi-model management system

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AP209 Exchange Capability

Web-BasedMSC/STEPviewer

PDM-AXS

PDMread/write

FEA + Geom. + PDM

FEA + Geom.

MSC / PATRAN

FEA

EB / COMMANDS

AP209STEP File

CADverter CATIA V4CATIA V5i developed by Dassault/MSC

FEA + Geom.

FEA

Testing Outside Systems:

ARA/NASA’s NextGRADE GUI- OpenCascade Netscape AP209 plug-in

Geometry + PDM

CAx-IF TestingPart 21 <-> Part 28

12/03/2002 Laurent Savary Page 1

CADLINK projects & perspectives

AP209

AP203Geometry

Material Profile

& SP

CADDS 5 PATRAN

CATIA V5

Future Future CADLINK with CADLINK with CATIA V5CATIA V5

Long term archiving

Other tools

CADLINK AP209 CADLINK AP209 studystudy

CADLINK DATA

Actual Actual CADLINKCADLINK

AIRBUS AP209 Integration

Aircraft Sections Database

SoftInWay File Checker

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AP209 Testing Example

AP209STEP File

MSC.Patran

Pro/E

EB / COMMANDS

CAx-IF Testing

CATIA V4 Theorem /CADverter

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Frequency & Mode Shape Analysisin CATIA using GPD

Outer surfaces used for thin-walled shell model

Original Box Model (Solid Brep) in CATIA V4

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AP209 File Imported into GD/EB’s COMMANDS

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Re-Analysis of Model in GD/EB’s COMMANDS/FESOL Matches Well

AP209 File Imported into EB’s COMMANDS and Create Data Base [30 Seconds]

Execute FESOL (Lanczos EigenvalueExtraction) from within COMMANDS [2 minutes and 30 seconds]

No changes to model as imported.

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Same AP209 File Imported into MSC.Patran

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Conclusion: Comparisons show a geometrically complex model can be shared in an AP209 Standardized manner and still match analyses extremely well

Re-Analysis of Model in MSC.NastranMatches CATIA and FESOL Well

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The Cax-IF is a testing forum where STEP implementors can confidentially test and share implementation information

AP209 Interoperability Testing Expanded to CAx-IF (PDES. Inc./Pro-STEP Testing Forum)

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Engineering Analysis AP209 Paper Given at NAFEMS World Congress

Presented byE.L. Stanton, T.E. Mack, H.D. Patel & J.W.

KlintworthMSC.Software, Santa Ana, CA

Conclusions and RecommendationsISO STEP AP 209 can capture the data and metadata

for composite beam structures at each stage of the design-build process. It is the only standard that linksCAD/CAE and PLM data for composite structures.

AP 209 is highly recommended for composite data and metadata exchange by design-build teams. It reduces risk.

Best practices for using AP 209 in Ply-Zone-Propertyiterations should be followed. Iterative composite designshould not recover individual ply data every iteration.

Conclusions and RecommendationsISO STEP AP 209 can capture the data and metadata

for composite beam structures at each stage of the design-build process. It is the only standard that linksCAD/CAE and PLM data for composite structures.

AP 209 is highly recommended for composite data and metadata exchange by design-build teams. It reduces risk.

Best practices for using AP 209 in Ply-Zone-Propertyiterations should be followed. Iterative composite designshould not recover individual ply data every iteration.

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ConclusionISO 10303-209:2001 is now the International Standard for CAD/CAE/PDM Integration

Extensive testing has proved functionality and capability

Two commercial ISO 10303-209 implementations are in Production

MSC.Patran and Theorem Solutions’ CATIA V4 translator commercially availableSeveral internal implementations now in place

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AP209 Backup Slides

NAFEMS Test Problem DocumentationPiloted in AP209 Format

Many NAFEMS Linear Static and Dynamic Test Problems piloted in AP209 format

Test Problems are used to documentknown solutionsAP209 files include:

• Geometry• FEM• Exact solution• FEM solution(s)

NAFEMS Benchmark Article – Oct. 2001by David LealOpen systems for Engineering Analysis - made possible by a standard

STEP for Electronics in use atRockwell Collins

STEP is playing a significant role in the design and manufacture of electronic circuit assemblies, interconnects, and packaging at Rockwell Collins

APs 203 and 210 being used for Simulation for flexible manufacturingComputer integrated manufacturingIntegration of electrical/mechanical designCapturing the product definition

STEP supports the implementation of Rockwell Collins’ enterpriseintegration strategy

Rockwell Collins led the development of AP210 along with other key contributors Boeing, Georgia Tech, LKSoft, NASA, NIST, Northrop Grumman, and the U.S. Army

STEP Production Deployment Reduces Costs for Raytheon Missile Systems

STEP Technical Data Package (TDP) delivery is currently deployed in production on Exoatmospheric Kill Vehicle (EKV) program, a component of the National Missile Defense system

Raytheon pilot (STAMP Program) demonstrated significant labor and cycle reduction for preparation and delivery of TDPs to its suppliers using STEP

50% - 88% labor, 59% cycle time savings at Raytheon42% labor, 95% cycle time savings at suppliers

Raytheon Missile Systems plans to deploy STEP TDP delivery on all programs and is actively participating in a pilot to enable STEPPDM data import from suppliers

Raytheon pilot (STAMP Program) demonstrated significant labor and cycle reduction for preparation and delivery of TDPs to its suppliers using STEP

Reduced Raytheon Labor 49% - 90% and Cycle time 96% -99%Reduced Supplier Labor 42% and Cycle time 95%

STEP Technical Data Package (TDP) delivery is being deployed in production across Raytheon Missile Systems supply chain

STEP Production Deployment Reduces Costs for Raytheon Missile Systems

Year # Suppliers

Annual Cost per supplier

Cost/Year All

Suppliers 80% PaybackAnnual

Cost 80% Payback ROI1 109 $20,000 $2,180,000 $1,393,280 $600,000 $26,210,400 102 $3,000 $327,000 $1,393,280 $30,000 $26,210,400 773 $3,000 $327,000 $1,393,280 $30,000 $26,210,400 774 $3,000 $327,000 $1,393,280 $30,000 $26,210,400 775 $3,000 $327,000 $1,393,280 $30,000 $26,210,400 77

Totals $3,488,000 $6,966,400 $720,000 $131,052,000 33

RAYTHEONSUPPLIERS

STEP PDM Standards Save MONEY!STEP PDM Standards Save MONEY!

Suppliers Save Money!

Prime Saves Money!

Currently exchanging geometry data via STEP for the A380 commercial aircraft between Engine Alliance and AIRBUS

On the Joint Strike Fighter military program Pratt & Whitney is effectively using STEP to communicate geometric engine interface data with program partners (Lockheed Martin, Boeing, and Rolls-Royce)

Pratt & Whitney is “STEP-ready” and recommends and encourages the use of STEP for communication of design information with customers

Pratt & Whitney is using STEP inaircraft engine production with Boeing

Eurofighter Typhoon is a four nation military program Eurofighter Typhoon is a four nation military program implementing STEP for Product Data Management (PDM)implementing STEP for Product Data Management (PDM)Partners include BAE Systems, Alenia (Italy), and Partners include BAE Systems, Alenia (Italy), and EADSEADS——European Aeronautic, Defense, and Space European Aeronautic, Defense, and Space (consisting of CASA from Spain and Daimler Chrysler (consisting of CASA from Spain and Daimler Chrysler Aerospace from Germany) Aerospace from Germany) AIRBUS industry partners are currently developing STEP AIRBUS industry partners are currently developing STEP capability for CAD and PDM data exchange on the A3XX capability for CAD and PDM data exchange on the A3XX commercial aircraft programcommercial aircraft program

Currently implementing STEP on the Eurofighter Typhoon Project

Currently NASA is exchanging CAD models using STEP between SDRC Ideas, PTC ProEngineer, PTC ComputerVision, Solidworks, and AutoCAD

Planned uses of STEP include PDM, electronics design, thermal analysis, systems engineering, structural analysis, and machining

NASA’s long term vision is to develop a STEP infrastructure of services supporting end-to-end, interdisciplinary data integration and data reuse

The U.S. National Aeronautics and Space Administration (NASA) has adopted STEP for data exchange

VISION for 2008

• STEP-driven design and manufacturing widespread

• Entire supply chains integrated with STEP

• Significant reductions in cost, development time

• STEP a proven mechanism for Long Term Data Retention

• Demonstrate next generation STEP data exchange (AP203 E2, AP209, AP210, AP214, AP232, and others)

• Validate STEP use for Long Term Data Retention

• Deploy Systems Engineering modules for industry use

DEPLOYMENT• Pilot Projects• Production Use by Members,

e.g.,CSTAR / C-17 aircraftEurofighter Typhoon aircraftPrinted circuit assembliesA380 aircraftEKV missile system

• Support STEP pilot projects and prototype implementations

• Continue CAx-IF interoperability testing and validate modules (AP203 E2-GD&T, AP209, AP233, and others)

• Maintain deployed APs and modules

SUPPORT• Pilot Projects• Vendor Product Development• Testing

• STEP widely accepted and PDES, Inc. membership robust

• Recruit and nurture PDES, Inc. members from the larger community

• Provide public demonstrations of STEP technology

• Publicize interoperability testing results • Disseminate STEP technologies through

demonstrations, freely available tools

OUTREACH• STEP Education and Training• STEP Promotion

PLANS for 2004-2006Roadmap to Achieve the PDES, Inc. VisionRoadmap to Achieve the PDES, Inc. Vision (abridged)(abridged)PDES, Inc.®

LEGEND: AP203-Geometrical Design, AP209-Engineering Analysis, AP210-Printed Circuit Assemblies, AP214-AutomotiveMechanical Design Processes, AP232-Technical Data Packages, AP233-Systems Engineering

• Develop standardized data models and modular architecture

• Continue integrating STEP with mainstream modeling technologies

• Modular STEP used easily• Web-based STEP

implementations common• STEP Systems Engineering

demo’d in complex systems

DEVELOPMENT• STEP Foundations• STEP Applications• Technical Solutions• Modularization

ACCOMPLISHMENTS through 2004

PDES, Inc.®