View
1.490
Download
10
Tags:
Embed Size (px)
DESCRIPTION
This was a 2012 Americas HTC Crashworthiness training presentation. This presentation focuses on the use of HyperWorks tools for Automotive Crash applications. It will also discuss the interface of TeamCenter-HyperMesh integration for batchmeshing and setting up the model in HyperCrash for Analysis.
Citation preview
Innovation Intelligence®
HTC 2012 : Crashworthiness Training
Shan Bala
Program Manager
May 15, 2012
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Agenda
1. TeamCenter-HyperMesh Integration for Assembly – Shan Bala
2. Forming Results Initialization – Subir Roy
3. Multidomain in Radioss – Jean-Pierre Bobineau
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
TeamCenter-HyperMesh Integration Overview
Part#:
YT29-89112081-9901002
3
SIEMENS
TEAMCENTER
Teamcenter Side
HyperWorks Side
Import PLMXML
Batchmesh
Assemble
Connections
Export HM/decks
Export PLMXML
PLM XML EXPORT
PLM XML EXPORT
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
Solution Elements
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
En
vir
on
men
t P
rocess
Co
nfi
gu
rati
on
PLMXML
Import
Teamcenter
PLMXML
Transfer Mode
PLMXML
File
Working
Directory HYPERMESH
CAD
Translation
PLMXML
Export
Post
Operations
HYPERMESH
Mapping Table
Teamcenter
Data Model
PLMXML
Export HM
HM
Scri
pt
TC
PLMXML
Import
TC
HM
Solution Elements
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
Configuration
- The target is to use only one PLMXML
Transfer Mode for all use cases.
- The HYPERMESH Mapping Table is a
configuration file available in the
HYPERMESH directory. This file is common
to all sites and can only be modified by the
administrator.
Process
- The user should be able to start manually
each process independently either from
Teamcenter or from the working directory.
- The same process is applied for all use
cases.
- The HYPERMESH-PLMXML Import and
HYPERMESH-CAD Translation processes
may be considered as one unique process
Environment
- The Working Directory is the temporary
location where Teamcenter and
HYPERMESH are exchanging the files.
- The PLMXML File exported by Teamcenter
is overwritten by HYPERMESH at the
HYPERMESH-PLMXML Export process after
a copy of the original file has been created.
Solution Elements - Details
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
En
vir
on
men
t P
rocess
Co
nfi
gu
rati
on
PLMXML
Import
Teamcenter
PLMXML
Transfer Mode
PLMXML
File
Working
Directory HYPERMESH
CAD
Translation
PLMXML
Export
Post
Operations
HYPERMESH
Mapping Table
Teamcenter
Data Model
PLMXML
Export HM
HM
HM
Scri
pt
TC
PLMXML
Import
TC
Solution Elements Teamcenter – PLMXML Export
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
En
vir
on
men
t P
rocess
Co
nfi
gu
rati
on
PLMXML
Import
Teamcenter
PLMXML
Transfer Mode
PLMXML
File
Working
Directory HYPERMESH
CAD
Translation
PLMXML
Export
Post
Operations
HYPERMESH
Mapping Table
Teamcenter
Data Model
PLMXML
Export HM
HM
HM
Scri
pt
TC
PLMXML
Import
TC
Solution Elements Teamcenter – PLMXML Export
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
En
vir
on
men
t P
rocess
Co
nfi
gu
rati
on
PLMXML
Import
Teamcenter
PLMXML
Transfer Mode
PLMXML
File
Working
Directory HYPERMESH
CAD
Translation
PLMXML
Export
Post
Operations
HYPERMESH
Mapping Table
Teamcenter
Data Model
PLMXML
Export HM
HM
HM
Scri
pt
TC
PLMXML
Import
TC
Solution Elements HyperMesh – CAD Translation
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
En
vir
on
men
t P
rocess
Co
nfi
gu
rati
on
PLMXML
Import
Teamcenter
PLMXML
Transfer Mode
PLMXML
File
Working
Directory HYPERMESH
CAD
Translation
PLMXML
Export
Post
Operations
HYPERMESH
Mapping Table
Teamcenter
Data Model
PLMXML
Export HM
HM
HM
Scri
pt
TC
PLMXML
Import
TC
Solution Elements HyperMesh – PLMXML Export
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
En
vir
on
men
t P
rocess
Co
nfi
gu
rati
on
PLMXML
Import
Teamcenter
PLMXML
Transfer Mode
PLMXML
File
Working
Directory HYPERMESH
CAD
Translation
PLMXML
Export
Post
Operations
HYPERMESH
Mapping Table
Teamcenter
Data Model
PLMXML
Export HM
HM
HM
Scri
pt
TC
PLMXML
Import
TC
Solution Elements Script – Post Operations
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
En
vir
on
men
t P
rocess
Co
nfi
gu
rati
on
PLMXML
Import
Teamcenter
PLMXML
Transfer Mode
PLMXML
File
Working
Directory HYPERMESH
CAD
Translation
PLMXML
Export
Post
Operations
HYPERMESH
Mapping Table
Teamcenter
Data Model
PLMXML
Export HM
HM
HM
Scri
pt
TC
PLMXML
Import
TC
Solution Elements TeamCenter – PLMXML Import
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
TeamCenter-HyperMesh Integration Overview
Part#:
YT29-89112081-9901002
13
SIEMENS
TEAMCENTER
Teamcenter Side
HyperWorks Side
Import PLMXML
Batchmesh
Assemble
Connections
Export HM/decks
Export PLMXML
PLM XML EXPORT
PLM XML EXPORT
© 2009. Siemens Product Lifecycle Management Software Inc. All rights reserved.
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
TeamCenter-HyperMesh Integration Overview
Part#:
YT29-89112081-9901002
14
SIEMENS
TEAMCENTER
Teamcenter Side
HyperWorks Side
Import PLMXML
Batchmesh
Assemble
Connections
Export HM/decks
Export PLMXML
PLM XML EXPORT
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Product Demo
Demo
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Agenda
1. TeamCenter-HyperMesh Integration for Assembly – Shan Bala
2. Forming Results Initialization – Subir Roy
3. Multidomain in Radioss – Jean-Pierre Bobineau
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Agenda
1. TeamCenter-HyperMesh Integration for Assembly – Shan Bala
2. Forming Results Initialization – Subir Roy
3. Multidomain in Radioss – Jean-Pierre Bobineau
Innovation Intelligence®
Automated Forming Results Initialization for Full Vehicle Crash Models
Subir RoyDirector – Industry SolutionsMay 15, 2012
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Outline
Motivation
Options
Implementation
Validation
Application
Conclusion
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Motivation
1) Enable seamless incorporation of stamping effects into structural CAE to improve accuracy
2) Leverage the effect of work hardening in stamping for possible weight reduction
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Option 1
• Map incremental analysis results
• Use accurate incremental stamping analysis with adaptive mesh followed by mapping of results to structural mesh
• Need stamping experts to define a feasible process which is difficult at the early product feasibility phase
• Time consuming to run large number of parts
• Possibility of error from mapping between somewhat different geometries
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Option 2
• Use inverse analysis directly on structural mesh
• Use One Step stamping analysis on the structural mesh and directly include the stamping results with the structural model
• Addendum effect needs to be approximated with edge boundary condition
• Possible to run large number of parts within a short time
• Accurate enough for crash analysis
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
One Step vs Incremental (Numisheet 2005 part)
Incremental 1-step
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Validation with Test Data (PSA, Altair EHTC 2010)
Test
With stampingTest
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Validation with Test Data (PSA, Altair EHTC 2010)
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
PSA Peugeot Citroën: HyperWorks Improves Development Process
Challenge: Define a new simulation process development that includes accurate component data(thickness, residual strains, etc.)
Solution: • Use HyperForm and RADIOSS in product
development• Evaluate the impact of the manufacturing process onto
the component formability• Seamlessly include forming results into RADIOSS
crash simulations
Business Impact:• Reduce overall development time• Get a better correlation with test results• Improve product quality and process robustness
“We are in the position to predict crash results via simulation much better than in the past. Building on this approach will lead to sustainable time savings and better products for our customers.”
– Fabien Beda, Senior Engineer Crash & Fluid Simulations PSA Peugeot Citroën
Different deformation pattens (Reference, Without and With Blankholder) at 0,008 Sec
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Workflow
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
User Interface
I. GUI Mode
• User remains in the model setup environment (HyperMesh/HyperCrash)• Stamping analysis conducted in background on user’s machine• Results posted for review • Include files created at the final step• Solvers supported: RADIOSS and LSDYNA• Demo
II. Batch Mode
• User provides the structural model and list of parts (from any pre-processor)• Stamping analysis launched in batch mode on a cluster• Include files created at the final step• Solvers supported: RADIOSS and LSDYNA• Demo
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
User Interface (HyperMesh)
Select parts to initialize Review results
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
User Interface (HyperCrash)
Select initialization option Review parts initialized
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Features
1) Material properties interpreted from crash model
2) Addendum effect via edge Blankholder force via following options:a. Optimum FLC: Iteratively optimizes the blank holder force based on FLC to
minimize failure b. Qualitative: Low, Medium, High, Nonec. Optional: Cut off plastic strain to eliminate local hot spots
3) Automatic undercut check parts invalid for stamping
4) Automatic hole filling
5) Run in parallel mode
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Materials Supported
• LSDYNA
• MATL24• MATL33• MATL36• MATL37• MATL39• MATL81• MATL98• MATL122• MATL123• MATL133
RADIOSS
• M2_PLAS_JOHNS_ZERIL• M3_HYDPLA• M4_HYD_JCOOK• M22_DAMA • MLAW23 • M27_PLAS_BRIT • M32_HILL• M36_PLAS_TAB• M43_HILL_TAB• M44_COWPER• M48_ZHAO• M57_BARLAT3
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Case Study 1: Ford Taurus Frontal Crash Model
Plastic strains from forming
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
LSDYNA Frontal Impact Crash Results
Without stamping With stamping
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Case Study 2: Dodge Neon Side Impact Model
Plastic strains from forming
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
RADIOSS Side Impact Crash Results
Without stamping With stamping
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Conclusion
Incorporating stamping data can improve the correlation of structural
CAE models for stiffness and deformation modes
The magnitude of the influence of stamping on structural CAE
depends on the loading path
Standardization of structural CAE processes with stamping data for full
vehicle models is now feasible
Case studies to continue for NVH and Durability
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Results Mapper 11.0
• General purpose mapping tool inside HyperCrash• Map thickness, plastic strain, stresses, fiber orientation• Read forming data from Radioss, Dyna, AutoForm• Write mapped data to Radioss, Dyna, Abaqus input format• Map results between solids, hydro-formed parts• Handle symmetry• Fill holes • Batch process: Save and Replay• Demo
Forming mesh Crash mesh
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Thank you!
HyperForm 1-step solver based stamping results initialization being used successfully at many OEMs and suppliers globally
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Agenda
1. TeamCenter-HyperMesh Integration for Assembly – Shan Bala
2. Forming Results Initialization – Subir Roy
3. Multi-Domain in RADIOSS – Jean-Pierre Bobineau
Innovation Intelligence®
Multi-Domain Approach to Parallel Computations in Structure Dynamics using RADIOSS
Jean-Pierre Bobineau
May 15, 2012
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multi-Domain approach to parallel computations
Facts
Method
The target of the Multi-Domain approach is to reduce the needed CPU time in order to
compute models with very different mesh sizes needing very different computation times.
The goal is to reduce the elapsed time without losing accuracy.
One of the challenges is to compute: cast, extruded and/or plastic parts (e.g. meshed with
Tetra10 solid elements) inside a “classical” full vehicle crash model in order to predict the
rupture mode of these specific detailed parts and their effects at global model scale.
The idea is to replace this global model by physically equivalent sub-domains, separating
parts with different minimal time step. Each sub domain is resolved as a distinct RADIOSS
model using its own time step, the force and momentum transfers between them being
calculated by a separate program handling stability constraints
• Time step discrepancy is a major bottleneck in explicit computations
• The smallest time step affects the performance of the whole model
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multi-Domain approach to parallel computations
Time step = dt_a Time step = dt_b Time step = dt_c
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multi-Domain approach to parallel computations
Synchronization time
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multi-Domain approach to parallel computations
Radioss V10 – multiple starter input file (Classical approach)
• Each domain is built as a separate complete RADIOSS model using its own
complete input files.
• The RADIOSS runs are completely independent and do not communicate
directly with each other. Each one is using its own time step.
• The time step of each domain is arbitrary but to allow the best optimization
gain it should be significantly different from each other.
• All communication, data transfers, time step synchronization, equilibrium and
stability conditions on the domain frontiers are managed by the master program.
The main interest of this strategy is that each model is independent and may be replaced
by another one. This allows a modular approach for modeling, for example testing runs
with equivalent domains with different mesh size (multigrid approach). Reason why this
approach is still useful and is kept in Radioss V11.
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multi-Domain approach to parallel computations
Multi-Domain in
Version 10
Rad2rad
Radioss
engine 1
dt_a
Radioss
starter 1
Radioss
starter 2
Radioss
starter 3
P1_0000.rad P2_0000.rad P3_0000.rad
Radioss
engine 2
dt_b
Radioss
engine 3
dt_c
P1_0000.rst P2_0000.rst P3_0000.rst
input.dat
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multi-Domain approach to parallel computations
Radioss V11 – single starter input file format ( sub-domain approach)
• One drawback of the classical approach is that it implies additional work for
the user to manually build several independent input files.
• Furthermore it can become very long, difficult and a source of errors when the
small domains are extracted from large and complex models like full vehicle.
• The idea of the new approach in Radioss version 11 is to simplify the task of
the user by building sub-domains automatically :
• Only one starter input is now required including the entire model, like a
classical Radioss computation.
• The user only has to specify the parts of the model that he wants to place
in sub-domains.
• The starter automatically extracts the specified domains from the full
model and generates one restart file for each domain.
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multi-Domain approach to parallel computations
Multi-Domain in
Version 11
dt_a dt_b dt_c
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multi-Domain approach to parallel computations
New subdomain approach : definition of the subdomains
The subdomains are specified by parts
/SUBDOMAIN/subdomain_Id
subdomain_title
ID_part1 ID_part2 ... ID_partn
Where:
- ID_part are the Id of the parts that are in the sub-domain
- subdomain_Id is the domain identifier.
- subdomain_title is the sub-domain name
Radioss Engine input file
In Radioss V11 as in V10 an engine input file is required for each domain and in
order to activate the multi-domain coupling these files must contain the following
command line:
/RAD2RAD/ON
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multi-Domain approach to parallel computations
can be used to connect:
– Shell nodes to Shell nodes
– Shell nodes to Solid nodes
– Solid nodes to Solid nodes
– Beam nodes to Beam nodes
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
PSA head impact v. windshield wiper motor
Model
Head impact :
PART1 : 13803 shell elements PART2 : 303648 shell elements
time step : 2.97e-7 sec [4.3%] [95.7%] time step : 8.00e-7 sec
Courtesy of PSA
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
---- MONO-DOMAIN
---- MULTI-DOMAIN
Note: In this case results quality is high also because there is small interaction between the 2 domains
Results quality
Head acceleration vs time
PSA head impact v. windshield wiper motor
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Head impact : scalability performances (elapsed time) :
Time step factor = (dt domain 1) / (dt domain2) = 2.6
Mono-domain = complete model with common time step
Speed UP = elapsed time Mono-domain / elapsed time Multi-domains
Case 1 : using synchronisation with total CPU number allocated to all processes
Case 2 : Case 1 + optimisation of MPI internal process communications (SPMD)
1 CPU 16 CPUs (2 nodes) 32 CPUs (4 nodes) 64 CPus
Monodomain 63500 s 5420 s 3470 s 2790 s
Multidomain case 1 27260 s
2740 s 2100 s
Multidomain case 2
- // -
2584 s 1670 s 1390 s
Speed up case 1 2.33 2.00 1.65
Speed up case 2 2.30 2.09 2.08 2.01
PSA head impact v. windshield wiper motor
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Coarse Mesh in 1.Domain:
Timestep = 5.0e-007 [s]
Refined Mesh in 2,Domain:
Timestep = 1.0e-007 [s]
t = 00.00 ms t = 80.00 ms
NEON Full Frontal with refined subframe
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Application : Neon model
• Result
o The results are the same between the mono domain computed with a time step of 0.1ms
and the computation with sub-domain.
Rigid wall force
Internal
energy
Mono domain : 71700 s
Multi domains : 35100 s
Speedup of ~2
compared to the
Mono-Domain with
same (small) Time step
NEON Full Frontal with refined subframe
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Multi-Domain approach to parallel computations
Conclusions
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Open for questions…
• Jean-Pierre Bobineau
• Phone: (248) 709 09 42
• E-Mail: [email protected]