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CAE Overview

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Technology Leadership
1967 Company Founded
1st Modal Analysis Package
1970 1st Graphical FE Package
1st NURBS Solid Modeler
1980 Automatic Mesh Generation
1st Commercial Enterprise Data Management System
1985 Architecture for Hardware Independence
Relational Engineering Database
1990 Adaptive Analysis / Optimization
Variational Design
1993 I-DEAS Master Series Introduced
Dynamic Navigator™
1994 Concurrent Associativity™
Non-Manifold Topology
Generative Machining
1995 Metaphase Series Introduced
Variational Equations
Advanced Surfacing
1997 Product of the Year 1996
Design News Magazine, Mar 1998 Hybrid Modeling
VGX™
1997 Metaphase Enterprise
Solution Series
Imageware Surfacer 1998 Imageware Acquired
Top Award 1st Variational Analysis
EuroMold ‘98, Dec 1998
1999 Capability

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Product Development Process
• Time to Market controlled by Product Development
Process Part &
Design Product Detailing
Manufacturing
Evaluation Tools & Plans
/

Production
Product
Design

Product Performance
Concept Certification

Customer Product Recycling


Requirement

Design Evaluation Manufacturing

Total process time is the only TTM metric


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Product Evaluation Process
“Virtual” Computer Simulation Low Cost
“Low” Fidelity
Easy to Explore/Re-use
Model Creation

Solution

Analyze Results

Physical Test & Measurement High Cost


“High” Fidelity
Prototype Difficult to Explore/Re-use
Construction

Data Acquisition

Analyze Results

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Analysis Process & Tools
Design Geometry

IF Foreign CAD CAD Data


Translator Finite Element
Geometry

IF Integrated CAD Pre-


Processor

FE Data IF External Solver

Finite Element Translator


Results

[ ] x1 x2 x3
y1 y2 y3
z1 z2 z3
Solver

Post-
IF Integrated Solver
Visualized
Result

Processor

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Objective 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 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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Powerful modeling technology
A complete set of tools for creating finite element models...

• 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 Control
for Better Quality
- Improved interaction
- Edge proximity
• Meshing Improvements
- Parity
- Smoother

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Abstraction 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 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 Options

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Augmentation 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 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.

• 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 Library

• Over 87 different kinds of elements can be


created

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Beam Element
• The most extensive beam element support
in industry for over 20 years

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Beam 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 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 Phys. Prop. UI for Model Solution
above and MSC.Nastran below
- 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
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capabilities for external use
Composite Shell Elements

Laminate definition
- support convenient layup
- repeat 45°
- symmetric
- anti-symmetric
90°
- groups of plies can be
replicated

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Composite Shell Element

Curve rotated about


axis of dome

Material orientations almost never matches element CS


- stationary curve tangent
- dynamic curve tangent
- s,t surface directions,

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Communication 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 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.

• 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 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 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 Renault

• Four parts
• 48 Spot
welds defined

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Auto generate connections at spot welds

Using point data in separate part


•Associative connection between
a section entity (boundary or inside)

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Solution 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 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 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 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 Analysis
Variational Variational FE Variational Result
Geometry Mesh
Criteria = F(Design
Variables)

Example:
Stress =
F(width,height)

Same result as Design Variable


“constant” + + Design Curves
Sensitivity
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analysis
Variational 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 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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Lucas 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

“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 Kunze
Senior Design Engineer/Analyst
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Lucas Varity - Heavy Vehicle
Braking Systems
• Situation
• Goals
- Leverage geometry created by
manufacturer
- Increase evaluation accuracy
• Demanded by critical safety
factors

“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 Kunze
Senior Design Engineer/Analyst
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Lucas 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
“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 Kunze
Senior Design Engineer/Analyst
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Industrial Packaging Systems

• Situation
- Provides custom containers used by
auto makers to ship parts

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

Dave Wahl,
President
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Industrial 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

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

Dave Wahl,
President
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Industrial Packaging Systems

• Situation
• Goals
• Results
- Reduced evaluation cycle time by
40%
- Decreased packaging system costs
anywhere from 10% to 200%

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

Dave Wahl,
President
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British 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

“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
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British Aerospace
• Situation
• Goals
- Easily evaluate thermal and structural
performance of new power supply
- Reduce/eliminate iterative stages of
physical prototyping

“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
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British 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
“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
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Sollac
• Situation
- Consulting firm that assists automotive
companies in developing new steel
components.
- Design a new brake pedal for large
Automotive supplier.

“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
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Sollac

• 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. “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
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Sollac
• 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%.

“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
Get There Faster™

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