a tool to simulate the behaviour of brake pipes within catia v5 · pdf filep morelle this...

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Autosim seminar 4 – 5 May. 2006, This document is the property of SAMTECH S.A.

TEA Pipe

A tool to simulate the behaviour of brake pipes

within CATIA V5P. Morelle, Samtech Deutschland GmbH

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Samtech group, who are we ?

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SAMTECH Presentation

Key Activities

� Computer Aided Engineering� Integrated and associative modelling environment SAMCEF Field

and CATIA V5

� Calculation of linear and non-linear structures with metallic or composite materials

� Thermal and thermo-mechanical analyses

� Random vibration and fatigue

� Fracture mechanics and damage tolerance

� Dynamics of rigid or flexible mechanical systems (rotors, wind turbines, machine-tools, transmissions, deployable structures…)

� Impact and explosion simulation

� Multi-physics analyses (vibroacoustic, piezoelectricity…)

� Parametrical analysis, statistical analysis, model updating and multidisciplinary optimisation

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Integrated SW Offer in Automotive Industry

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Integration

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General

L

LC L-LC

x

Analyses-Strategy

SimpleSimulationwith predef.parameters

AutomaticSimulation

(Optimisation)

INTEGRATED in CATIA V5

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Materials

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General

What is needed to perform a simulation with TEA-PIPE:

- midpoint of pipe connectors- Direction vector of connectors(line)

- Manufacturer database withpipe dimensions

- Material database- eventually kinematicfile(name.txt)

-> open TEA-PIPE menuevia icon

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Confidence

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RED = simulated pipe; BLUE = Measured point cloud

3. Meassurement

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What makes TEA Pipe ?

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• CATIA-Kinematics can be taken into accountAll for the simulation of pipes necessary movements of points and faces can be used from CATIA-kinematics.

Connectors, supports, surfaces, …• starr verbunden zu "Moving

Points"• (intern) positioniert in Bezug

auf diese Punkte

Kinematik-Definition (Link mit CATIA DMU Kinematics)

1. Simple Analyses

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1. Simple Analyses

• Manually definition of the pipe with connectors and length, diameter, thickness and material

or

values from database

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1. Simple Analyses

• Input data for pipes with stiffners and spirales

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1. Simple Analyses

• Input data for intermediate support

It’s possible to define up to 3 intermediate supports,

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CLAMPED NOT CLAMPED

1. Simple Analyses

• Intermediate support can be used as rigid (clamped) or “free eye”, the input datas are: point of location, direction vector and distance to contact face, length of the contact face and connection to the kinematics of the intermediate support.

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1. Simple Analyses : deformed positions

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1. Simple Analyses

• Collision with surrounding parts can checked

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2. Simple Analyses - Postprocessing

• Postprocessing with classical CATIA-functions

Deformed geometry

Curvature

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Result Collisions distance to preselected surface(colour mode)

2. Postprocessing

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Result Collisions distance topreselected surface(value mode)

2. Postprocessing

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3: Pipe Optimization

Compute and Retrieve the Optimization Results

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What is hidden behind the transparent tool ?

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Transparent non linear finite element analysis

• TEA Pipe automatically defines the analysis problem :

•Meshing (mesh density is predefined)

•Element type (beams here)

•Boundary conditions - ex : clamped, non clamped support

• The user picks a material and a type in the DB

• Then TEA Pipe starts trying to simulate the mounting of the pipe. Severall scenariiare tested (ex : first I position connector one, then I move connector 2 to the end point, then I turn connector 2 to the right direction). Unstable scenarii are eliminated a stable mounting history defined

• The following positions from the kinematics are then computed (TEA Pipe “moves”from one position to the next one)

• We could do better if the user really defines a “movie” rather than photos. We could even compute with inertia so to check the pipes in a scenario the car is moving in a fast curve for example.

CLAMPED NOT CLAMPED

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Transparent gradient based optimisation

• TEA Pipe automatically defines the optimisation problem :

•Economy of material (find the shortest pipe satisfying the constraints)

•Safest design (find the pipe staying as far as possible of dangerous parts)

• The user defines the design variables (connectors position and/or orientation, pipe length

• TEA Pipe transparently compute sensitivities

• TEA Pipe transparently solve the optimisation problem (iterative process)

• The optimal pipe is proposed to the user as a new object

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Thanks for your attention!

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2. Postprocessing

Vorgehensweise zur Darstellung der Ergebnisse mittels der sogenannten Porcupine-Analyses:

• ins Product zurück-wechseln mittels Doppelklick

• Insert Analyses /Porcupine Analyses

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2. Postprocessing

• Curvature oder Radius einstellen

• dann Pipe-Object selektieren

• mit der Maus über die Fläche zeigt immer denaktuellen Wert an Maus-position an.

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Darstellung der Schlauchkrümmung(Porcupine-Analyse)

2. Postprocessing

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Darstellung des Krümmungs-Radiuses(Porcupine-Analyse)

2. Postprocessing

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Strategy

L

LC L-LC

x

Analyses-Strategy

SimpleSimulationwith predef.parameters

AutomaticSimulation

(Optimisation)

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3. Automatic Simulation (Optimisation)

Within that simulation, opened with a double click on “TEA-Pipe Optimisation Set.1“ in the data tree a pipe-optimisation can be done automatically. All parameters from a “simple analyses” can be usedand the programm willfind automatically forexample the minimum length of a brake pipe with respect to surroun-ding collision surfacesof other parts.Or the connector-point-positions and the tangents can be optimised.

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Input mask for defining parameters and the possible objectives (Length, Torsion,Curvature, collision distance).


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The first step is to launch an optimisation with the corresponding button.

Afterwards pressing the button “Solution” will show all iterations and reached optimums reached with yourchosen restraints, then alast calculation is performedwith your chosen results! These will be automatically transfered into the TEA-Pipe mask!

1 2


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Parametric study = Several “Simple calculations”, but automatically performed!


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?????√√√√o. Opt.m. Stütz-schlauch

???????mit Opt.mit Koll.mit Stütz.

???√√√√√√√√√√√√√√√√m. Opt.m. Koll.

(√√√√ )√√√√√√√√√√√√√√√√√√√√o. Opt.m. Koll.

√√√√√√√√√√√√√√√√√√√√√√√√o. Opt.o. Koll.

mit Kin.m.Zw.Aug

mit Kin.m. Zw. fix

mit Kin.o. Zw.h.

ohne Kin.m.Zw.Aug

ohne Kin.m.Zw.fix

ohne Kin.o. Zw.h.


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Optimierte Simulationmit 12 Positions-kinematik (Connector 1-Winkel und Schlauchlänge als Parameter)


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General – Settings within Tools/Options

The following settings can be made within the CATIA-Tools / options menue: Memory and Working directory for temporary files (/tmp).Furthermore the Database for Pipe manufacturer and Materialsshould be selected.

The databases can be editedby administrators (List, Edit),also the minimum pipe radiusand the max. torsion.

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Optional

1. Simple Analyses

Aktivate Kinematic-Loadcases within TEA-PIPE:

With the button FILE OPEN (Kinematic Description) in the main windows of TEA-PIPE, all the previous stored kinematic-positions can be reloaded. Then the basic- or mounting position has to be selected in “Mount Reference Case”, this will be the stressless starting position for the simulation.

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Procedure:

1. Using Measure-Tools (icon a. Origin point of connector or support (e.g. Connector-Point)b. one FIRST axes (e.g. Connector-axes, pipe direction)c. one SECOND axes (e.g. Connector-line perpendicular to first axes)

These meassure values appear in the datatree under Applications/Measure.

2. Renaming the objects in the following way:a. Origin point: <anyname>_Ob. FIRST axes: <anyname>_Xc. SECOND axes: <anyname>_Y

Attention: the convention anyname_X and _Y must beused, regardless how the axes are located.

The datatree should look like this:

1. Simple Analyses

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3. Choice of sensors for recording

First of all the simulation window must be opened with the icon and the sensors have to be activated (Activate Sensors check box)In this window you can see the predefined meassure points (Gx, Gy, Gz) and -directions (Dirx, Diry, Dirz). They can be activated by simply clicking on them.

1. Simple Analyses

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4. Using Kinematic-Positions

Activate in the simulation windows the parameter On request and Number of steps 1.Then move to the prefered position (e.g. FEDERN L –96 = suspension out, this is the so called Mounting position!!!) and all the other positions, also the so called K0-straight-position (which is the CATIA original position, where the car is standing on the wheels witout steering).In the History-window the recorded positions will be listed.

5. Saving in a TEXT-File:

With the Button “FILE” all the listed positions can be stored in a MS-EXCEL- or TEXT-file. TEA-PIPE will use these informations from a TEXT-File (name.txt).

1. Simple Analyses

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6. Aktivate Kinematic-Loadcases within TEA-PIPE:

With the button FILE OPEN (Kinematic Description) in the main windows of TEA-PIPE, all the previous stored kinematic-positions can be reloaded. Then the basic- or mounting position has to be selected in “Mount Reference Case”, this will be the stressless starting position for the simulation.

1. Simple Analyses

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DEFORMED MESH

DISTANCES/SURFACES

CURVATURE

FORCES

MOMENTS

THICK SURFACE

1

2Choose TEA Pipe Solution Set

3

1. Simple Analyses

• Running a simulation and possible results

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2. Postprocessing

D E FO R M E D M E S H

D IS TAN C E S /S U R F AC E S

C U R V ATU R E

FO R C E S

M O M E N TS

TH IC K S U R F AC E

Zuerst mit “Deformed Mesh”Ergebnisse laden

(Link-Manager: Show/Hide)

Dann mittels “Thick Surface”und Selektion des TEA-Pipe-Parts die Volumenschläuche

darin erzeugen.

1

2

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2. Postprocessing

Automatische Generierung aller berechneten Schlauchpositionen in aus SMARAGD-kommenden Parts, welche vom Konstrukteur bereits festgelegt wurde. (Namenskonvention wird aktuell noch geändert!)

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2. Postprocessing

• The “Distances/Surfaces” icon displays coloured bullets on the pipeshowing the distance from the pipe centre line to the selected surfaces

• The “Curvature” icon access the curvature tensor:

o component 1 = torsion (angle / length unit)

o component 2 = curvature in local orientation 1

o component 3 = curvature in local orientation 2

Note that global curvature or the curvature radii can be drawn using standard CATIA features

• The “Forces” icon access the force vector (N,T1,T2) (normal force, shear forces for orientations 1 and 2)

• The “Moment” icon access the moment vector (MT,MB1,MB2) (torsion moment, bending moments for orientations 1 and 2)

a tool to simulate the behaviour of brake pipes within catia v5 · pdf filep morelle this...

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