daniel scuzzarello, m.sc. virtual product development ... simulations and deliver results faster ......

Restricted © Siemens AG 2016 All rights reserved. siemens.com/mdx

Virtual Product Development using advanced

CAE and Design Exploration

Daniel Scuzzarello, M.Sc.

Restricted © Siemens AG 2016 All rights reserved.

2016-10-31 Siemens DF PL CD PDT

Agenda

• Challenges for Product Development

• Product Development with CAE

• Virtual Product Development with Advance CAE and Design

Exploration

• Teamcenter for Simulation

• Design Exploration



Challenges for Product Development

Increasing product complexity and requirements

More product variants and configurations

Greater collaboration needs for multiple location dispersed teams

Increasing CAE simulation usage

Greater variety and complexity of simulations

Vastly greater amounts of simulation data

Lack of resources can not be solved with more resources, but with strategy!!!



Product Development with CAE

In a Nutshell

Data Storage

(Models & Results)

Product Data

PDM

Configuration

Requests

Analyst

Requirements

Program Managers

Analysts

Simulation

Applications

Typical Unmanaged Analyst Environment

Validate Troubleshoot Predict

Typical CAE Analyst Environment




Analysts are spending significant amount of time on

searching for data and providing data to others.

Lack of traceability & pedigree.

Huge volumes of data

Inefficiencies in Product Development





Multiple engineering teams

Collaboration is manual

Simulation tasks are outsourced to external suppliers

Protecting IP is a big issue

Poor Collaboration and IP Protection





Start from scratch every time

Redo analysis, Redo geometry simplification, Redo

meshing, Redo load case definition etc

Don’t know, don’t trust …

Do More Simulations … (With Less)





Different processes, different types of analysis, and

different applications

Integrating & capturing data seamlessly without adding

much overhead

Repeatability issues

Lost know-how

Lost process knowledge

Disparate Processes and Tools






ImportGeometry Mesh Select

Physics Solve and

Post-Process

Change Design(geometry and physics)

Design #N+1 Design #N

Manual and Laborious Process



Virtual Product Development with Advanced CAE and Design Exploration

Data Storage

(Models & Results)

Product Data

PDM

Configuration

Requests

Analyst

Requirements

Program Managers

Analysts

Simulation

Applications

Requests

Product Data

Teamcenter

Configuration

Simulation Data

Simulation Tools

Simulation Workflows

Requirements

Analysts

Schedules

Simulation

Applications

Program Managers

Typical Unmanaged Analyst Environment Managed & Streamlined Analyst Environment





Validate Troubleshoot Predict Explore Optimize

Discover Better Designs… Faster

= Feasible = Infeasible

Objective 1

Obje

ctive 2

Virtual Product Development



VA

LU

E

EXPLORE DIGITALLY, CONFIRM PHYSICALLYPROACTIVEREACTIVE

Validate Troubleshoot Predict Automate Explore

Redefining Simulation Strategy for Innovation

SIMULATION PURPOSE

Most companies operate here

to reduce time and cost

Discover Better Designs, Faster!

Our customers operate here

to design better products




Managed & Streamlined Analyst Environment

Teamcenter Simulation





Simulation Data Management

Simulation Lifecycle Management

Closed Loop Product Validation

Simulation Structure Management

Simulation Structure Automation

Simulation Process Management

Simulation Visualization

Design and

Simulation Process



Teamcenter Simulation: Simulation Data Management

15

CAEModel

Solver(number cruncher)

CAEResult

CAD ItemCAEGeometry

Bulk data deck

Named Reference

Binary output file

Named Reference

CAEAnalysis



Illustration

Teamcenter provides complete

traceability between product and

all the simulation data (simplified

geometry, models, load cases,

results, reports etc.) in both

directions.

Teamcenter Simulation: Simulation Data Management

Simulation Pedigree

Multiple Model Structures builtMultiple Analysis

run by different attributes

CAD Structure



Illustration

Capture & Manage Lifecycle of

Simulation Data

Perform lifecycle operations on the

simulation data (Create, Revise,

Update, Delete, Release, Archive etc.)

Manage simulation lifecycle

independent from the product lifecycle,

while maintaining the relationship

Revise the geometry, models, analysis

and results independent from each

other (for example multiple meshes on

the same geometry, multiple analysis

with different load cases using the

same mesh etc.)

Move data into cheaper storage

mechanisms for long-term archival

while maintaining associativity and

access (using Hierarchical Storage

Management capabilities).

Teamcenter Simulation: Simulation Lifecycle Management

Simulation Lifecycle Management

Product

Evolution

Analysis

Evolution



Execute CAE Packages (optional)

Teamcenter Simulation: Closed Loop Product Validation

Design Engineer

Create Validation

ContractWorkflow

Define Contract

Product Revision

Configuration (variants)

Requirements

TEAMCENTER

Analyst

Retrieve

Validation Data

Create / Reuse Mesh

Models

Run the solverPost-ProcessCreate Reports

Apply connections,

Load cases etc.

Simulation Reports

Product Revision

External Simulation

Applications

Simulation Tool Launch Framework

Validation Contract in the context of 3D simulation



Illustration

Capture and manage all

the product performance

requirements, product

validation requirements,

validation procedures etc.

related to simulation.

These requirements are

associated to the simulation

data for complete

traceability.

Analysts can validate

requirements against

simulation results to close

the loop.

Teamcenter Simulation: Closed Loop Product Validation

Link with Requirements

Requirements

Simulation Results

Traceability Report



Illustration

Business Process Automation

Formalize communication of

requirements, design data, results etc.

between various disciplines (systems

engineers, design team, CAE attributes

etc.).

Capture and document simulation

process steps, resulting in repeatable

and standardized processes, which

provide guidance to the users.

Capture and execute workflows at user

level, group level or across disciplines.

Establish traceability between

processes and the data captured.

Teamcenter Simulation: Simulation Process Management

Process Automation

Example customer simulation business

process captured as a workflow



Teamcenter Simulation: Simulation Process Management

Initiate



Illustration

Teamcenter provides different

types of dashboards to Analysts,

Program Managers, IT Managers

etc. for different purposes.

These dashboards are supported

through powerful data mining

techniques.

These include:

Simulation Data Monitor

BOM Reporting

Analysis Reporting

Reporting & Analytics

Teamcenter Simulation: Dashboard and Signoff

Dashboards



Monitor Results

Domain Architect

Engineer

Incorporate Proposed Solution

Create Validation Package

Domain Architect

Study Alternate

Approaches

Approve Proposed

Solution

20%

Simulation

Engineer

Initiate and Run Simulation

Perform Analysis / Report Results

8%

Teamcenter Simulation: Systems Driven Product Development (SDPD)




Benefits

Speed-up simulations and deliver results faster

Remove clerical tasks

Eliminate rework

Improve collaboration

Capture knowledge

Process Automation

Make better product decisions

Deliver simulation results on time

Improved confidence in simulation results

Minimize implementation costs and risk

Configure applications and capture data

Leverage out-of-the-box capabilities with configuration




Managed & Streamlined Analyst Environment





VA

LU

E

EXPLORE DIGITALLY, CONFIRM PHYSICALLYPROACTIVEREACTIVE

Validate Troubleshoot Predict Automate Explore

Redefining Simulation Strategy for Innovation

SIMULATION PURPOSE Discover Better Designs, Faster!



Airbus Static Air Mixer

• Use STAR-CCM+ to gain insight into pre-conditioned air supply for

climate control and de-icing equipment

• Quickly and simply generate and test a design variant

• Automate this change to intelligently search the design space



Challenge:•Find vehicle ride elements that:•Satisfy 40 constraints• Improve 44 ride factor variables•Subject to 7 vehicle maneuvers•Minimize sum of absorbed power

and max vertical acceleration•Previously, after 12 man weeks

of manual effort using DOEs, no feasible designs were found

Results:•After 200 evaluations, HEEDS

discovered 61 feasible designs

• Identified design with best performance after 123 evals

•Stellar vehicle performance!

Pratt & Miller - Military Vehicle Design

“HEEDS® is superior to anything else on the market today.” - Jesper Slattengren, Pratt & Miller

Simulation Constraint #

10" half-round GCW Vertical accel 4

10" half-round CVW Vertical accel 4

Drop-off GVWRide frequencies 4

Ride damping 4

Drop-off CVWRide frequencies 4

Ride damping 4

Offroad CVW Absorbed power 4

Offroad GVW Absorbed power 4

Step steer

Yaw overshoot 1

Roll overshoot 1

Yaw damping 1

Roll damping 1

Constant radius

Understeer gradient 2

Max lateral accel 1

Roll gradient 1

Total 40

Factors

Front

Dual rate spring 5

Position sensitive damper 12

Anti-roll bar 3

Geometry 3

Rear

Dual rate spring 5

Position sensitive damper 12

Anti-roll bar 3

Geometry 1

Total 44

“That’s the best vehicle I’ve ever ridden in.” - Frank Sturek, Infantry Battalion Commander

Designed with HEEDS!Baseline Best run



Challenge:

• Improve plant exhaust filtering

•Maximize velocity uniformity through filter

•Constraints

•Largely frozen plant design

•Design variables

•Geometry of limited region with

or w/o deflectors

Results:

• Increased flow uniformity from 75% to 91%

Customer Example: Concrete Plant Exhaust Treatment

Gas

inflow

Gas

outflow

filter

Plant design is frozen, can only modify parts in “red”

80 % 85 % 91 %

76 % 95 % 96 %

Co

nce

pts

Exp

lore

d

Ideal

Current

UNIFORM ACHIEVED: from 75% to 91 %

• 60 runs , 10 minutes

ExtrudeDistance2

ExtrudeDistance1

TranslationVector

Uniformity improved from 75 to 91%



Challenge:

•Minimize Body-In-White weight

•Maintain manufacturability

•Obtain the same or better performance

•System-level requirements

•Full vehicle requirements

•Constrain increases in cost

•Previous complex optimizations (with 484 variables)

were not possible

Results:

•After 250 evaluations, found 49 feasible designs

• Identified the best design with an 18% reduction

in weight and less than 5% increase in cost

EDAG - Full Vehicle Weight Reduction

TARGET WEIGHT

(20% saving) TARGET COST

(10% up)

BODY NVH

FRONT CRASH (all

load cases)

OCCUPANT

RESTRAINTS (all

load cases)

SIDE CRASH (all

load cases)REAR CRASH

(all load cases)

ROOF CRUSH

(all load cases)

DURABILITY

BODY STIFFNESS

(global and local)

MDOPERFORMANCE

ASSESSMENT

BASELINE

“HEEDS® allowed us to meet DFSS requirements in record time.” – Javier Rodriguez, EDAG



EDAG - Full Vehicle Design



Virtual Product Development using Advanced CAE and Design Exploration

Lack of resources can not be solved with more resources, but with strategy!!!

SELECT GET STARTED EXTEND

Project 1

Project 6

Quick Start

Baseline Design Space Better Designs

TODAYYour Innovation

Goal

Project 3

Project 4

Project 5

Project 2

Project 7

EXPLORE 1ST SUCCESS INNOVATE




Daniel Scuzzarello

Sales Director

Phone: +55 (11) 4228 7600

Mobile: +55 (11) 9 8415 5332

E-mail:

[email protected]

siemens.com/mdx

daniel scuzzarello, m.sc. virtual product development ... simulations and deliver results faster ......

Documents