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PLM World ‘06
Premium Partners:
Developing a Leaner Simulation Process
Ruben FairmanSenior Engineer, Design Development SolutionsEngineering Tools Center of ExcellenceGE [email protected]
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Agenda
· GE at a Glance· Lean Initiative· Waste in Simulation Pre-Processing· Examples of NX4 Reducing Waste· Further Opportunities for NX· Questions????
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GE at a Glance
· Founded by Thomas Edison in 1878· Only company still listed in Dow Jones Index from
original 18 companies in 1896· 320,000+ employees worldwide· 2005 Earnings=$16B net on $150B revenues · Diverse Portfolio of Businesses and Products
· Infrastructure (aircraft engines, wind turbines, locomotives…)· Industrial (plastics, security, appliances, lighting…)· Healthcare (diagnostic imaging, IT, clinical systems…)· Commercial Finance· Consumer Finance· NBC Universal
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GE Infrastructure
· Aviation
· Energy
· Transportation
· Oil & Gas
· Water & Process Technologies
· Commercial Aviation Services
· Energy Financial Services
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Engineering Tools Center of Excellence
Blended IM & Engineering Organization spanning GE Infrastructure
Initially formed in 2005
Unique synergies to accelerate the development and advancement of integrated solutions, resulting in:
· improved product capability
· greater NPI capacity
· standard engineering processes and methods across GE Infrastructure
ETCoE
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Benefits of Simulation Tools
Predictive validation and design space exploration/optimization· Composites save 700 lbs. per aircraft· First composite fan blades – 1995· First composite fan case – 2005
Composite fan case Measured resultsPredicted containment
6
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See the waste in a process
After
Before
Wait / Waste . . .Non Value Add TimeWait / Waste . . .Non Value Add Time
Lean Attacks Waste in the Process
Work . . . Value Add Time Work . . .Value Add Time
Lead Time
• Reduced cycles• Better delivery• More capacity• Better quality• Productivity• Customer satisfaction
Increased process velocity yields:
Benefits of Lean
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Primary Simulation Application Usageno. of unique users in 2005
LS-DYNA
Hyperworks
NASTRAN
VAST/VISTA (GE)
ICEM
UG/Scenario
P/Thermal
PATRAN
SIESTA (GE)
ANSYS2300 Users
Primary applicationfor mechanicalpre,solver,post
CFX
Fluent
6000 UG NX CAD Users
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2300 ANSYS User Breakdown
2D Axi-symmetric27%
Tetrahedral24%
Hexahedral22%
2D Planar11%
Thin shell9%
Pipe/Beam7%
GE Aviation65%
GE Energy22%
GE Transportation10%
Other3%
By Dominant Element GeometryBy Business
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Fully Featured 3D Master Models
(UG NX)
2D Stress/Modal Analysis(ANSYS)
Simulation Geometry Flow @ GE Aviation
Engine Cross Section(UG NX)
2D Engine Dynamics Analysis
(GE Proprietary)
Heat Transfer Analysis(Patran/P-Thermal)
System-level Interfaces(UG NX)
Engine System 3D Clearance Analysis
(ANSYS)
External CFD(ICEM)
3D Stress/Modal Analysis(ANSYS)
3D Engine Dynamics Analysis
(Patran/Nastran)
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Simulation Preparation Process
Collect master
geometry
Create context
geometry
Tag geometry
Map BC’s and loads
Repair geometry
Chunk(partition) geometry
Collect input BC’s and
loads
Translate geometry
Abstract (de-feature) geometry
Create material
definitions
Start Prep
Create mesh(es)
Create Connections
Model Prep Complete
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7 Wastes Product Flow Knowledge FlowOverproduction
Inventory
Extra Processing
Motion
Defects
Waiting
Transportation
• Processing before next operation is ready• Processing prior to need
• Multiple credit applications awaiting approval• Unnecessary document / data storage
• Navigating multiple screens to input data• Multiple ways to do the same task• Printed material• Duplicate entries
• Navigating multiple screens to input data• Printing Material• Ergo…walking, bending, twisting• Looking for data / info
• Personal data incorrect• Missed customer due dates• Data entry errors• Rework
• Credit applications awaiting approval• Info awaiting an overnight “systems batch run”• Manual decisions• System downtime / response time
• Delivering hard-copies• Shipping hard-copies that requiring signature
• Sub assemblies and components between feeder & main lines
• Material between operations & process steps• Inventory stored in warehouses• Buffer & safety stock inventory
• Planned re-work• Un planned re-work• Handwork…polishing, deburring
• Operators bending, turning, twisting, reaching, walking• Machines “cutting air”• Robotic motion “getting back to home”
• Poor quality of materials• Equipment failures• Missing customer due dates…internal & external
• Operators waiting• Machines waiting • Customers waiting
• Conveyance of any materials, tooling• Conveyance systems
Seven Types of Waste
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7 WastesOverproduction
Inventory
Extra Processing
Motion
Defects
Waiting
Transportation
Simulation Model Flow• Excessive element count generated for target
fidelity
• Extra databases stored on local machine• Geometry waiting for processing• Temporary files generated
• Planned re-work• Un planned re-work• Handwork…polishing,
• Searching for input data • Transferring data/files between apps• Transforming
• Failed translations• Failure to mesh geometry• Reworking geometry to fix gaps and make
meshable
• Analysts waiting• Computers waiting • Customers of results waiting
• Translation of geometry from CAD to CAE• Network transfer of files
Seven Types of Waste
ValueStream
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Tetrahedral Meshing Test Parts
0:00:00
0:05:00
0:10:00
0:15:00
0:20:00
0:25:00ANSYS
Workbench 10.0
Scenario NX2.0
PATRAN 2005
Adv SimNX4.0
ANSYS Classic 10.0
Mes
h C
reat
ion
Tim
e (m
inut
es)
Description Impeller Support
Case Sector
TMF Strut
Oil Cooler
Pylon Panel
HPTR Fwd Shaft
Stage 1 HPT
Blade
Stage 1 HPT
Blade
TMF Case
Stage 1 HPT
Nozzle
HPT Disk Stage 1 HPT
Nozzle
4401# Faces 125 143 420 456 566 803 1597 1807 2322 2646 4019
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First Time Yield
0 0.2 0.4 0.6 0.8 1
ANSYS Classic10.0
ANSYSWorkbench
10.0
PATRAN 2005
Scenario NX2.0
Adv Sim NX4.0
Geometry Access FTYMesh Creation FTY Failed Parts
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Tetrahedral Meshing Comparison
ANSYS Workbench 10.0
PATRAN 2005
Adv Sim NX4.0
Scenario NX2.0
Geometry Access Time
Mesh Creation Time
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Mesh Size Comparison
0 50 100 150 200 250 300 350
Thousands
PATRAN 2005
ANSYS Workbench10.0
Scenario NX2.0
Adv Sim NX4.0
Mesh Size
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Tetrahedral Meshing: Fillet Pre-Processing
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Hexahedral Meshing
NX2 Fails to Mesh NX4 MeshFTY=1
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Merge faces eases prep for sweeping
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Merge faces eases prep for sweeping
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Hex Meshing
· 30~80% reduction in volume chunking due to merge face capability in NX4
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NX Opportunities
· Mesh Morphing· CAE Topology edit updates with CAD· Mesh copy from face to face· Pyramid element transitions· BC Transfer between .sim models· Partitioning on CAE Topology vs CAD
topology
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Derivative Approach Dominates Evolution of New Products
Morphed Geometry, Significant Improvement in Performance…TypicalMorphed Geometry, Significant Improvement in Performance…Typical
CF6-80E1Introduction in 1994
72k lb Max Thrust
CF6-50Introduction in 197252k lb Max Thrust
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Leverages Initial Time Spent:Mesh generationAssembly of mating componentsLoad and boundary condition mapsApplication of materialsModel validation/correlation
Enables:Re-use of legacy FE modelsRapid update of analysisSensitivity studies
NX Opportunity: Mesh Morphing
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Summary
· Good show of functionality progress in NX4· Expecting increased user demand and
significant engineering productivity across GE Infrastructure
· Opportunities exist to reduce waste in the overall simulation process
· Development focus should be on maximizing reuse and completing advanced functionality
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Thanks
Questions????