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Page 1: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

MSC Software Magazine | Volume V Summer 2015 Issue

Sept 16-17 2015 Troy Michigan

Global Ground Vehicle amp Heavy Machinery Industry Conference 2015

Register Today wwwmscsoftwarecomgv-hmi

9

11

13

14

TABLE OF CONTENTS

EDITOR LETTER

1Reaching the Apex

LETTER FROM THE CEO

3Simulating the Complete Engineering Process

MSC IN THE NEWS

4Simulation News amp Media Coverage

PRODUCT NEWS IN-BRIEF

62015 MSC New Product Releases

CO-SIMULATION SPOTLIGHT

8Noise Prediction of Moving MechanismsCo-Simulation Feature

10Evaluating Suspension Components Earlier in DesignVolvo Car

12System Analysis 15X Faster with Co-SimulationLitens Automotive

14Tackling Conflicting Performance Requirements Ford Motor Company

16Simulations Give Insight into Bedsore ProblemsCEI

22FEATURE STORY

Volume V - Summer 2015 | 4

3228 36

TECH TIPS

18Marc Defining Axis of Rotation of a Rigid BodyJoe Satkunananthan MSC Software

19Patran Useful Tools for Contact AnalysisChristian Aparicio MSC Software

20Adams The New ANCF Object FE_PartMaziar Rostamian MSC Software

PARTNER SHOWCASE

30Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc and SimManagerVCollab

SPECIAL SPOTLIGHT

32Simufact Welcome to the MSC FamilyVolker Mensing Simufact

FEATURE STORY

22MSC Apex Latest Release Delivers Dramatic Time-Savings in Mid-Surface Modeling

23Accelerated Mid-Surface Model Construction Workflow

24Analyzing Design Modifications FasterTLG Aerospace

25From Two Days to One HourDynetics

26Aero Supplier Achieves Dramatic Time Savings DEMA

28The Award-WinningMSC Apex

34Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntel

362015 Simulating Reality Contest Winners

39MSC Learning Centerrsquos e-LearningChristopher Anderson MSC Software

CUSTOMER SPOTLIGHT

40Simulating Complex Package Folding ProcedureIIT

UNIVERSITY amp RESEARCH

42Adams Curriculum Kit 2nd Edition is Here

by LESLIE BODNAR Executive Editor

Executive Editor

Leslie Bodnar lesliebodnarmscsoftwarecom

EditorGraphic Designer

Marina Carpenter marinacarpentermscsoftwarecom

Assistant Editors Graphics Contributors

Daryen Thompson

daryenthompsonmscsoftwarecom

Jennifer Betonio

jenniferbetoniomscsoftwarecom

MSC Software Corporation

4675 MacArthur Court Suite 900

Newport Beach CA 92660

7145408900

wwwmscsoftwarecom

Volume V - Summer 2015 | 1

Reaching the top and pursuing greatness in the application of engineering simulation throughout the stages of new product development and into design validation is what we will always strive to help engineers do

EDITOR LETTER

Reaching the ApexIs modeling and simulation finally reaching higher levels of usability accuracy and efficiency

Engineers are telling us yes In fact it is

In this issue we introduce new technology that is already pushing the envelope by creating dramatic time savings for engineers involved in the initial stages of the analysis process - specifically geometry repair modeling and meshing These mundane and repetitive tasks are where our customers tell us they simply need a new approach a better one

Our answer ndash MSC Apex

And this is just the beginning of whatrsquos to come

Already in its fourth release MSC Apex is producing real time savings for companies like TLG Aerospace DEMA and Dynetics Technical Services

On page 24 TLG Aerospace engineers describe how they were able to reduce geometry cleanup and meshing time by 75 While DEMA engineers were able to reduce the time required to analyze their design by 60 See page 26

Also included in this issue is a dedicated Co-Simulation Spotlight

Beginning on page 8 we introduce five stories each describing different methods for applying co-simulation such that engineers are now able to test more scenarios with higher fidelity and better accuracy than ever before through virtual testing

Integration of simulation technologies also cuts development time and drives rapid innovation in products For example Volvo Car is coupling multibody dynamics and nonlinear FEA to design lighter suspension systems and look at more design alternatives See their story on page 10 Litens Automotive is able to achieve a 90 reduction in computation time using the same approach See page 12

The automotive and machinery industries arenrsquot the only ones benefiting from advancements in co-simulation technology On page 16 see how itrsquos revealing hidden insights into bedsore problems for hospital equipment manufacturers

Reaching the top and pursuing greatness in the application of engineering simulation throughout the stages of new product development and into design validation is what we will always strive to help engineers do

Thank you to everyone who shared their story with us

Sincerely

REALITYsimulating

2015 USER CONFERENCES

For more information visit wwwmscsoftwarecom

Beijing ChinaMay 27

Xian ChinaMay 29

Tokyo Japan June 4

Paris FranceJune 10-11

Brno Czech RepublicJune 10-11

Istanbul TurkeyJune 11-12

Gothenburg SwedenJune 15

Munich Germany June 16-17

Napoli ItalyJuly 10

Queretaro MexicoAugust 18

Pune IndiaSeptember 4

Michigan USASeptember 16-17

Tampere FinlandSeptember 22

Moscow Russia October 7-8

Budapest HungaryOctober 8

Bologna ItalyOctober 14

Rotterdam NetherlandsOctober 15

BelgiumOctober 15

Torino ItalyNovember 11

Madrid SpainOctober

Pretoria South AfricaMarch 17 2016

Simulating Reality Delivering Certainty

Volume V - Summer 2015 | 3

by DOMINIC GALLELLO President amp CEO

MSC Software

LETTER FROM THE CEO

Simulating the Complete Engineering Process

A few years ago I attended a global leadership conference where the attendees on the opening night sat right in the middle of the Los Angeles Symphony Orchestra

They powerfully demonstrated the sounds that an orchestra would make if they were not working well together It was not good Finally the conductor took control of all the sections and to no surprise the music was fantastic If you think about the number of simulations that take place in a product development process it is really not much different If one of the members of the simulation orchestra delivers great results but they are alone and disconnected from the rest of the development process it is pretty clear that the results will not be optimal

Over the past few years we have been assembling the major sections of the simulation orchestra to simulate the complete engineering process

bull Materials ndash The design of new materials which reduce weight and provide same or better structural integrity with reduced part count materials that have better acoustics properties etc is becoming more and more critical This can be for materials of chopped fiber and continuous fiber composites as well as metal which is still the predominant material for cars trains and planes Design testing and management of new materials should be a natural part of the design process not relegated to just a ldquospecial fewrdquo We enable engineers to use the design variables of new advanced materials with certainty as a natural part of their design process

bull Fabrication ndash As the materials are chosen they need to be formed into parts Forming forging and other fabrication processes are done by a huge number of companies Forming simulation we have done before but annealing rolling curing 3D printing and general simulation of fabrication is something new and offers our customers the ability to use simulation to explore the impact of fabrication on the materials behaviors and the robustness of their designs in the face of realizable material variability Support the simulation of the as-manufactured spatial property variation to enable partssystems designers to design to robust manufactured parts with minimal margins Enable the fabrication engineering departments to decide on the best ways to work the material to obtain the design targeted properties

bull Parts ndash The ability to quickly model and shape parts for simulation that runs the first time has been difficult to achieve over the years And now as light-weighting is driving engineers to refine their parts designs and 3D printing and other fabrication methods are opening new design options it is even more critical to enable engineers to design the parts It is no longer enough to validate that the part meets its operational criteria

Make simulation tools easier to use and tie them more closely to the geometrical design parameters Enable the easy exploration of fabrication methods in the simulation of parts behaviors

bull Assembly ndashIdealized parts from the traditional design process donrsquot always behave the way you want after being fabricated and then joined to an assembly Welding riveting annealing and spatial variations from strain hardening and forming of steel and aluminum change the characteristics of the subsystems and systems and this cannot be ignored The joining process is another very important input into the design process to understand overall system behavior and how to exploit it in the design of parts and in the design of the assembly process itself

bull Systems ndash Getting the system model just right gets more and more challenging Lightweighting acoustical optimization energy management stability augmentation of the dynamic behavior and more and more specialized load cases coupled with a need to minimize the use of margins of safety to create certainty in the design creates a seemingly endless back and forth between the system model and the myriad of part models The reduction of just one loads cycle has incredibly positive time and cost impact on the overall development process Enable the systems model and its criteria to be visible throughout the design process Simplify the exchange of systems and parts behaviors and properties through the supply chain

All five pieces of the process are now in place With the building blocks laid down it offers us incredible opportunities to assist our customers to accelerate not only each piece of the process but also to exploit even greater design improvements by simulating the materials to systems processes We look forward to working with you to realize the full potential

4 | MSC Software

MSC IN THE NEWS

More people are living side-by-side with their appliances in smaller spaces so they want quieter machines but not completely silent machines They want enough sound to confirm the refrigerator is working or the washing machine has completed its cycle but no more At the same time that engineers are trying to strike that balance government agencies are mandating greater energy efficiency and ldquoend of liferdquo design that minimizes waste and maximizes re-use Throw cost style and size into the mix and engineers face a tangle of conflicting priorities Acoustic simulation can resolve that conflict by giving engineers insight for developing products with appropriate sound profiles while balancing other design considerations Integrating acoustic simulation technology into their design processes provides manufacturers with the insight necessary to know where the balance between consumer preference and government restrictions lies They donrsquot need the resources of a multinational corporation to do it They just need to know that they have options for understanding their productsrsquo acoustic behaviors without raising their costs

Acoustic Simulation Software Helps Appliance Engineers Meet Demands Appliance Design

httpbitly1ddtJRj

Lugging is a familiar ndash and unwelcome ndash challenge that symbolizes the tension between fuel economy and noise vibration and harshness (NVH) in motor vehicle design today Lugging occurs when a vehicle is operating at a high gear and a low engine speed ndash below 2000 RPM ndash and the driver hits the accelerator Engineers can adjust the vehiclersquos transmission to accelerate smoothly in high gear ndash a process called ldquoslippingrdquo ndash but doing so reduces the carrsquos fuel economy Therein lies the conflict Consumers want the smoother rides that slipping the transmission yields but automotive engineers are under enormous pressure to improve fuel efficiency to meet ever-stricter government mileage requirements Fordrsquos solution came through a combination of simulation and modeling technology and an open standard for co-simulation called Functional Mock-Up Interface (FMI) Ford created detailed 3D models of the drivetrain and the entire vehicle in MSC Softwarersquos Adams multi-body dynamics software Simulation results demonstrated that a slip of 40rpm slip was the optimal trade-off between NVH and fuel economy Simulation will help engineers develop vehicles that deliver the comfort and performance required to appeal to customers and the efficiency to meet increasingly stringent fuel economy standards

Ford Applies New Simulation Technology to Solve ChallengesDesign World

httpbitly1GizEzv

In February 2015 MSC Software acquired Simufact creators of metal forming and joining simulation software The software is a popular nonlinear CAE Tool used by the automotive OEM aerospace and machine part industries The tool is designed to reduce the trial and error associated with manufacturing a product on the shop floor In fact some Simufact customers have reported that they have been able to cut their physical testing in half and reduce the cycle time of a new part to a single week when using the software For MSC users however Simufact will help to complete the simulation process chain This will give engineers the ability to simplify the assessments of their ldquoas manufacturedrdquo designs

Nonlinear Forming amp Welding Simulation Brings ldquoAs Manufacturedrdquo Data to MSCEngineeringcom

httpbitly1AL3dFy

Simulation News amp Media Coverage

Volume V - Summer 2015 | 5

Software that is easier to use allows engineers more time to focus on simulation and analysis of the data rather than trying to adapt to new software learn proprietary coding languages or the worrying about how to map algorithms to the latest GPU or accelerator technology For instance aircraft noise has become a major concern and in some cases is an obstacle to growth in air transport as numbers of airports place restrictions on the amount of noise that can be generated by an aircraft Designers and engineers must work hard to reduce the noise of jet engines by placing acoustic liners in the nacelle a housing that holds engines or equipment on an aircraft to minimize the fan noise radiated from the engine One example of the use of MSC software for acoustic simulation looked at the use of nacelle liners on Airbus aircraft The company evaluated several different shapes and materials to understand the best performance Airbus found that it could dramatically reduce the time required to design and evaluate acoustic liners by moving to a simulation-based process using Actran acoustic simulation software developed by Free Field Technologies (FFT) a subsidiary of MSC

Simplifying SimulationScientific Computing World

httpbitly1JSrlcP

A new generation of materials management technology will open a window on lighter more efficient vehicles Composites reinforced plastics and lightweight steel and aluminum are being deployed across the automotive industry at record rates to improve fuel efficiency Automotive OEMs are integrating new materials into parts and assemblies in existing designs and developing completely reimagined platforms around them such as the BMW i3 and i8 New material systems provide significant benefits in specific weight and stiffness However because of their variability due to new manufacturing methods and engineersrsquo lack of familiarity with them new material systems demand significantly more and different types of testing ndash potentially increasing up-front cost This expansion of testing obligates OEMs to rethink how material systems are managed and how they must evolve to support wider uses of new materials Such a system must put materials in the forefront of engineering to use materials as an essential design variable to innovate The ability to model material properties quickly easily and in detail is essential to adopting new materials that will make automobiles lighter more fuel efficient and ultimately better for the environment

Materials to Reduce Vehicle WeightTodayrsquos Motor Vehicles

httpbitly1S4iudL

In February 2015 the United States Marine Corps put some of its engineers through an intensive nine-day training course on Adams In less than two weeks the students realized that learning Adams could put them on equal footing with engineers in the private sector Adamsrsquo powerful analysis capabilities are giving the USMC the ability to start bringing engineering work back in-house allowing them to quickly and accurately analyze any vehicle mishaps that may occur

Class Gives United States Marine Corps Engineers New Analytical Tool Defense Video amp Imagery Distribution System

httpbitly1PPUK9i

6 | MSC Software

PRODUCT NEWS IN-BRIEF

2015 New Product Releases

MSC Apex Diamond Python

The latest release of MSC Apex enhances the engineerrsquos workflow and daily productivity with many innovative modeling and analysis capabilities The MSC Apex Diamond Python release introduces

bull The fourth release of MSC Apex Modeler - A CAE Specific direct modeling and meshing solution that streamlines CAD clean-up simplification and meshing workflow

bull The second release of MSC Apex Structures - An add-on to MSC Apex Modeler which now expands MSC Apex to a fully integrated and generative structural analysis solution

bull New incremental Mid-surface modeling workflow (SmartMidsurface trade) for dramatic time savings

Diamond Python delivers a solver integrated solution for interactive and incremental structural analysis Modeling validating solving and exploring designs has never been this efficient and easy MSC Apex helps users to dramatically reduce the amount of time that it takes to build and validate models a task that does not add any value to the design process This frees users to focus on delivering not just acceptable designs but ones that are optimal - in an environment that is fun to use

For details please visit wwwmscapexcom

Delivers two products Modeler and Structures + SmartMidsurfacetrade

Adams 2015 The Adams 2015 release delivers new functionality and major enhancements in many areas especially for AdamsCar Automotive engineers will benefit from new out-of-the-box customized solutions for model setup and vehicle event simulations The new features also give users the ability to create higher fidelity subsystems in their vehicle models Highlights of the release include

Extends Vehicle Simulation Scope for Automotive Engineers

The 2015 product release lineup delivers new event simulations for vehicle modeling coupled physics extended material modeling methods an all-new release of MSC Apex and a range of advanced engineering simulation technologies for streamlining the analysis workflow In addition to the releases mentioned below please expect later this year to see new 2015 releases of Marc MSC Nastran amp Patran SimManager and additional releases of Digimat Simufact and Actran New Release Highlights

Higher Fidelity Modelingbull AdamsMachinery Compatibility in AdamsCar - High fidelity

gear and motor modeling in car amp drivelinebull Nonlinear FE Part Support for AdamsCar ndash Geometric

nonlinearity for vehicle subsystems modeling and simulationbull Adams-Marc Co-simulation Enhancements ndash Easier and faster

Multibody Dynamics-Nonlinear FEA Integrationbull New Vehicle Database ndash Provides availability of key vehicle types

out-of-the-box

New Vehicle Eventsbull Full-vehicle Suspension Parameter Measurement Machine

(SPMM) - Tune suspension parameters for desired vehicle behavior without costly iteration with physical prototypes

bull Static Vehicle Characteristics (SVC) ndash Computes and reports key metrics of the vehicle at static equilibrium

bull Tandem Axle Suspension Analysis (TASA) ndash Delivers support for tuning of multi-axle architectures

For details please visit wwwmscsoftwarecomproductadams

Volume V - Summer 2015 | 7

Digimat 60

Material Databanks

MaterialCenter 2015

This latest Digimat 60 release brings a series of new features and improvements for modeling and analyzing composite materials from Short Fiber Reinforced Plastics (SFRP) to Discontinuous Fiber Composites (DFC) and Continuous Fiber Reinforced Composites (CFRP)

The new release also introduces Digimat-VA a unique software solution dedicated to accurate virtual characterization of CFRPs to dramatically reduce the cost and time associated with material characterization and qualification Digimat-VA which stands for Virtual Allowables offers a dedicated integrated workflow starting with easy and efficient creation of advanced multi-scale material models (including micro-level variability and progressive failure) FEA simulations of common test coupons and automatic post-processing for computing mean strength and AB-basis values

Any engineer concerned with characterizing a new composite material exploring the design space or better understanding widespread mechanical properties will find in Digimat-VA a productive solution to save time and money

For details please visit wwwe-xstreamcom

The MSC Material Databanks are collections of technical materials information in electronic format The databanks are developed and maintained through MSCrsquos partnerships with premier sources of materials information They provide a comprehensive source of material property data for use by engineers for design and analysis Benefits include bull Easy access to high-quality reliable material data from around the world to improve team efficiency and information workflow bull Improved quality and consistency with engineering data derived from a single sourcebull Reduced transcription errors with electronic data transferbull Increased accuracy of predictive analysis product design and simulation using certified material data records for CAD CAE

or PLM software

For details please visit wwwmscsoftwarecom

MaterialCenter 2015 is an out-of-the-box Material Process and Data Lifecycle Management solution with direct integration into many of the CAE pre- and post-processing tools commonly

used by engineers The integration provides direct support to retrieve a material model from MaterialCenter without leaving the native CAE pre- and post-processing application

MaterialCenter 2015 also enables users to create and edit material data directly from the browser environment Along with MaterialCenterrsquos Excel integration this provides a completely traceable system to ensure users are aware of all the modifications made to the data

MaterialCenter is the single point of entry for all of your materials related activities including physical test data entry and reduction multi-scale materials modeling approval workflow and the export of simulation ready data to analysis

For details please visit wwwmscsoftwarecomproductmaterialcenter

The material modeling platform for simulating a range of composites

Secure reliable and fast access to material data

Delivers material data integration and ease of use to dramatically improve engineering simulation workflows

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

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irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

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Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 2: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Sept 16-17 2015 Troy Michigan

Global Ground Vehicle amp Heavy Machinery Industry Conference 2015

Register Today wwwmscsoftwarecomgv-hmi

9

11

13

14

TABLE OF CONTENTS

EDITOR LETTER

1Reaching the Apex

LETTER FROM THE CEO

3Simulating the Complete Engineering Process

MSC IN THE NEWS

4Simulation News amp Media Coverage

PRODUCT NEWS IN-BRIEF

62015 MSC New Product Releases

CO-SIMULATION SPOTLIGHT

8Noise Prediction of Moving MechanismsCo-Simulation Feature

10Evaluating Suspension Components Earlier in DesignVolvo Car

12System Analysis 15X Faster with Co-SimulationLitens Automotive

14Tackling Conflicting Performance Requirements Ford Motor Company

16Simulations Give Insight into Bedsore ProblemsCEI

22FEATURE STORY

Volume V - Summer 2015 | 4

3228 36

TECH TIPS

18Marc Defining Axis of Rotation of a Rigid BodyJoe Satkunananthan MSC Software

19Patran Useful Tools for Contact AnalysisChristian Aparicio MSC Software

20Adams The New ANCF Object FE_PartMaziar Rostamian MSC Software

PARTNER SHOWCASE

30Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc and SimManagerVCollab

SPECIAL SPOTLIGHT

32Simufact Welcome to the MSC FamilyVolker Mensing Simufact

FEATURE STORY

22MSC Apex Latest Release Delivers Dramatic Time-Savings in Mid-Surface Modeling

23Accelerated Mid-Surface Model Construction Workflow

24Analyzing Design Modifications FasterTLG Aerospace

25From Two Days to One HourDynetics

26Aero Supplier Achieves Dramatic Time Savings DEMA

28The Award-WinningMSC Apex

34Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntel

362015 Simulating Reality Contest Winners

39MSC Learning Centerrsquos e-LearningChristopher Anderson MSC Software

CUSTOMER SPOTLIGHT

40Simulating Complex Package Folding ProcedureIIT

UNIVERSITY amp RESEARCH

42Adams Curriculum Kit 2nd Edition is Here

by LESLIE BODNAR Executive Editor

Executive Editor

Leslie Bodnar lesliebodnarmscsoftwarecom

EditorGraphic Designer

Marina Carpenter marinacarpentermscsoftwarecom

Assistant Editors Graphics Contributors

Daryen Thompson

daryenthompsonmscsoftwarecom

Jennifer Betonio

jenniferbetoniomscsoftwarecom

MSC Software Corporation

4675 MacArthur Court Suite 900

Newport Beach CA 92660

7145408900

wwwmscsoftwarecom

Volume V - Summer 2015 | 1

Reaching the top and pursuing greatness in the application of engineering simulation throughout the stages of new product development and into design validation is what we will always strive to help engineers do

EDITOR LETTER

Reaching the ApexIs modeling and simulation finally reaching higher levels of usability accuracy and efficiency

Engineers are telling us yes In fact it is

In this issue we introduce new technology that is already pushing the envelope by creating dramatic time savings for engineers involved in the initial stages of the analysis process - specifically geometry repair modeling and meshing These mundane and repetitive tasks are where our customers tell us they simply need a new approach a better one

Our answer ndash MSC Apex

And this is just the beginning of whatrsquos to come

Already in its fourth release MSC Apex is producing real time savings for companies like TLG Aerospace DEMA and Dynetics Technical Services

On page 24 TLG Aerospace engineers describe how they were able to reduce geometry cleanup and meshing time by 75 While DEMA engineers were able to reduce the time required to analyze their design by 60 See page 26

Also included in this issue is a dedicated Co-Simulation Spotlight

Beginning on page 8 we introduce five stories each describing different methods for applying co-simulation such that engineers are now able to test more scenarios with higher fidelity and better accuracy than ever before through virtual testing

Integration of simulation technologies also cuts development time and drives rapid innovation in products For example Volvo Car is coupling multibody dynamics and nonlinear FEA to design lighter suspension systems and look at more design alternatives See their story on page 10 Litens Automotive is able to achieve a 90 reduction in computation time using the same approach See page 12

The automotive and machinery industries arenrsquot the only ones benefiting from advancements in co-simulation technology On page 16 see how itrsquos revealing hidden insights into bedsore problems for hospital equipment manufacturers

Reaching the top and pursuing greatness in the application of engineering simulation throughout the stages of new product development and into design validation is what we will always strive to help engineers do

Thank you to everyone who shared their story with us

Sincerely

REALITYsimulating

2015 USER CONFERENCES

For more information visit wwwmscsoftwarecom

Beijing ChinaMay 27

Xian ChinaMay 29

Tokyo Japan June 4

Paris FranceJune 10-11

Brno Czech RepublicJune 10-11

Istanbul TurkeyJune 11-12

Gothenburg SwedenJune 15

Munich Germany June 16-17

Napoli ItalyJuly 10

Queretaro MexicoAugust 18

Pune IndiaSeptember 4

Michigan USASeptember 16-17

Tampere FinlandSeptember 22

Moscow Russia October 7-8

Budapest HungaryOctober 8

Bologna ItalyOctober 14

Rotterdam NetherlandsOctober 15

BelgiumOctober 15

Torino ItalyNovember 11

Madrid SpainOctober

Pretoria South AfricaMarch 17 2016

Simulating Reality Delivering Certainty

Volume V - Summer 2015 | 3

by DOMINIC GALLELLO President amp CEO

MSC Software

LETTER FROM THE CEO

Simulating the Complete Engineering Process

A few years ago I attended a global leadership conference where the attendees on the opening night sat right in the middle of the Los Angeles Symphony Orchestra

They powerfully demonstrated the sounds that an orchestra would make if they were not working well together It was not good Finally the conductor took control of all the sections and to no surprise the music was fantastic If you think about the number of simulations that take place in a product development process it is really not much different If one of the members of the simulation orchestra delivers great results but they are alone and disconnected from the rest of the development process it is pretty clear that the results will not be optimal

Over the past few years we have been assembling the major sections of the simulation orchestra to simulate the complete engineering process

bull Materials ndash The design of new materials which reduce weight and provide same or better structural integrity with reduced part count materials that have better acoustics properties etc is becoming more and more critical This can be for materials of chopped fiber and continuous fiber composites as well as metal which is still the predominant material for cars trains and planes Design testing and management of new materials should be a natural part of the design process not relegated to just a ldquospecial fewrdquo We enable engineers to use the design variables of new advanced materials with certainty as a natural part of their design process

bull Fabrication ndash As the materials are chosen they need to be formed into parts Forming forging and other fabrication processes are done by a huge number of companies Forming simulation we have done before but annealing rolling curing 3D printing and general simulation of fabrication is something new and offers our customers the ability to use simulation to explore the impact of fabrication on the materials behaviors and the robustness of their designs in the face of realizable material variability Support the simulation of the as-manufactured spatial property variation to enable partssystems designers to design to robust manufactured parts with minimal margins Enable the fabrication engineering departments to decide on the best ways to work the material to obtain the design targeted properties

bull Parts ndash The ability to quickly model and shape parts for simulation that runs the first time has been difficult to achieve over the years And now as light-weighting is driving engineers to refine their parts designs and 3D printing and other fabrication methods are opening new design options it is even more critical to enable engineers to design the parts It is no longer enough to validate that the part meets its operational criteria

Make simulation tools easier to use and tie them more closely to the geometrical design parameters Enable the easy exploration of fabrication methods in the simulation of parts behaviors

bull Assembly ndashIdealized parts from the traditional design process donrsquot always behave the way you want after being fabricated and then joined to an assembly Welding riveting annealing and spatial variations from strain hardening and forming of steel and aluminum change the characteristics of the subsystems and systems and this cannot be ignored The joining process is another very important input into the design process to understand overall system behavior and how to exploit it in the design of parts and in the design of the assembly process itself

bull Systems ndash Getting the system model just right gets more and more challenging Lightweighting acoustical optimization energy management stability augmentation of the dynamic behavior and more and more specialized load cases coupled with a need to minimize the use of margins of safety to create certainty in the design creates a seemingly endless back and forth between the system model and the myriad of part models The reduction of just one loads cycle has incredibly positive time and cost impact on the overall development process Enable the systems model and its criteria to be visible throughout the design process Simplify the exchange of systems and parts behaviors and properties through the supply chain

All five pieces of the process are now in place With the building blocks laid down it offers us incredible opportunities to assist our customers to accelerate not only each piece of the process but also to exploit even greater design improvements by simulating the materials to systems processes We look forward to working with you to realize the full potential

4 | MSC Software

MSC IN THE NEWS

More people are living side-by-side with their appliances in smaller spaces so they want quieter machines but not completely silent machines They want enough sound to confirm the refrigerator is working or the washing machine has completed its cycle but no more At the same time that engineers are trying to strike that balance government agencies are mandating greater energy efficiency and ldquoend of liferdquo design that minimizes waste and maximizes re-use Throw cost style and size into the mix and engineers face a tangle of conflicting priorities Acoustic simulation can resolve that conflict by giving engineers insight for developing products with appropriate sound profiles while balancing other design considerations Integrating acoustic simulation technology into their design processes provides manufacturers with the insight necessary to know where the balance between consumer preference and government restrictions lies They donrsquot need the resources of a multinational corporation to do it They just need to know that they have options for understanding their productsrsquo acoustic behaviors without raising their costs

Acoustic Simulation Software Helps Appliance Engineers Meet Demands Appliance Design

httpbitly1ddtJRj

Lugging is a familiar ndash and unwelcome ndash challenge that symbolizes the tension between fuel economy and noise vibration and harshness (NVH) in motor vehicle design today Lugging occurs when a vehicle is operating at a high gear and a low engine speed ndash below 2000 RPM ndash and the driver hits the accelerator Engineers can adjust the vehiclersquos transmission to accelerate smoothly in high gear ndash a process called ldquoslippingrdquo ndash but doing so reduces the carrsquos fuel economy Therein lies the conflict Consumers want the smoother rides that slipping the transmission yields but automotive engineers are under enormous pressure to improve fuel efficiency to meet ever-stricter government mileage requirements Fordrsquos solution came through a combination of simulation and modeling technology and an open standard for co-simulation called Functional Mock-Up Interface (FMI) Ford created detailed 3D models of the drivetrain and the entire vehicle in MSC Softwarersquos Adams multi-body dynamics software Simulation results demonstrated that a slip of 40rpm slip was the optimal trade-off between NVH and fuel economy Simulation will help engineers develop vehicles that deliver the comfort and performance required to appeal to customers and the efficiency to meet increasingly stringent fuel economy standards

Ford Applies New Simulation Technology to Solve ChallengesDesign World

httpbitly1GizEzv

In February 2015 MSC Software acquired Simufact creators of metal forming and joining simulation software The software is a popular nonlinear CAE Tool used by the automotive OEM aerospace and machine part industries The tool is designed to reduce the trial and error associated with manufacturing a product on the shop floor In fact some Simufact customers have reported that they have been able to cut their physical testing in half and reduce the cycle time of a new part to a single week when using the software For MSC users however Simufact will help to complete the simulation process chain This will give engineers the ability to simplify the assessments of their ldquoas manufacturedrdquo designs

Nonlinear Forming amp Welding Simulation Brings ldquoAs Manufacturedrdquo Data to MSCEngineeringcom

httpbitly1AL3dFy

Simulation News amp Media Coverage

Volume V - Summer 2015 | 5

Software that is easier to use allows engineers more time to focus on simulation and analysis of the data rather than trying to adapt to new software learn proprietary coding languages or the worrying about how to map algorithms to the latest GPU or accelerator technology For instance aircraft noise has become a major concern and in some cases is an obstacle to growth in air transport as numbers of airports place restrictions on the amount of noise that can be generated by an aircraft Designers and engineers must work hard to reduce the noise of jet engines by placing acoustic liners in the nacelle a housing that holds engines or equipment on an aircraft to minimize the fan noise radiated from the engine One example of the use of MSC software for acoustic simulation looked at the use of nacelle liners on Airbus aircraft The company evaluated several different shapes and materials to understand the best performance Airbus found that it could dramatically reduce the time required to design and evaluate acoustic liners by moving to a simulation-based process using Actran acoustic simulation software developed by Free Field Technologies (FFT) a subsidiary of MSC

Simplifying SimulationScientific Computing World

httpbitly1JSrlcP

A new generation of materials management technology will open a window on lighter more efficient vehicles Composites reinforced plastics and lightweight steel and aluminum are being deployed across the automotive industry at record rates to improve fuel efficiency Automotive OEMs are integrating new materials into parts and assemblies in existing designs and developing completely reimagined platforms around them such as the BMW i3 and i8 New material systems provide significant benefits in specific weight and stiffness However because of their variability due to new manufacturing methods and engineersrsquo lack of familiarity with them new material systems demand significantly more and different types of testing ndash potentially increasing up-front cost This expansion of testing obligates OEMs to rethink how material systems are managed and how they must evolve to support wider uses of new materials Such a system must put materials in the forefront of engineering to use materials as an essential design variable to innovate The ability to model material properties quickly easily and in detail is essential to adopting new materials that will make automobiles lighter more fuel efficient and ultimately better for the environment

Materials to Reduce Vehicle WeightTodayrsquos Motor Vehicles

httpbitly1S4iudL

In February 2015 the United States Marine Corps put some of its engineers through an intensive nine-day training course on Adams In less than two weeks the students realized that learning Adams could put them on equal footing with engineers in the private sector Adamsrsquo powerful analysis capabilities are giving the USMC the ability to start bringing engineering work back in-house allowing them to quickly and accurately analyze any vehicle mishaps that may occur

Class Gives United States Marine Corps Engineers New Analytical Tool Defense Video amp Imagery Distribution System

httpbitly1PPUK9i

6 | MSC Software

PRODUCT NEWS IN-BRIEF

2015 New Product Releases

MSC Apex Diamond Python

The latest release of MSC Apex enhances the engineerrsquos workflow and daily productivity with many innovative modeling and analysis capabilities The MSC Apex Diamond Python release introduces

bull The fourth release of MSC Apex Modeler - A CAE Specific direct modeling and meshing solution that streamlines CAD clean-up simplification and meshing workflow

bull The second release of MSC Apex Structures - An add-on to MSC Apex Modeler which now expands MSC Apex to a fully integrated and generative structural analysis solution

bull New incremental Mid-surface modeling workflow (SmartMidsurface trade) for dramatic time savings

Diamond Python delivers a solver integrated solution for interactive and incremental structural analysis Modeling validating solving and exploring designs has never been this efficient and easy MSC Apex helps users to dramatically reduce the amount of time that it takes to build and validate models a task that does not add any value to the design process This frees users to focus on delivering not just acceptable designs but ones that are optimal - in an environment that is fun to use

For details please visit wwwmscapexcom

Delivers two products Modeler and Structures + SmartMidsurfacetrade

Adams 2015 The Adams 2015 release delivers new functionality and major enhancements in many areas especially for AdamsCar Automotive engineers will benefit from new out-of-the-box customized solutions for model setup and vehicle event simulations The new features also give users the ability to create higher fidelity subsystems in their vehicle models Highlights of the release include

Extends Vehicle Simulation Scope for Automotive Engineers

The 2015 product release lineup delivers new event simulations for vehicle modeling coupled physics extended material modeling methods an all-new release of MSC Apex and a range of advanced engineering simulation technologies for streamlining the analysis workflow In addition to the releases mentioned below please expect later this year to see new 2015 releases of Marc MSC Nastran amp Patran SimManager and additional releases of Digimat Simufact and Actran New Release Highlights

Higher Fidelity Modelingbull AdamsMachinery Compatibility in AdamsCar - High fidelity

gear and motor modeling in car amp drivelinebull Nonlinear FE Part Support for AdamsCar ndash Geometric

nonlinearity for vehicle subsystems modeling and simulationbull Adams-Marc Co-simulation Enhancements ndash Easier and faster

Multibody Dynamics-Nonlinear FEA Integrationbull New Vehicle Database ndash Provides availability of key vehicle types

out-of-the-box

New Vehicle Eventsbull Full-vehicle Suspension Parameter Measurement Machine

(SPMM) - Tune suspension parameters for desired vehicle behavior without costly iteration with physical prototypes

bull Static Vehicle Characteristics (SVC) ndash Computes and reports key metrics of the vehicle at static equilibrium

bull Tandem Axle Suspension Analysis (TASA) ndash Delivers support for tuning of multi-axle architectures

For details please visit wwwmscsoftwarecomproductadams

Volume V - Summer 2015 | 7

Digimat 60

Material Databanks

MaterialCenter 2015

This latest Digimat 60 release brings a series of new features and improvements for modeling and analyzing composite materials from Short Fiber Reinforced Plastics (SFRP) to Discontinuous Fiber Composites (DFC) and Continuous Fiber Reinforced Composites (CFRP)

The new release also introduces Digimat-VA a unique software solution dedicated to accurate virtual characterization of CFRPs to dramatically reduce the cost and time associated with material characterization and qualification Digimat-VA which stands for Virtual Allowables offers a dedicated integrated workflow starting with easy and efficient creation of advanced multi-scale material models (including micro-level variability and progressive failure) FEA simulations of common test coupons and automatic post-processing for computing mean strength and AB-basis values

Any engineer concerned with characterizing a new composite material exploring the design space or better understanding widespread mechanical properties will find in Digimat-VA a productive solution to save time and money

For details please visit wwwe-xstreamcom

The MSC Material Databanks are collections of technical materials information in electronic format The databanks are developed and maintained through MSCrsquos partnerships with premier sources of materials information They provide a comprehensive source of material property data for use by engineers for design and analysis Benefits include bull Easy access to high-quality reliable material data from around the world to improve team efficiency and information workflow bull Improved quality and consistency with engineering data derived from a single sourcebull Reduced transcription errors with electronic data transferbull Increased accuracy of predictive analysis product design and simulation using certified material data records for CAD CAE

or PLM software

For details please visit wwwmscsoftwarecom

MaterialCenter 2015 is an out-of-the-box Material Process and Data Lifecycle Management solution with direct integration into many of the CAE pre- and post-processing tools commonly

used by engineers The integration provides direct support to retrieve a material model from MaterialCenter without leaving the native CAE pre- and post-processing application

MaterialCenter 2015 also enables users to create and edit material data directly from the browser environment Along with MaterialCenterrsquos Excel integration this provides a completely traceable system to ensure users are aware of all the modifications made to the data

MaterialCenter is the single point of entry for all of your materials related activities including physical test data entry and reduction multi-scale materials modeling approval workflow and the export of simulation ready data to analysis

For details please visit wwwmscsoftwarecomproductmaterialcenter

The material modeling platform for simulating a range of composites

Secure reliable and fast access to material data

Delivers material data integration and ease of use to dramatically improve engineering simulation workflows

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 3: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

9

11

13

14

TABLE OF CONTENTS

EDITOR LETTER

1Reaching the Apex

LETTER FROM THE CEO

3Simulating the Complete Engineering Process

MSC IN THE NEWS

4Simulation News amp Media Coverage

PRODUCT NEWS IN-BRIEF

62015 MSC New Product Releases

CO-SIMULATION SPOTLIGHT

8Noise Prediction of Moving MechanismsCo-Simulation Feature

10Evaluating Suspension Components Earlier in DesignVolvo Car

12System Analysis 15X Faster with Co-SimulationLitens Automotive

14Tackling Conflicting Performance Requirements Ford Motor Company

16Simulations Give Insight into Bedsore ProblemsCEI

22FEATURE STORY

Volume V - Summer 2015 | 4

3228 36

TECH TIPS

18Marc Defining Axis of Rotation of a Rigid BodyJoe Satkunananthan MSC Software

19Patran Useful Tools for Contact AnalysisChristian Aparicio MSC Software

20Adams The New ANCF Object FE_PartMaziar Rostamian MSC Software

PARTNER SHOWCASE

30Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc and SimManagerVCollab

SPECIAL SPOTLIGHT

32Simufact Welcome to the MSC FamilyVolker Mensing Simufact

FEATURE STORY

22MSC Apex Latest Release Delivers Dramatic Time-Savings in Mid-Surface Modeling

23Accelerated Mid-Surface Model Construction Workflow

24Analyzing Design Modifications FasterTLG Aerospace

25From Two Days to One HourDynetics

26Aero Supplier Achieves Dramatic Time Savings DEMA

28The Award-WinningMSC Apex

34Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntel

362015 Simulating Reality Contest Winners

39MSC Learning Centerrsquos e-LearningChristopher Anderson MSC Software

CUSTOMER SPOTLIGHT

40Simulating Complex Package Folding ProcedureIIT

UNIVERSITY amp RESEARCH

42Adams Curriculum Kit 2nd Edition is Here

by LESLIE BODNAR Executive Editor

Executive Editor

Leslie Bodnar lesliebodnarmscsoftwarecom

EditorGraphic Designer

Marina Carpenter marinacarpentermscsoftwarecom

Assistant Editors Graphics Contributors

Daryen Thompson

daryenthompsonmscsoftwarecom

Jennifer Betonio

jenniferbetoniomscsoftwarecom

MSC Software Corporation

4675 MacArthur Court Suite 900

Newport Beach CA 92660

7145408900

wwwmscsoftwarecom

Volume V - Summer 2015 | 1

Reaching the top and pursuing greatness in the application of engineering simulation throughout the stages of new product development and into design validation is what we will always strive to help engineers do

EDITOR LETTER

Reaching the ApexIs modeling and simulation finally reaching higher levels of usability accuracy and efficiency

Engineers are telling us yes In fact it is

In this issue we introduce new technology that is already pushing the envelope by creating dramatic time savings for engineers involved in the initial stages of the analysis process - specifically geometry repair modeling and meshing These mundane and repetitive tasks are where our customers tell us they simply need a new approach a better one

Our answer ndash MSC Apex

And this is just the beginning of whatrsquos to come

Already in its fourth release MSC Apex is producing real time savings for companies like TLG Aerospace DEMA and Dynetics Technical Services

On page 24 TLG Aerospace engineers describe how they were able to reduce geometry cleanup and meshing time by 75 While DEMA engineers were able to reduce the time required to analyze their design by 60 See page 26

Also included in this issue is a dedicated Co-Simulation Spotlight

Beginning on page 8 we introduce five stories each describing different methods for applying co-simulation such that engineers are now able to test more scenarios with higher fidelity and better accuracy than ever before through virtual testing

Integration of simulation technologies also cuts development time and drives rapid innovation in products For example Volvo Car is coupling multibody dynamics and nonlinear FEA to design lighter suspension systems and look at more design alternatives See their story on page 10 Litens Automotive is able to achieve a 90 reduction in computation time using the same approach See page 12

The automotive and machinery industries arenrsquot the only ones benefiting from advancements in co-simulation technology On page 16 see how itrsquos revealing hidden insights into bedsore problems for hospital equipment manufacturers

Reaching the top and pursuing greatness in the application of engineering simulation throughout the stages of new product development and into design validation is what we will always strive to help engineers do

Thank you to everyone who shared their story with us

Sincerely

REALITYsimulating

2015 USER CONFERENCES

For more information visit wwwmscsoftwarecom

Beijing ChinaMay 27

Xian ChinaMay 29

Tokyo Japan June 4

Paris FranceJune 10-11

Brno Czech RepublicJune 10-11

Istanbul TurkeyJune 11-12

Gothenburg SwedenJune 15

Munich Germany June 16-17

Napoli ItalyJuly 10

Queretaro MexicoAugust 18

Pune IndiaSeptember 4

Michigan USASeptember 16-17

Tampere FinlandSeptember 22

Moscow Russia October 7-8

Budapest HungaryOctober 8

Bologna ItalyOctober 14

Rotterdam NetherlandsOctober 15

BelgiumOctober 15

Torino ItalyNovember 11

Madrid SpainOctober

Pretoria South AfricaMarch 17 2016

Simulating Reality Delivering Certainty

Volume V - Summer 2015 | 3

by DOMINIC GALLELLO President amp CEO

MSC Software

LETTER FROM THE CEO

Simulating the Complete Engineering Process

A few years ago I attended a global leadership conference where the attendees on the opening night sat right in the middle of the Los Angeles Symphony Orchestra

They powerfully demonstrated the sounds that an orchestra would make if they were not working well together It was not good Finally the conductor took control of all the sections and to no surprise the music was fantastic If you think about the number of simulations that take place in a product development process it is really not much different If one of the members of the simulation orchestra delivers great results but they are alone and disconnected from the rest of the development process it is pretty clear that the results will not be optimal

Over the past few years we have been assembling the major sections of the simulation orchestra to simulate the complete engineering process

bull Materials ndash The design of new materials which reduce weight and provide same or better structural integrity with reduced part count materials that have better acoustics properties etc is becoming more and more critical This can be for materials of chopped fiber and continuous fiber composites as well as metal which is still the predominant material for cars trains and planes Design testing and management of new materials should be a natural part of the design process not relegated to just a ldquospecial fewrdquo We enable engineers to use the design variables of new advanced materials with certainty as a natural part of their design process

bull Fabrication ndash As the materials are chosen they need to be formed into parts Forming forging and other fabrication processes are done by a huge number of companies Forming simulation we have done before but annealing rolling curing 3D printing and general simulation of fabrication is something new and offers our customers the ability to use simulation to explore the impact of fabrication on the materials behaviors and the robustness of their designs in the face of realizable material variability Support the simulation of the as-manufactured spatial property variation to enable partssystems designers to design to robust manufactured parts with minimal margins Enable the fabrication engineering departments to decide on the best ways to work the material to obtain the design targeted properties

bull Parts ndash The ability to quickly model and shape parts for simulation that runs the first time has been difficult to achieve over the years And now as light-weighting is driving engineers to refine their parts designs and 3D printing and other fabrication methods are opening new design options it is even more critical to enable engineers to design the parts It is no longer enough to validate that the part meets its operational criteria

Make simulation tools easier to use and tie them more closely to the geometrical design parameters Enable the easy exploration of fabrication methods in the simulation of parts behaviors

bull Assembly ndashIdealized parts from the traditional design process donrsquot always behave the way you want after being fabricated and then joined to an assembly Welding riveting annealing and spatial variations from strain hardening and forming of steel and aluminum change the characteristics of the subsystems and systems and this cannot be ignored The joining process is another very important input into the design process to understand overall system behavior and how to exploit it in the design of parts and in the design of the assembly process itself

bull Systems ndash Getting the system model just right gets more and more challenging Lightweighting acoustical optimization energy management stability augmentation of the dynamic behavior and more and more specialized load cases coupled with a need to minimize the use of margins of safety to create certainty in the design creates a seemingly endless back and forth between the system model and the myriad of part models The reduction of just one loads cycle has incredibly positive time and cost impact on the overall development process Enable the systems model and its criteria to be visible throughout the design process Simplify the exchange of systems and parts behaviors and properties through the supply chain

All five pieces of the process are now in place With the building blocks laid down it offers us incredible opportunities to assist our customers to accelerate not only each piece of the process but also to exploit even greater design improvements by simulating the materials to systems processes We look forward to working with you to realize the full potential

4 | MSC Software

MSC IN THE NEWS

More people are living side-by-side with their appliances in smaller spaces so they want quieter machines but not completely silent machines They want enough sound to confirm the refrigerator is working or the washing machine has completed its cycle but no more At the same time that engineers are trying to strike that balance government agencies are mandating greater energy efficiency and ldquoend of liferdquo design that minimizes waste and maximizes re-use Throw cost style and size into the mix and engineers face a tangle of conflicting priorities Acoustic simulation can resolve that conflict by giving engineers insight for developing products with appropriate sound profiles while balancing other design considerations Integrating acoustic simulation technology into their design processes provides manufacturers with the insight necessary to know where the balance between consumer preference and government restrictions lies They donrsquot need the resources of a multinational corporation to do it They just need to know that they have options for understanding their productsrsquo acoustic behaviors without raising their costs

Acoustic Simulation Software Helps Appliance Engineers Meet Demands Appliance Design

httpbitly1ddtJRj

Lugging is a familiar ndash and unwelcome ndash challenge that symbolizes the tension between fuel economy and noise vibration and harshness (NVH) in motor vehicle design today Lugging occurs when a vehicle is operating at a high gear and a low engine speed ndash below 2000 RPM ndash and the driver hits the accelerator Engineers can adjust the vehiclersquos transmission to accelerate smoothly in high gear ndash a process called ldquoslippingrdquo ndash but doing so reduces the carrsquos fuel economy Therein lies the conflict Consumers want the smoother rides that slipping the transmission yields but automotive engineers are under enormous pressure to improve fuel efficiency to meet ever-stricter government mileage requirements Fordrsquos solution came through a combination of simulation and modeling technology and an open standard for co-simulation called Functional Mock-Up Interface (FMI) Ford created detailed 3D models of the drivetrain and the entire vehicle in MSC Softwarersquos Adams multi-body dynamics software Simulation results demonstrated that a slip of 40rpm slip was the optimal trade-off between NVH and fuel economy Simulation will help engineers develop vehicles that deliver the comfort and performance required to appeal to customers and the efficiency to meet increasingly stringent fuel economy standards

Ford Applies New Simulation Technology to Solve ChallengesDesign World

httpbitly1GizEzv

In February 2015 MSC Software acquired Simufact creators of metal forming and joining simulation software The software is a popular nonlinear CAE Tool used by the automotive OEM aerospace and machine part industries The tool is designed to reduce the trial and error associated with manufacturing a product on the shop floor In fact some Simufact customers have reported that they have been able to cut their physical testing in half and reduce the cycle time of a new part to a single week when using the software For MSC users however Simufact will help to complete the simulation process chain This will give engineers the ability to simplify the assessments of their ldquoas manufacturedrdquo designs

Nonlinear Forming amp Welding Simulation Brings ldquoAs Manufacturedrdquo Data to MSCEngineeringcom

httpbitly1AL3dFy

Simulation News amp Media Coverage

Volume V - Summer 2015 | 5

Software that is easier to use allows engineers more time to focus on simulation and analysis of the data rather than trying to adapt to new software learn proprietary coding languages or the worrying about how to map algorithms to the latest GPU or accelerator technology For instance aircraft noise has become a major concern and in some cases is an obstacle to growth in air transport as numbers of airports place restrictions on the amount of noise that can be generated by an aircraft Designers and engineers must work hard to reduce the noise of jet engines by placing acoustic liners in the nacelle a housing that holds engines or equipment on an aircraft to minimize the fan noise radiated from the engine One example of the use of MSC software for acoustic simulation looked at the use of nacelle liners on Airbus aircraft The company evaluated several different shapes and materials to understand the best performance Airbus found that it could dramatically reduce the time required to design and evaluate acoustic liners by moving to a simulation-based process using Actran acoustic simulation software developed by Free Field Technologies (FFT) a subsidiary of MSC

Simplifying SimulationScientific Computing World

httpbitly1JSrlcP

A new generation of materials management technology will open a window on lighter more efficient vehicles Composites reinforced plastics and lightweight steel and aluminum are being deployed across the automotive industry at record rates to improve fuel efficiency Automotive OEMs are integrating new materials into parts and assemblies in existing designs and developing completely reimagined platforms around them such as the BMW i3 and i8 New material systems provide significant benefits in specific weight and stiffness However because of their variability due to new manufacturing methods and engineersrsquo lack of familiarity with them new material systems demand significantly more and different types of testing ndash potentially increasing up-front cost This expansion of testing obligates OEMs to rethink how material systems are managed and how they must evolve to support wider uses of new materials Such a system must put materials in the forefront of engineering to use materials as an essential design variable to innovate The ability to model material properties quickly easily and in detail is essential to adopting new materials that will make automobiles lighter more fuel efficient and ultimately better for the environment

Materials to Reduce Vehicle WeightTodayrsquos Motor Vehicles

httpbitly1S4iudL

In February 2015 the United States Marine Corps put some of its engineers through an intensive nine-day training course on Adams In less than two weeks the students realized that learning Adams could put them on equal footing with engineers in the private sector Adamsrsquo powerful analysis capabilities are giving the USMC the ability to start bringing engineering work back in-house allowing them to quickly and accurately analyze any vehicle mishaps that may occur

Class Gives United States Marine Corps Engineers New Analytical Tool Defense Video amp Imagery Distribution System

httpbitly1PPUK9i

6 | MSC Software

PRODUCT NEWS IN-BRIEF

2015 New Product Releases

MSC Apex Diamond Python

The latest release of MSC Apex enhances the engineerrsquos workflow and daily productivity with many innovative modeling and analysis capabilities The MSC Apex Diamond Python release introduces

bull The fourth release of MSC Apex Modeler - A CAE Specific direct modeling and meshing solution that streamlines CAD clean-up simplification and meshing workflow

bull The second release of MSC Apex Structures - An add-on to MSC Apex Modeler which now expands MSC Apex to a fully integrated and generative structural analysis solution

bull New incremental Mid-surface modeling workflow (SmartMidsurface trade) for dramatic time savings

Diamond Python delivers a solver integrated solution for interactive and incremental structural analysis Modeling validating solving and exploring designs has never been this efficient and easy MSC Apex helps users to dramatically reduce the amount of time that it takes to build and validate models a task that does not add any value to the design process This frees users to focus on delivering not just acceptable designs but ones that are optimal - in an environment that is fun to use

For details please visit wwwmscapexcom

Delivers two products Modeler and Structures + SmartMidsurfacetrade

Adams 2015 The Adams 2015 release delivers new functionality and major enhancements in many areas especially for AdamsCar Automotive engineers will benefit from new out-of-the-box customized solutions for model setup and vehicle event simulations The new features also give users the ability to create higher fidelity subsystems in their vehicle models Highlights of the release include

Extends Vehicle Simulation Scope for Automotive Engineers

The 2015 product release lineup delivers new event simulations for vehicle modeling coupled physics extended material modeling methods an all-new release of MSC Apex and a range of advanced engineering simulation technologies for streamlining the analysis workflow In addition to the releases mentioned below please expect later this year to see new 2015 releases of Marc MSC Nastran amp Patran SimManager and additional releases of Digimat Simufact and Actran New Release Highlights

Higher Fidelity Modelingbull AdamsMachinery Compatibility in AdamsCar - High fidelity

gear and motor modeling in car amp drivelinebull Nonlinear FE Part Support for AdamsCar ndash Geometric

nonlinearity for vehicle subsystems modeling and simulationbull Adams-Marc Co-simulation Enhancements ndash Easier and faster

Multibody Dynamics-Nonlinear FEA Integrationbull New Vehicle Database ndash Provides availability of key vehicle types

out-of-the-box

New Vehicle Eventsbull Full-vehicle Suspension Parameter Measurement Machine

(SPMM) - Tune suspension parameters for desired vehicle behavior without costly iteration with physical prototypes

bull Static Vehicle Characteristics (SVC) ndash Computes and reports key metrics of the vehicle at static equilibrium

bull Tandem Axle Suspension Analysis (TASA) ndash Delivers support for tuning of multi-axle architectures

For details please visit wwwmscsoftwarecomproductadams

Volume V - Summer 2015 | 7

Digimat 60

Material Databanks

MaterialCenter 2015

This latest Digimat 60 release brings a series of new features and improvements for modeling and analyzing composite materials from Short Fiber Reinforced Plastics (SFRP) to Discontinuous Fiber Composites (DFC) and Continuous Fiber Reinforced Composites (CFRP)

The new release also introduces Digimat-VA a unique software solution dedicated to accurate virtual characterization of CFRPs to dramatically reduce the cost and time associated with material characterization and qualification Digimat-VA which stands for Virtual Allowables offers a dedicated integrated workflow starting with easy and efficient creation of advanced multi-scale material models (including micro-level variability and progressive failure) FEA simulations of common test coupons and automatic post-processing for computing mean strength and AB-basis values

Any engineer concerned with characterizing a new composite material exploring the design space or better understanding widespread mechanical properties will find in Digimat-VA a productive solution to save time and money

For details please visit wwwe-xstreamcom

The MSC Material Databanks are collections of technical materials information in electronic format The databanks are developed and maintained through MSCrsquos partnerships with premier sources of materials information They provide a comprehensive source of material property data for use by engineers for design and analysis Benefits include bull Easy access to high-quality reliable material data from around the world to improve team efficiency and information workflow bull Improved quality and consistency with engineering data derived from a single sourcebull Reduced transcription errors with electronic data transferbull Increased accuracy of predictive analysis product design and simulation using certified material data records for CAD CAE

or PLM software

For details please visit wwwmscsoftwarecom

MaterialCenter 2015 is an out-of-the-box Material Process and Data Lifecycle Management solution with direct integration into many of the CAE pre- and post-processing tools commonly

used by engineers The integration provides direct support to retrieve a material model from MaterialCenter without leaving the native CAE pre- and post-processing application

MaterialCenter 2015 also enables users to create and edit material data directly from the browser environment Along with MaterialCenterrsquos Excel integration this provides a completely traceable system to ensure users are aware of all the modifications made to the data

MaterialCenter is the single point of entry for all of your materials related activities including physical test data entry and reduction multi-scale materials modeling approval workflow and the export of simulation ready data to analysis

For details please visit wwwmscsoftwarecomproductmaterialcenter

The material modeling platform for simulating a range of composites

Secure reliable and fast access to material data

Delivers material data integration and ease of use to dramatically improve engineering simulation workflows

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 4: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Volume V - Summer 2015 | 4

3228 36

TECH TIPS

18Marc Defining Axis of Rotation of a Rigid BodyJoe Satkunananthan MSC Software

19Patran Useful Tools for Contact AnalysisChristian Aparicio MSC Software

20Adams The New ANCF Object FE_PartMaziar Rostamian MSC Software

PARTNER SHOWCASE

30Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc and SimManagerVCollab

SPECIAL SPOTLIGHT

32Simufact Welcome to the MSC FamilyVolker Mensing Simufact

FEATURE STORY

22MSC Apex Latest Release Delivers Dramatic Time-Savings in Mid-Surface Modeling

23Accelerated Mid-Surface Model Construction Workflow

24Analyzing Design Modifications FasterTLG Aerospace

25From Two Days to One HourDynetics

26Aero Supplier Achieves Dramatic Time Savings DEMA

28The Award-WinningMSC Apex

34Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntel

362015 Simulating Reality Contest Winners

39MSC Learning Centerrsquos e-LearningChristopher Anderson MSC Software

CUSTOMER SPOTLIGHT

40Simulating Complex Package Folding ProcedureIIT

UNIVERSITY amp RESEARCH

42Adams Curriculum Kit 2nd Edition is Here

by LESLIE BODNAR Executive Editor

Executive Editor

Leslie Bodnar lesliebodnarmscsoftwarecom

EditorGraphic Designer

Marina Carpenter marinacarpentermscsoftwarecom

Assistant Editors Graphics Contributors

Daryen Thompson

daryenthompsonmscsoftwarecom

Jennifer Betonio

jenniferbetoniomscsoftwarecom

MSC Software Corporation

4675 MacArthur Court Suite 900

Newport Beach CA 92660

7145408900

wwwmscsoftwarecom

Volume V - Summer 2015 | 1

Reaching the top and pursuing greatness in the application of engineering simulation throughout the stages of new product development and into design validation is what we will always strive to help engineers do

EDITOR LETTER

Reaching the ApexIs modeling and simulation finally reaching higher levels of usability accuracy and efficiency

Engineers are telling us yes In fact it is

In this issue we introduce new technology that is already pushing the envelope by creating dramatic time savings for engineers involved in the initial stages of the analysis process - specifically geometry repair modeling and meshing These mundane and repetitive tasks are where our customers tell us they simply need a new approach a better one

Our answer ndash MSC Apex

And this is just the beginning of whatrsquos to come

Already in its fourth release MSC Apex is producing real time savings for companies like TLG Aerospace DEMA and Dynetics Technical Services

On page 24 TLG Aerospace engineers describe how they were able to reduce geometry cleanup and meshing time by 75 While DEMA engineers were able to reduce the time required to analyze their design by 60 See page 26

Also included in this issue is a dedicated Co-Simulation Spotlight

Beginning on page 8 we introduce five stories each describing different methods for applying co-simulation such that engineers are now able to test more scenarios with higher fidelity and better accuracy than ever before through virtual testing

Integration of simulation technologies also cuts development time and drives rapid innovation in products For example Volvo Car is coupling multibody dynamics and nonlinear FEA to design lighter suspension systems and look at more design alternatives See their story on page 10 Litens Automotive is able to achieve a 90 reduction in computation time using the same approach See page 12

The automotive and machinery industries arenrsquot the only ones benefiting from advancements in co-simulation technology On page 16 see how itrsquos revealing hidden insights into bedsore problems for hospital equipment manufacturers

Reaching the top and pursuing greatness in the application of engineering simulation throughout the stages of new product development and into design validation is what we will always strive to help engineers do

Thank you to everyone who shared their story with us

Sincerely

REALITYsimulating

2015 USER CONFERENCES

For more information visit wwwmscsoftwarecom

Beijing ChinaMay 27

Xian ChinaMay 29

Tokyo Japan June 4

Paris FranceJune 10-11

Brno Czech RepublicJune 10-11

Istanbul TurkeyJune 11-12

Gothenburg SwedenJune 15

Munich Germany June 16-17

Napoli ItalyJuly 10

Queretaro MexicoAugust 18

Pune IndiaSeptember 4

Michigan USASeptember 16-17

Tampere FinlandSeptember 22

Moscow Russia October 7-8

Budapest HungaryOctober 8

Bologna ItalyOctober 14

Rotterdam NetherlandsOctober 15

BelgiumOctober 15

Torino ItalyNovember 11

Madrid SpainOctober

Pretoria South AfricaMarch 17 2016

Simulating Reality Delivering Certainty

Volume V - Summer 2015 | 3

by DOMINIC GALLELLO President amp CEO

MSC Software

LETTER FROM THE CEO

Simulating the Complete Engineering Process

A few years ago I attended a global leadership conference where the attendees on the opening night sat right in the middle of the Los Angeles Symphony Orchestra

They powerfully demonstrated the sounds that an orchestra would make if they were not working well together It was not good Finally the conductor took control of all the sections and to no surprise the music was fantastic If you think about the number of simulations that take place in a product development process it is really not much different If one of the members of the simulation orchestra delivers great results but they are alone and disconnected from the rest of the development process it is pretty clear that the results will not be optimal

Over the past few years we have been assembling the major sections of the simulation orchestra to simulate the complete engineering process

bull Materials ndash The design of new materials which reduce weight and provide same or better structural integrity with reduced part count materials that have better acoustics properties etc is becoming more and more critical This can be for materials of chopped fiber and continuous fiber composites as well as metal which is still the predominant material for cars trains and planes Design testing and management of new materials should be a natural part of the design process not relegated to just a ldquospecial fewrdquo We enable engineers to use the design variables of new advanced materials with certainty as a natural part of their design process

bull Fabrication ndash As the materials are chosen they need to be formed into parts Forming forging and other fabrication processes are done by a huge number of companies Forming simulation we have done before but annealing rolling curing 3D printing and general simulation of fabrication is something new and offers our customers the ability to use simulation to explore the impact of fabrication on the materials behaviors and the robustness of their designs in the face of realizable material variability Support the simulation of the as-manufactured spatial property variation to enable partssystems designers to design to robust manufactured parts with minimal margins Enable the fabrication engineering departments to decide on the best ways to work the material to obtain the design targeted properties

bull Parts ndash The ability to quickly model and shape parts for simulation that runs the first time has been difficult to achieve over the years And now as light-weighting is driving engineers to refine their parts designs and 3D printing and other fabrication methods are opening new design options it is even more critical to enable engineers to design the parts It is no longer enough to validate that the part meets its operational criteria

Make simulation tools easier to use and tie them more closely to the geometrical design parameters Enable the easy exploration of fabrication methods in the simulation of parts behaviors

bull Assembly ndashIdealized parts from the traditional design process donrsquot always behave the way you want after being fabricated and then joined to an assembly Welding riveting annealing and spatial variations from strain hardening and forming of steel and aluminum change the characteristics of the subsystems and systems and this cannot be ignored The joining process is another very important input into the design process to understand overall system behavior and how to exploit it in the design of parts and in the design of the assembly process itself

bull Systems ndash Getting the system model just right gets more and more challenging Lightweighting acoustical optimization energy management stability augmentation of the dynamic behavior and more and more specialized load cases coupled with a need to minimize the use of margins of safety to create certainty in the design creates a seemingly endless back and forth between the system model and the myriad of part models The reduction of just one loads cycle has incredibly positive time and cost impact on the overall development process Enable the systems model and its criteria to be visible throughout the design process Simplify the exchange of systems and parts behaviors and properties through the supply chain

All five pieces of the process are now in place With the building blocks laid down it offers us incredible opportunities to assist our customers to accelerate not only each piece of the process but also to exploit even greater design improvements by simulating the materials to systems processes We look forward to working with you to realize the full potential

4 | MSC Software

MSC IN THE NEWS

More people are living side-by-side with their appliances in smaller spaces so they want quieter machines but not completely silent machines They want enough sound to confirm the refrigerator is working or the washing machine has completed its cycle but no more At the same time that engineers are trying to strike that balance government agencies are mandating greater energy efficiency and ldquoend of liferdquo design that minimizes waste and maximizes re-use Throw cost style and size into the mix and engineers face a tangle of conflicting priorities Acoustic simulation can resolve that conflict by giving engineers insight for developing products with appropriate sound profiles while balancing other design considerations Integrating acoustic simulation technology into their design processes provides manufacturers with the insight necessary to know where the balance between consumer preference and government restrictions lies They donrsquot need the resources of a multinational corporation to do it They just need to know that they have options for understanding their productsrsquo acoustic behaviors without raising their costs

Acoustic Simulation Software Helps Appliance Engineers Meet Demands Appliance Design

httpbitly1ddtJRj

Lugging is a familiar ndash and unwelcome ndash challenge that symbolizes the tension between fuel economy and noise vibration and harshness (NVH) in motor vehicle design today Lugging occurs when a vehicle is operating at a high gear and a low engine speed ndash below 2000 RPM ndash and the driver hits the accelerator Engineers can adjust the vehiclersquos transmission to accelerate smoothly in high gear ndash a process called ldquoslippingrdquo ndash but doing so reduces the carrsquos fuel economy Therein lies the conflict Consumers want the smoother rides that slipping the transmission yields but automotive engineers are under enormous pressure to improve fuel efficiency to meet ever-stricter government mileage requirements Fordrsquos solution came through a combination of simulation and modeling technology and an open standard for co-simulation called Functional Mock-Up Interface (FMI) Ford created detailed 3D models of the drivetrain and the entire vehicle in MSC Softwarersquos Adams multi-body dynamics software Simulation results demonstrated that a slip of 40rpm slip was the optimal trade-off between NVH and fuel economy Simulation will help engineers develop vehicles that deliver the comfort and performance required to appeal to customers and the efficiency to meet increasingly stringent fuel economy standards

Ford Applies New Simulation Technology to Solve ChallengesDesign World

httpbitly1GizEzv

In February 2015 MSC Software acquired Simufact creators of metal forming and joining simulation software The software is a popular nonlinear CAE Tool used by the automotive OEM aerospace and machine part industries The tool is designed to reduce the trial and error associated with manufacturing a product on the shop floor In fact some Simufact customers have reported that they have been able to cut their physical testing in half and reduce the cycle time of a new part to a single week when using the software For MSC users however Simufact will help to complete the simulation process chain This will give engineers the ability to simplify the assessments of their ldquoas manufacturedrdquo designs

Nonlinear Forming amp Welding Simulation Brings ldquoAs Manufacturedrdquo Data to MSCEngineeringcom

httpbitly1AL3dFy

Simulation News amp Media Coverage

Volume V - Summer 2015 | 5

Software that is easier to use allows engineers more time to focus on simulation and analysis of the data rather than trying to adapt to new software learn proprietary coding languages or the worrying about how to map algorithms to the latest GPU or accelerator technology For instance aircraft noise has become a major concern and in some cases is an obstacle to growth in air transport as numbers of airports place restrictions on the amount of noise that can be generated by an aircraft Designers and engineers must work hard to reduce the noise of jet engines by placing acoustic liners in the nacelle a housing that holds engines or equipment on an aircraft to minimize the fan noise radiated from the engine One example of the use of MSC software for acoustic simulation looked at the use of nacelle liners on Airbus aircraft The company evaluated several different shapes and materials to understand the best performance Airbus found that it could dramatically reduce the time required to design and evaluate acoustic liners by moving to a simulation-based process using Actran acoustic simulation software developed by Free Field Technologies (FFT) a subsidiary of MSC

Simplifying SimulationScientific Computing World

httpbitly1JSrlcP

A new generation of materials management technology will open a window on lighter more efficient vehicles Composites reinforced plastics and lightweight steel and aluminum are being deployed across the automotive industry at record rates to improve fuel efficiency Automotive OEMs are integrating new materials into parts and assemblies in existing designs and developing completely reimagined platforms around them such as the BMW i3 and i8 New material systems provide significant benefits in specific weight and stiffness However because of their variability due to new manufacturing methods and engineersrsquo lack of familiarity with them new material systems demand significantly more and different types of testing ndash potentially increasing up-front cost This expansion of testing obligates OEMs to rethink how material systems are managed and how they must evolve to support wider uses of new materials Such a system must put materials in the forefront of engineering to use materials as an essential design variable to innovate The ability to model material properties quickly easily and in detail is essential to adopting new materials that will make automobiles lighter more fuel efficient and ultimately better for the environment

Materials to Reduce Vehicle WeightTodayrsquos Motor Vehicles

httpbitly1S4iudL

In February 2015 the United States Marine Corps put some of its engineers through an intensive nine-day training course on Adams In less than two weeks the students realized that learning Adams could put them on equal footing with engineers in the private sector Adamsrsquo powerful analysis capabilities are giving the USMC the ability to start bringing engineering work back in-house allowing them to quickly and accurately analyze any vehicle mishaps that may occur

Class Gives United States Marine Corps Engineers New Analytical Tool Defense Video amp Imagery Distribution System

httpbitly1PPUK9i

6 | MSC Software

PRODUCT NEWS IN-BRIEF

2015 New Product Releases

MSC Apex Diamond Python

The latest release of MSC Apex enhances the engineerrsquos workflow and daily productivity with many innovative modeling and analysis capabilities The MSC Apex Diamond Python release introduces

bull The fourth release of MSC Apex Modeler - A CAE Specific direct modeling and meshing solution that streamlines CAD clean-up simplification and meshing workflow

bull The second release of MSC Apex Structures - An add-on to MSC Apex Modeler which now expands MSC Apex to a fully integrated and generative structural analysis solution

bull New incremental Mid-surface modeling workflow (SmartMidsurface trade) for dramatic time savings

Diamond Python delivers a solver integrated solution for interactive and incremental structural analysis Modeling validating solving and exploring designs has never been this efficient and easy MSC Apex helps users to dramatically reduce the amount of time that it takes to build and validate models a task that does not add any value to the design process This frees users to focus on delivering not just acceptable designs but ones that are optimal - in an environment that is fun to use

For details please visit wwwmscapexcom

Delivers two products Modeler and Structures + SmartMidsurfacetrade

Adams 2015 The Adams 2015 release delivers new functionality and major enhancements in many areas especially for AdamsCar Automotive engineers will benefit from new out-of-the-box customized solutions for model setup and vehicle event simulations The new features also give users the ability to create higher fidelity subsystems in their vehicle models Highlights of the release include

Extends Vehicle Simulation Scope for Automotive Engineers

The 2015 product release lineup delivers new event simulations for vehicle modeling coupled physics extended material modeling methods an all-new release of MSC Apex and a range of advanced engineering simulation technologies for streamlining the analysis workflow In addition to the releases mentioned below please expect later this year to see new 2015 releases of Marc MSC Nastran amp Patran SimManager and additional releases of Digimat Simufact and Actran New Release Highlights

Higher Fidelity Modelingbull AdamsMachinery Compatibility in AdamsCar - High fidelity

gear and motor modeling in car amp drivelinebull Nonlinear FE Part Support for AdamsCar ndash Geometric

nonlinearity for vehicle subsystems modeling and simulationbull Adams-Marc Co-simulation Enhancements ndash Easier and faster

Multibody Dynamics-Nonlinear FEA Integrationbull New Vehicle Database ndash Provides availability of key vehicle types

out-of-the-box

New Vehicle Eventsbull Full-vehicle Suspension Parameter Measurement Machine

(SPMM) - Tune suspension parameters for desired vehicle behavior without costly iteration with physical prototypes

bull Static Vehicle Characteristics (SVC) ndash Computes and reports key metrics of the vehicle at static equilibrium

bull Tandem Axle Suspension Analysis (TASA) ndash Delivers support for tuning of multi-axle architectures

For details please visit wwwmscsoftwarecomproductadams

Volume V - Summer 2015 | 7

Digimat 60

Material Databanks

MaterialCenter 2015

This latest Digimat 60 release brings a series of new features and improvements for modeling and analyzing composite materials from Short Fiber Reinforced Plastics (SFRP) to Discontinuous Fiber Composites (DFC) and Continuous Fiber Reinforced Composites (CFRP)

The new release also introduces Digimat-VA a unique software solution dedicated to accurate virtual characterization of CFRPs to dramatically reduce the cost and time associated with material characterization and qualification Digimat-VA which stands for Virtual Allowables offers a dedicated integrated workflow starting with easy and efficient creation of advanced multi-scale material models (including micro-level variability and progressive failure) FEA simulations of common test coupons and automatic post-processing for computing mean strength and AB-basis values

Any engineer concerned with characterizing a new composite material exploring the design space or better understanding widespread mechanical properties will find in Digimat-VA a productive solution to save time and money

For details please visit wwwe-xstreamcom

The MSC Material Databanks are collections of technical materials information in electronic format The databanks are developed and maintained through MSCrsquos partnerships with premier sources of materials information They provide a comprehensive source of material property data for use by engineers for design and analysis Benefits include bull Easy access to high-quality reliable material data from around the world to improve team efficiency and information workflow bull Improved quality and consistency with engineering data derived from a single sourcebull Reduced transcription errors with electronic data transferbull Increased accuracy of predictive analysis product design and simulation using certified material data records for CAD CAE

or PLM software

For details please visit wwwmscsoftwarecom

MaterialCenter 2015 is an out-of-the-box Material Process and Data Lifecycle Management solution with direct integration into many of the CAE pre- and post-processing tools commonly

used by engineers The integration provides direct support to retrieve a material model from MaterialCenter without leaving the native CAE pre- and post-processing application

MaterialCenter 2015 also enables users to create and edit material data directly from the browser environment Along with MaterialCenterrsquos Excel integration this provides a completely traceable system to ensure users are aware of all the modifications made to the data

MaterialCenter is the single point of entry for all of your materials related activities including physical test data entry and reduction multi-scale materials modeling approval workflow and the export of simulation ready data to analysis

For details please visit wwwmscsoftwarecomproductmaterialcenter

The material modeling platform for simulating a range of composites

Secure reliable and fast access to material data

Delivers material data integration and ease of use to dramatically improve engineering simulation workflows

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 5: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

by LESLIE BODNAR Executive Editor

Executive Editor

Leslie Bodnar lesliebodnarmscsoftwarecom

EditorGraphic Designer

Marina Carpenter marinacarpentermscsoftwarecom

Assistant Editors Graphics Contributors

Daryen Thompson

daryenthompsonmscsoftwarecom

Jennifer Betonio

jenniferbetoniomscsoftwarecom

MSC Software Corporation

4675 MacArthur Court Suite 900

Newport Beach CA 92660

7145408900

wwwmscsoftwarecom

Volume V - Summer 2015 | 1

Reaching the top and pursuing greatness in the application of engineering simulation throughout the stages of new product development and into design validation is what we will always strive to help engineers do

EDITOR LETTER

Reaching the ApexIs modeling and simulation finally reaching higher levels of usability accuracy and efficiency

Engineers are telling us yes In fact it is

In this issue we introduce new technology that is already pushing the envelope by creating dramatic time savings for engineers involved in the initial stages of the analysis process - specifically geometry repair modeling and meshing These mundane and repetitive tasks are where our customers tell us they simply need a new approach a better one

Our answer ndash MSC Apex

And this is just the beginning of whatrsquos to come

Already in its fourth release MSC Apex is producing real time savings for companies like TLG Aerospace DEMA and Dynetics Technical Services

On page 24 TLG Aerospace engineers describe how they were able to reduce geometry cleanup and meshing time by 75 While DEMA engineers were able to reduce the time required to analyze their design by 60 See page 26

Also included in this issue is a dedicated Co-Simulation Spotlight

Beginning on page 8 we introduce five stories each describing different methods for applying co-simulation such that engineers are now able to test more scenarios with higher fidelity and better accuracy than ever before through virtual testing

Integration of simulation technologies also cuts development time and drives rapid innovation in products For example Volvo Car is coupling multibody dynamics and nonlinear FEA to design lighter suspension systems and look at more design alternatives See their story on page 10 Litens Automotive is able to achieve a 90 reduction in computation time using the same approach See page 12

The automotive and machinery industries arenrsquot the only ones benefiting from advancements in co-simulation technology On page 16 see how itrsquos revealing hidden insights into bedsore problems for hospital equipment manufacturers

Reaching the top and pursuing greatness in the application of engineering simulation throughout the stages of new product development and into design validation is what we will always strive to help engineers do

Thank you to everyone who shared their story with us

Sincerely

REALITYsimulating

2015 USER CONFERENCES

For more information visit wwwmscsoftwarecom

Beijing ChinaMay 27

Xian ChinaMay 29

Tokyo Japan June 4

Paris FranceJune 10-11

Brno Czech RepublicJune 10-11

Istanbul TurkeyJune 11-12

Gothenburg SwedenJune 15

Munich Germany June 16-17

Napoli ItalyJuly 10

Queretaro MexicoAugust 18

Pune IndiaSeptember 4

Michigan USASeptember 16-17

Tampere FinlandSeptember 22

Moscow Russia October 7-8

Budapest HungaryOctober 8

Bologna ItalyOctober 14

Rotterdam NetherlandsOctober 15

BelgiumOctober 15

Torino ItalyNovember 11

Madrid SpainOctober

Pretoria South AfricaMarch 17 2016

Simulating Reality Delivering Certainty

Volume V - Summer 2015 | 3

by DOMINIC GALLELLO President amp CEO

MSC Software

LETTER FROM THE CEO

Simulating the Complete Engineering Process

A few years ago I attended a global leadership conference where the attendees on the opening night sat right in the middle of the Los Angeles Symphony Orchestra

They powerfully demonstrated the sounds that an orchestra would make if they were not working well together It was not good Finally the conductor took control of all the sections and to no surprise the music was fantastic If you think about the number of simulations that take place in a product development process it is really not much different If one of the members of the simulation orchestra delivers great results but they are alone and disconnected from the rest of the development process it is pretty clear that the results will not be optimal

Over the past few years we have been assembling the major sections of the simulation orchestra to simulate the complete engineering process

bull Materials ndash The design of new materials which reduce weight and provide same or better structural integrity with reduced part count materials that have better acoustics properties etc is becoming more and more critical This can be for materials of chopped fiber and continuous fiber composites as well as metal which is still the predominant material for cars trains and planes Design testing and management of new materials should be a natural part of the design process not relegated to just a ldquospecial fewrdquo We enable engineers to use the design variables of new advanced materials with certainty as a natural part of their design process

bull Fabrication ndash As the materials are chosen they need to be formed into parts Forming forging and other fabrication processes are done by a huge number of companies Forming simulation we have done before but annealing rolling curing 3D printing and general simulation of fabrication is something new and offers our customers the ability to use simulation to explore the impact of fabrication on the materials behaviors and the robustness of their designs in the face of realizable material variability Support the simulation of the as-manufactured spatial property variation to enable partssystems designers to design to robust manufactured parts with minimal margins Enable the fabrication engineering departments to decide on the best ways to work the material to obtain the design targeted properties

bull Parts ndash The ability to quickly model and shape parts for simulation that runs the first time has been difficult to achieve over the years And now as light-weighting is driving engineers to refine their parts designs and 3D printing and other fabrication methods are opening new design options it is even more critical to enable engineers to design the parts It is no longer enough to validate that the part meets its operational criteria

Make simulation tools easier to use and tie them more closely to the geometrical design parameters Enable the easy exploration of fabrication methods in the simulation of parts behaviors

bull Assembly ndashIdealized parts from the traditional design process donrsquot always behave the way you want after being fabricated and then joined to an assembly Welding riveting annealing and spatial variations from strain hardening and forming of steel and aluminum change the characteristics of the subsystems and systems and this cannot be ignored The joining process is another very important input into the design process to understand overall system behavior and how to exploit it in the design of parts and in the design of the assembly process itself

bull Systems ndash Getting the system model just right gets more and more challenging Lightweighting acoustical optimization energy management stability augmentation of the dynamic behavior and more and more specialized load cases coupled with a need to minimize the use of margins of safety to create certainty in the design creates a seemingly endless back and forth between the system model and the myriad of part models The reduction of just one loads cycle has incredibly positive time and cost impact on the overall development process Enable the systems model and its criteria to be visible throughout the design process Simplify the exchange of systems and parts behaviors and properties through the supply chain

All five pieces of the process are now in place With the building blocks laid down it offers us incredible opportunities to assist our customers to accelerate not only each piece of the process but also to exploit even greater design improvements by simulating the materials to systems processes We look forward to working with you to realize the full potential

4 | MSC Software

MSC IN THE NEWS

More people are living side-by-side with their appliances in smaller spaces so they want quieter machines but not completely silent machines They want enough sound to confirm the refrigerator is working or the washing machine has completed its cycle but no more At the same time that engineers are trying to strike that balance government agencies are mandating greater energy efficiency and ldquoend of liferdquo design that minimizes waste and maximizes re-use Throw cost style and size into the mix and engineers face a tangle of conflicting priorities Acoustic simulation can resolve that conflict by giving engineers insight for developing products with appropriate sound profiles while balancing other design considerations Integrating acoustic simulation technology into their design processes provides manufacturers with the insight necessary to know where the balance between consumer preference and government restrictions lies They donrsquot need the resources of a multinational corporation to do it They just need to know that they have options for understanding their productsrsquo acoustic behaviors without raising their costs

Acoustic Simulation Software Helps Appliance Engineers Meet Demands Appliance Design

httpbitly1ddtJRj

Lugging is a familiar ndash and unwelcome ndash challenge that symbolizes the tension between fuel economy and noise vibration and harshness (NVH) in motor vehicle design today Lugging occurs when a vehicle is operating at a high gear and a low engine speed ndash below 2000 RPM ndash and the driver hits the accelerator Engineers can adjust the vehiclersquos transmission to accelerate smoothly in high gear ndash a process called ldquoslippingrdquo ndash but doing so reduces the carrsquos fuel economy Therein lies the conflict Consumers want the smoother rides that slipping the transmission yields but automotive engineers are under enormous pressure to improve fuel efficiency to meet ever-stricter government mileage requirements Fordrsquos solution came through a combination of simulation and modeling technology and an open standard for co-simulation called Functional Mock-Up Interface (FMI) Ford created detailed 3D models of the drivetrain and the entire vehicle in MSC Softwarersquos Adams multi-body dynamics software Simulation results demonstrated that a slip of 40rpm slip was the optimal trade-off between NVH and fuel economy Simulation will help engineers develop vehicles that deliver the comfort and performance required to appeal to customers and the efficiency to meet increasingly stringent fuel economy standards

Ford Applies New Simulation Technology to Solve ChallengesDesign World

httpbitly1GizEzv

In February 2015 MSC Software acquired Simufact creators of metal forming and joining simulation software The software is a popular nonlinear CAE Tool used by the automotive OEM aerospace and machine part industries The tool is designed to reduce the trial and error associated with manufacturing a product on the shop floor In fact some Simufact customers have reported that they have been able to cut their physical testing in half and reduce the cycle time of a new part to a single week when using the software For MSC users however Simufact will help to complete the simulation process chain This will give engineers the ability to simplify the assessments of their ldquoas manufacturedrdquo designs

Nonlinear Forming amp Welding Simulation Brings ldquoAs Manufacturedrdquo Data to MSCEngineeringcom

httpbitly1AL3dFy

Simulation News amp Media Coverage

Volume V - Summer 2015 | 5

Software that is easier to use allows engineers more time to focus on simulation and analysis of the data rather than trying to adapt to new software learn proprietary coding languages or the worrying about how to map algorithms to the latest GPU or accelerator technology For instance aircraft noise has become a major concern and in some cases is an obstacle to growth in air transport as numbers of airports place restrictions on the amount of noise that can be generated by an aircraft Designers and engineers must work hard to reduce the noise of jet engines by placing acoustic liners in the nacelle a housing that holds engines or equipment on an aircraft to minimize the fan noise radiated from the engine One example of the use of MSC software for acoustic simulation looked at the use of nacelle liners on Airbus aircraft The company evaluated several different shapes and materials to understand the best performance Airbus found that it could dramatically reduce the time required to design and evaluate acoustic liners by moving to a simulation-based process using Actran acoustic simulation software developed by Free Field Technologies (FFT) a subsidiary of MSC

Simplifying SimulationScientific Computing World

httpbitly1JSrlcP

A new generation of materials management technology will open a window on lighter more efficient vehicles Composites reinforced plastics and lightweight steel and aluminum are being deployed across the automotive industry at record rates to improve fuel efficiency Automotive OEMs are integrating new materials into parts and assemblies in existing designs and developing completely reimagined platforms around them such as the BMW i3 and i8 New material systems provide significant benefits in specific weight and stiffness However because of their variability due to new manufacturing methods and engineersrsquo lack of familiarity with them new material systems demand significantly more and different types of testing ndash potentially increasing up-front cost This expansion of testing obligates OEMs to rethink how material systems are managed and how they must evolve to support wider uses of new materials Such a system must put materials in the forefront of engineering to use materials as an essential design variable to innovate The ability to model material properties quickly easily and in detail is essential to adopting new materials that will make automobiles lighter more fuel efficient and ultimately better for the environment

Materials to Reduce Vehicle WeightTodayrsquos Motor Vehicles

httpbitly1S4iudL

In February 2015 the United States Marine Corps put some of its engineers through an intensive nine-day training course on Adams In less than two weeks the students realized that learning Adams could put them on equal footing with engineers in the private sector Adamsrsquo powerful analysis capabilities are giving the USMC the ability to start bringing engineering work back in-house allowing them to quickly and accurately analyze any vehicle mishaps that may occur

Class Gives United States Marine Corps Engineers New Analytical Tool Defense Video amp Imagery Distribution System

httpbitly1PPUK9i

6 | MSC Software

PRODUCT NEWS IN-BRIEF

2015 New Product Releases

MSC Apex Diamond Python

The latest release of MSC Apex enhances the engineerrsquos workflow and daily productivity with many innovative modeling and analysis capabilities The MSC Apex Diamond Python release introduces

bull The fourth release of MSC Apex Modeler - A CAE Specific direct modeling and meshing solution that streamlines CAD clean-up simplification and meshing workflow

bull The second release of MSC Apex Structures - An add-on to MSC Apex Modeler which now expands MSC Apex to a fully integrated and generative structural analysis solution

bull New incremental Mid-surface modeling workflow (SmartMidsurface trade) for dramatic time savings

Diamond Python delivers a solver integrated solution for interactive and incremental structural analysis Modeling validating solving and exploring designs has never been this efficient and easy MSC Apex helps users to dramatically reduce the amount of time that it takes to build and validate models a task that does not add any value to the design process This frees users to focus on delivering not just acceptable designs but ones that are optimal - in an environment that is fun to use

For details please visit wwwmscapexcom

Delivers two products Modeler and Structures + SmartMidsurfacetrade

Adams 2015 The Adams 2015 release delivers new functionality and major enhancements in many areas especially for AdamsCar Automotive engineers will benefit from new out-of-the-box customized solutions for model setup and vehicle event simulations The new features also give users the ability to create higher fidelity subsystems in their vehicle models Highlights of the release include

Extends Vehicle Simulation Scope for Automotive Engineers

The 2015 product release lineup delivers new event simulations for vehicle modeling coupled physics extended material modeling methods an all-new release of MSC Apex and a range of advanced engineering simulation technologies for streamlining the analysis workflow In addition to the releases mentioned below please expect later this year to see new 2015 releases of Marc MSC Nastran amp Patran SimManager and additional releases of Digimat Simufact and Actran New Release Highlights

Higher Fidelity Modelingbull AdamsMachinery Compatibility in AdamsCar - High fidelity

gear and motor modeling in car amp drivelinebull Nonlinear FE Part Support for AdamsCar ndash Geometric

nonlinearity for vehicle subsystems modeling and simulationbull Adams-Marc Co-simulation Enhancements ndash Easier and faster

Multibody Dynamics-Nonlinear FEA Integrationbull New Vehicle Database ndash Provides availability of key vehicle types

out-of-the-box

New Vehicle Eventsbull Full-vehicle Suspension Parameter Measurement Machine

(SPMM) - Tune suspension parameters for desired vehicle behavior without costly iteration with physical prototypes

bull Static Vehicle Characteristics (SVC) ndash Computes and reports key metrics of the vehicle at static equilibrium

bull Tandem Axle Suspension Analysis (TASA) ndash Delivers support for tuning of multi-axle architectures

For details please visit wwwmscsoftwarecomproductadams

Volume V - Summer 2015 | 7

Digimat 60

Material Databanks

MaterialCenter 2015

This latest Digimat 60 release brings a series of new features and improvements for modeling and analyzing composite materials from Short Fiber Reinforced Plastics (SFRP) to Discontinuous Fiber Composites (DFC) and Continuous Fiber Reinforced Composites (CFRP)

The new release also introduces Digimat-VA a unique software solution dedicated to accurate virtual characterization of CFRPs to dramatically reduce the cost and time associated with material characterization and qualification Digimat-VA which stands for Virtual Allowables offers a dedicated integrated workflow starting with easy and efficient creation of advanced multi-scale material models (including micro-level variability and progressive failure) FEA simulations of common test coupons and automatic post-processing for computing mean strength and AB-basis values

Any engineer concerned with characterizing a new composite material exploring the design space or better understanding widespread mechanical properties will find in Digimat-VA a productive solution to save time and money

For details please visit wwwe-xstreamcom

The MSC Material Databanks are collections of technical materials information in electronic format The databanks are developed and maintained through MSCrsquos partnerships with premier sources of materials information They provide a comprehensive source of material property data for use by engineers for design and analysis Benefits include bull Easy access to high-quality reliable material data from around the world to improve team efficiency and information workflow bull Improved quality and consistency with engineering data derived from a single sourcebull Reduced transcription errors with electronic data transferbull Increased accuracy of predictive analysis product design and simulation using certified material data records for CAD CAE

or PLM software

For details please visit wwwmscsoftwarecom

MaterialCenter 2015 is an out-of-the-box Material Process and Data Lifecycle Management solution with direct integration into many of the CAE pre- and post-processing tools commonly

used by engineers The integration provides direct support to retrieve a material model from MaterialCenter without leaving the native CAE pre- and post-processing application

MaterialCenter 2015 also enables users to create and edit material data directly from the browser environment Along with MaterialCenterrsquos Excel integration this provides a completely traceable system to ensure users are aware of all the modifications made to the data

MaterialCenter is the single point of entry for all of your materials related activities including physical test data entry and reduction multi-scale materials modeling approval workflow and the export of simulation ready data to analysis

For details please visit wwwmscsoftwarecomproductmaterialcenter

The material modeling platform for simulating a range of composites

Secure reliable and fast access to material data

Delivers material data integration and ease of use to dramatically improve engineering simulation workflows

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 6: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

2015 USER CONFERENCES

For more information visit wwwmscsoftwarecom

Beijing ChinaMay 27

Xian ChinaMay 29

Tokyo Japan June 4

Paris FranceJune 10-11

Brno Czech RepublicJune 10-11

Istanbul TurkeyJune 11-12

Gothenburg SwedenJune 15

Munich Germany June 16-17

Napoli ItalyJuly 10

Queretaro MexicoAugust 18

Pune IndiaSeptember 4

Michigan USASeptember 16-17

Tampere FinlandSeptember 22

Moscow Russia October 7-8

Budapest HungaryOctober 8

Bologna ItalyOctober 14

Rotterdam NetherlandsOctober 15

BelgiumOctober 15

Torino ItalyNovember 11

Madrid SpainOctober

Pretoria South AfricaMarch 17 2016

Simulating Reality Delivering Certainty

Volume V - Summer 2015 | 3

by DOMINIC GALLELLO President amp CEO

MSC Software

LETTER FROM THE CEO

Simulating the Complete Engineering Process

A few years ago I attended a global leadership conference where the attendees on the opening night sat right in the middle of the Los Angeles Symphony Orchestra

They powerfully demonstrated the sounds that an orchestra would make if they were not working well together It was not good Finally the conductor took control of all the sections and to no surprise the music was fantastic If you think about the number of simulations that take place in a product development process it is really not much different If one of the members of the simulation orchestra delivers great results but they are alone and disconnected from the rest of the development process it is pretty clear that the results will not be optimal

Over the past few years we have been assembling the major sections of the simulation orchestra to simulate the complete engineering process

bull Materials ndash The design of new materials which reduce weight and provide same or better structural integrity with reduced part count materials that have better acoustics properties etc is becoming more and more critical This can be for materials of chopped fiber and continuous fiber composites as well as metal which is still the predominant material for cars trains and planes Design testing and management of new materials should be a natural part of the design process not relegated to just a ldquospecial fewrdquo We enable engineers to use the design variables of new advanced materials with certainty as a natural part of their design process

bull Fabrication ndash As the materials are chosen they need to be formed into parts Forming forging and other fabrication processes are done by a huge number of companies Forming simulation we have done before but annealing rolling curing 3D printing and general simulation of fabrication is something new and offers our customers the ability to use simulation to explore the impact of fabrication on the materials behaviors and the robustness of their designs in the face of realizable material variability Support the simulation of the as-manufactured spatial property variation to enable partssystems designers to design to robust manufactured parts with minimal margins Enable the fabrication engineering departments to decide on the best ways to work the material to obtain the design targeted properties

bull Parts ndash The ability to quickly model and shape parts for simulation that runs the first time has been difficult to achieve over the years And now as light-weighting is driving engineers to refine their parts designs and 3D printing and other fabrication methods are opening new design options it is even more critical to enable engineers to design the parts It is no longer enough to validate that the part meets its operational criteria

Make simulation tools easier to use and tie them more closely to the geometrical design parameters Enable the easy exploration of fabrication methods in the simulation of parts behaviors

bull Assembly ndashIdealized parts from the traditional design process donrsquot always behave the way you want after being fabricated and then joined to an assembly Welding riveting annealing and spatial variations from strain hardening and forming of steel and aluminum change the characteristics of the subsystems and systems and this cannot be ignored The joining process is another very important input into the design process to understand overall system behavior and how to exploit it in the design of parts and in the design of the assembly process itself

bull Systems ndash Getting the system model just right gets more and more challenging Lightweighting acoustical optimization energy management stability augmentation of the dynamic behavior and more and more specialized load cases coupled with a need to minimize the use of margins of safety to create certainty in the design creates a seemingly endless back and forth between the system model and the myriad of part models The reduction of just one loads cycle has incredibly positive time and cost impact on the overall development process Enable the systems model and its criteria to be visible throughout the design process Simplify the exchange of systems and parts behaviors and properties through the supply chain

All five pieces of the process are now in place With the building blocks laid down it offers us incredible opportunities to assist our customers to accelerate not only each piece of the process but also to exploit even greater design improvements by simulating the materials to systems processes We look forward to working with you to realize the full potential

4 | MSC Software

MSC IN THE NEWS

More people are living side-by-side with their appliances in smaller spaces so they want quieter machines but not completely silent machines They want enough sound to confirm the refrigerator is working or the washing machine has completed its cycle but no more At the same time that engineers are trying to strike that balance government agencies are mandating greater energy efficiency and ldquoend of liferdquo design that minimizes waste and maximizes re-use Throw cost style and size into the mix and engineers face a tangle of conflicting priorities Acoustic simulation can resolve that conflict by giving engineers insight for developing products with appropriate sound profiles while balancing other design considerations Integrating acoustic simulation technology into their design processes provides manufacturers with the insight necessary to know where the balance between consumer preference and government restrictions lies They donrsquot need the resources of a multinational corporation to do it They just need to know that they have options for understanding their productsrsquo acoustic behaviors without raising their costs

Acoustic Simulation Software Helps Appliance Engineers Meet Demands Appliance Design

httpbitly1ddtJRj

Lugging is a familiar ndash and unwelcome ndash challenge that symbolizes the tension between fuel economy and noise vibration and harshness (NVH) in motor vehicle design today Lugging occurs when a vehicle is operating at a high gear and a low engine speed ndash below 2000 RPM ndash and the driver hits the accelerator Engineers can adjust the vehiclersquos transmission to accelerate smoothly in high gear ndash a process called ldquoslippingrdquo ndash but doing so reduces the carrsquos fuel economy Therein lies the conflict Consumers want the smoother rides that slipping the transmission yields but automotive engineers are under enormous pressure to improve fuel efficiency to meet ever-stricter government mileage requirements Fordrsquos solution came through a combination of simulation and modeling technology and an open standard for co-simulation called Functional Mock-Up Interface (FMI) Ford created detailed 3D models of the drivetrain and the entire vehicle in MSC Softwarersquos Adams multi-body dynamics software Simulation results demonstrated that a slip of 40rpm slip was the optimal trade-off between NVH and fuel economy Simulation will help engineers develop vehicles that deliver the comfort and performance required to appeal to customers and the efficiency to meet increasingly stringent fuel economy standards

Ford Applies New Simulation Technology to Solve ChallengesDesign World

httpbitly1GizEzv

In February 2015 MSC Software acquired Simufact creators of metal forming and joining simulation software The software is a popular nonlinear CAE Tool used by the automotive OEM aerospace and machine part industries The tool is designed to reduce the trial and error associated with manufacturing a product on the shop floor In fact some Simufact customers have reported that they have been able to cut their physical testing in half and reduce the cycle time of a new part to a single week when using the software For MSC users however Simufact will help to complete the simulation process chain This will give engineers the ability to simplify the assessments of their ldquoas manufacturedrdquo designs

Nonlinear Forming amp Welding Simulation Brings ldquoAs Manufacturedrdquo Data to MSCEngineeringcom

httpbitly1AL3dFy

Simulation News amp Media Coverage

Volume V - Summer 2015 | 5

Software that is easier to use allows engineers more time to focus on simulation and analysis of the data rather than trying to adapt to new software learn proprietary coding languages or the worrying about how to map algorithms to the latest GPU or accelerator technology For instance aircraft noise has become a major concern and in some cases is an obstacle to growth in air transport as numbers of airports place restrictions on the amount of noise that can be generated by an aircraft Designers and engineers must work hard to reduce the noise of jet engines by placing acoustic liners in the nacelle a housing that holds engines or equipment on an aircraft to minimize the fan noise radiated from the engine One example of the use of MSC software for acoustic simulation looked at the use of nacelle liners on Airbus aircraft The company evaluated several different shapes and materials to understand the best performance Airbus found that it could dramatically reduce the time required to design and evaluate acoustic liners by moving to a simulation-based process using Actran acoustic simulation software developed by Free Field Technologies (FFT) a subsidiary of MSC

Simplifying SimulationScientific Computing World

httpbitly1JSrlcP

A new generation of materials management technology will open a window on lighter more efficient vehicles Composites reinforced plastics and lightweight steel and aluminum are being deployed across the automotive industry at record rates to improve fuel efficiency Automotive OEMs are integrating new materials into parts and assemblies in existing designs and developing completely reimagined platforms around them such as the BMW i3 and i8 New material systems provide significant benefits in specific weight and stiffness However because of their variability due to new manufacturing methods and engineersrsquo lack of familiarity with them new material systems demand significantly more and different types of testing ndash potentially increasing up-front cost This expansion of testing obligates OEMs to rethink how material systems are managed and how they must evolve to support wider uses of new materials Such a system must put materials in the forefront of engineering to use materials as an essential design variable to innovate The ability to model material properties quickly easily and in detail is essential to adopting new materials that will make automobiles lighter more fuel efficient and ultimately better for the environment

Materials to Reduce Vehicle WeightTodayrsquos Motor Vehicles

httpbitly1S4iudL

In February 2015 the United States Marine Corps put some of its engineers through an intensive nine-day training course on Adams In less than two weeks the students realized that learning Adams could put them on equal footing with engineers in the private sector Adamsrsquo powerful analysis capabilities are giving the USMC the ability to start bringing engineering work back in-house allowing them to quickly and accurately analyze any vehicle mishaps that may occur

Class Gives United States Marine Corps Engineers New Analytical Tool Defense Video amp Imagery Distribution System

httpbitly1PPUK9i

6 | MSC Software

PRODUCT NEWS IN-BRIEF

2015 New Product Releases

MSC Apex Diamond Python

The latest release of MSC Apex enhances the engineerrsquos workflow and daily productivity with many innovative modeling and analysis capabilities The MSC Apex Diamond Python release introduces

bull The fourth release of MSC Apex Modeler - A CAE Specific direct modeling and meshing solution that streamlines CAD clean-up simplification and meshing workflow

bull The second release of MSC Apex Structures - An add-on to MSC Apex Modeler which now expands MSC Apex to a fully integrated and generative structural analysis solution

bull New incremental Mid-surface modeling workflow (SmartMidsurface trade) for dramatic time savings

Diamond Python delivers a solver integrated solution for interactive and incremental structural analysis Modeling validating solving and exploring designs has never been this efficient and easy MSC Apex helps users to dramatically reduce the amount of time that it takes to build and validate models a task that does not add any value to the design process This frees users to focus on delivering not just acceptable designs but ones that are optimal - in an environment that is fun to use

For details please visit wwwmscapexcom

Delivers two products Modeler and Structures + SmartMidsurfacetrade

Adams 2015 The Adams 2015 release delivers new functionality and major enhancements in many areas especially for AdamsCar Automotive engineers will benefit from new out-of-the-box customized solutions for model setup and vehicle event simulations The new features also give users the ability to create higher fidelity subsystems in their vehicle models Highlights of the release include

Extends Vehicle Simulation Scope for Automotive Engineers

The 2015 product release lineup delivers new event simulations for vehicle modeling coupled physics extended material modeling methods an all-new release of MSC Apex and a range of advanced engineering simulation technologies for streamlining the analysis workflow In addition to the releases mentioned below please expect later this year to see new 2015 releases of Marc MSC Nastran amp Patran SimManager and additional releases of Digimat Simufact and Actran New Release Highlights

Higher Fidelity Modelingbull AdamsMachinery Compatibility in AdamsCar - High fidelity

gear and motor modeling in car amp drivelinebull Nonlinear FE Part Support for AdamsCar ndash Geometric

nonlinearity for vehicle subsystems modeling and simulationbull Adams-Marc Co-simulation Enhancements ndash Easier and faster

Multibody Dynamics-Nonlinear FEA Integrationbull New Vehicle Database ndash Provides availability of key vehicle types

out-of-the-box

New Vehicle Eventsbull Full-vehicle Suspension Parameter Measurement Machine

(SPMM) - Tune suspension parameters for desired vehicle behavior without costly iteration with physical prototypes

bull Static Vehicle Characteristics (SVC) ndash Computes and reports key metrics of the vehicle at static equilibrium

bull Tandem Axle Suspension Analysis (TASA) ndash Delivers support for tuning of multi-axle architectures

For details please visit wwwmscsoftwarecomproductadams

Volume V - Summer 2015 | 7

Digimat 60

Material Databanks

MaterialCenter 2015

This latest Digimat 60 release brings a series of new features and improvements for modeling and analyzing composite materials from Short Fiber Reinforced Plastics (SFRP) to Discontinuous Fiber Composites (DFC) and Continuous Fiber Reinforced Composites (CFRP)

The new release also introduces Digimat-VA a unique software solution dedicated to accurate virtual characterization of CFRPs to dramatically reduce the cost and time associated with material characterization and qualification Digimat-VA which stands for Virtual Allowables offers a dedicated integrated workflow starting with easy and efficient creation of advanced multi-scale material models (including micro-level variability and progressive failure) FEA simulations of common test coupons and automatic post-processing for computing mean strength and AB-basis values

Any engineer concerned with characterizing a new composite material exploring the design space or better understanding widespread mechanical properties will find in Digimat-VA a productive solution to save time and money

For details please visit wwwe-xstreamcom

The MSC Material Databanks are collections of technical materials information in electronic format The databanks are developed and maintained through MSCrsquos partnerships with premier sources of materials information They provide a comprehensive source of material property data for use by engineers for design and analysis Benefits include bull Easy access to high-quality reliable material data from around the world to improve team efficiency and information workflow bull Improved quality and consistency with engineering data derived from a single sourcebull Reduced transcription errors with electronic data transferbull Increased accuracy of predictive analysis product design and simulation using certified material data records for CAD CAE

or PLM software

For details please visit wwwmscsoftwarecom

MaterialCenter 2015 is an out-of-the-box Material Process and Data Lifecycle Management solution with direct integration into many of the CAE pre- and post-processing tools commonly

used by engineers The integration provides direct support to retrieve a material model from MaterialCenter without leaving the native CAE pre- and post-processing application

MaterialCenter 2015 also enables users to create and edit material data directly from the browser environment Along with MaterialCenterrsquos Excel integration this provides a completely traceable system to ensure users are aware of all the modifications made to the data

MaterialCenter is the single point of entry for all of your materials related activities including physical test data entry and reduction multi-scale materials modeling approval workflow and the export of simulation ready data to analysis

For details please visit wwwmscsoftwarecomproductmaterialcenter

The material modeling platform for simulating a range of composites

Secure reliable and fast access to material data

Delivers material data integration and ease of use to dramatically improve engineering simulation workflows

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 7: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Volume V - Summer 2015 | 3

by DOMINIC GALLELLO President amp CEO

MSC Software

LETTER FROM THE CEO

Simulating the Complete Engineering Process

A few years ago I attended a global leadership conference where the attendees on the opening night sat right in the middle of the Los Angeles Symphony Orchestra

They powerfully demonstrated the sounds that an orchestra would make if they were not working well together It was not good Finally the conductor took control of all the sections and to no surprise the music was fantastic If you think about the number of simulations that take place in a product development process it is really not much different If one of the members of the simulation orchestra delivers great results but they are alone and disconnected from the rest of the development process it is pretty clear that the results will not be optimal

Over the past few years we have been assembling the major sections of the simulation orchestra to simulate the complete engineering process

bull Materials ndash The design of new materials which reduce weight and provide same or better structural integrity with reduced part count materials that have better acoustics properties etc is becoming more and more critical This can be for materials of chopped fiber and continuous fiber composites as well as metal which is still the predominant material for cars trains and planes Design testing and management of new materials should be a natural part of the design process not relegated to just a ldquospecial fewrdquo We enable engineers to use the design variables of new advanced materials with certainty as a natural part of their design process

bull Fabrication ndash As the materials are chosen they need to be formed into parts Forming forging and other fabrication processes are done by a huge number of companies Forming simulation we have done before but annealing rolling curing 3D printing and general simulation of fabrication is something new and offers our customers the ability to use simulation to explore the impact of fabrication on the materials behaviors and the robustness of their designs in the face of realizable material variability Support the simulation of the as-manufactured spatial property variation to enable partssystems designers to design to robust manufactured parts with minimal margins Enable the fabrication engineering departments to decide on the best ways to work the material to obtain the design targeted properties

bull Parts ndash The ability to quickly model and shape parts for simulation that runs the first time has been difficult to achieve over the years And now as light-weighting is driving engineers to refine their parts designs and 3D printing and other fabrication methods are opening new design options it is even more critical to enable engineers to design the parts It is no longer enough to validate that the part meets its operational criteria

Make simulation tools easier to use and tie them more closely to the geometrical design parameters Enable the easy exploration of fabrication methods in the simulation of parts behaviors

bull Assembly ndashIdealized parts from the traditional design process donrsquot always behave the way you want after being fabricated and then joined to an assembly Welding riveting annealing and spatial variations from strain hardening and forming of steel and aluminum change the characteristics of the subsystems and systems and this cannot be ignored The joining process is another very important input into the design process to understand overall system behavior and how to exploit it in the design of parts and in the design of the assembly process itself

bull Systems ndash Getting the system model just right gets more and more challenging Lightweighting acoustical optimization energy management stability augmentation of the dynamic behavior and more and more specialized load cases coupled with a need to minimize the use of margins of safety to create certainty in the design creates a seemingly endless back and forth between the system model and the myriad of part models The reduction of just one loads cycle has incredibly positive time and cost impact on the overall development process Enable the systems model and its criteria to be visible throughout the design process Simplify the exchange of systems and parts behaviors and properties through the supply chain

All five pieces of the process are now in place With the building blocks laid down it offers us incredible opportunities to assist our customers to accelerate not only each piece of the process but also to exploit even greater design improvements by simulating the materials to systems processes We look forward to working with you to realize the full potential

4 | MSC Software

MSC IN THE NEWS

More people are living side-by-side with their appliances in smaller spaces so they want quieter machines but not completely silent machines They want enough sound to confirm the refrigerator is working or the washing machine has completed its cycle but no more At the same time that engineers are trying to strike that balance government agencies are mandating greater energy efficiency and ldquoend of liferdquo design that minimizes waste and maximizes re-use Throw cost style and size into the mix and engineers face a tangle of conflicting priorities Acoustic simulation can resolve that conflict by giving engineers insight for developing products with appropriate sound profiles while balancing other design considerations Integrating acoustic simulation technology into their design processes provides manufacturers with the insight necessary to know where the balance between consumer preference and government restrictions lies They donrsquot need the resources of a multinational corporation to do it They just need to know that they have options for understanding their productsrsquo acoustic behaviors without raising their costs

Acoustic Simulation Software Helps Appliance Engineers Meet Demands Appliance Design

httpbitly1ddtJRj

Lugging is a familiar ndash and unwelcome ndash challenge that symbolizes the tension between fuel economy and noise vibration and harshness (NVH) in motor vehicle design today Lugging occurs when a vehicle is operating at a high gear and a low engine speed ndash below 2000 RPM ndash and the driver hits the accelerator Engineers can adjust the vehiclersquos transmission to accelerate smoothly in high gear ndash a process called ldquoslippingrdquo ndash but doing so reduces the carrsquos fuel economy Therein lies the conflict Consumers want the smoother rides that slipping the transmission yields but automotive engineers are under enormous pressure to improve fuel efficiency to meet ever-stricter government mileage requirements Fordrsquos solution came through a combination of simulation and modeling technology and an open standard for co-simulation called Functional Mock-Up Interface (FMI) Ford created detailed 3D models of the drivetrain and the entire vehicle in MSC Softwarersquos Adams multi-body dynamics software Simulation results demonstrated that a slip of 40rpm slip was the optimal trade-off between NVH and fuel economy Simulation will help engineers develop vehicles that deliver the comfort and performance required to appeal to customers and the efficiency to meet increasingly stringent fuel economy standards

Ford Applies New Simulation Technology to Solve ChallengesDesign World

httpbitly1GizEzv

In February 2015 MSC Software acquired Simufact creators of metal forming and joining simulation software The software is a popular nonlinear CAE Tool used by the automotive OEM aerospace and machine part industries The tool is designed to reduce the trial and error associated with manufacturing a product on the shop floor In fact some Simufact customers have reported that they have been able to cut their physical testing in half and reduce the cycle time of a new part to a single week when using the software For MSC users however Simufact will help to complete the simulation process chain This will give engineers the ability to simplify the assessments of their ldquoas manufacturedrdquo designs

Nonlinear Forming amp Welding Simulation Brings ldquoAs Manufacturedrdquo Data to MSCEngineeringcom

httpbitly1AL3dFy

Simulation News amp Media Coverage

Volume V - Summer 2015 | 5

Software that is easier to use allows engineers more time to focus on simulation and analysis of the data rather than trying to adapt to new software learn proprietary coding languages or the worrying about how to map algorithms to the latest GPU or accelerator technology For instance aircraft noise has become a major concern and in some cases is an obstacle to growth in air transport as numbers of airports place restrictions on the amount of noise that can be generated by an aircraft Designers and engineers must work hard to reduce the noise of jet engines by placing acoustic liners in the nacelle a housing that holds engines or equipment on an aircraft to minimize the fan noise radiated from the engine One example of the use of MSC software for acoustic simulation looked at the use of nacelle liners on Airbus aircraft The company evaluated several different shapes and materials to understand the best performance Airbus found that it could dramatically reduce the time required to design and evaluate acoustic liners by moving to a simulation-based process using Actran acoustic simulation software developed by Free Field Technologies (FFT) a subsidiary of MSC

Simplifying SimulationScientific Computing World

httpbitly1JSrlcP

A new generation of materials management technology will open a window on lighter more efficient vehicles Composites reinforced plastics and lightweight steel and aluminum are being deployed across the automotive industry at record rates to improve fuel efficiency Automotive OEMs are integrating new materials into parts and assemblies in existing designs and developing completely reimagined platforms around them such as the BMW i3 and i8 New material systems provide significant benefits in specific weight and stiffness However because of their variability due to new manufacturing methods and engineersrsquo lack of familiarity with them new material systems demand significantly more and different types of testing ndash potentially increasing up-front cost This expansion of testing obligates OEMs to rethink how material systems are managed and how they must evolve to support wider uses of new materials Such a system must put materials in the forefront of engineering to use materials as an essential design variable to innovate The ability to model material properties quickly easily and in detail is essential to adopting new materials that will make automobiles lighter more fuel efficient and ultimately better for the environment

Materials to Reduce Vehicle WeightTodayrsquos Motor Vehicles

httpbitly1S4iudL

In February 2015 the United States Marine Corps put some of its engineers through an intensive nine-day training course on Adams In less than two weeks the students realized that learning Adams could put them on equal footing with engineers in the private sector Adamsrsquo powerful analysis capabilities are giving the USMC the ability to start bringing engineering work back in-house allowing them to quickly and accurately analyze any vehicle mishaps that may occur

Class Gives United States Marine Corps Engineers New Analytical Tool Defense Video amp Imagery Distribution System

httpbitly1PPUK9i

6 | MSC Software

PRODUCT NEWS IN-BRIEF

2015 New Product Releases

MSC Apex Diamond Python

The latest release of MSC Apex enhances the engineerrsquos workflow and daily productivity with many innovative modeling and analysis capabilities The MSC Apex Diamond Python release introduces

bull The fourth release of MSC Apex Modeler - A CAE Specific direct modeling and meshing solution that streamlines CAD clean-up simplification and meshing workflow

bull The second release of MSC Apex Structures - An add-on to MSC Apex Modeler which now expands MSC Apex to a fully integrated and generative structural analysis solution

bull New incremental Mid-surface modeling workflow (SmartMidsurface trade) for dramatic time savings

Diamond Python delivers a solver integrated solution for interactive and incremental structural analysis Modeling validating solving and exploring designs has never been this efficient and easy MSC Apex helps users to dramatically reduce the amount of time that it takes to build and validate models a task that does not add any value to the design process This frees users to focus on delivering not just acceptable designs but ones that are optimal - in an environment that is fun to use

For details please visit wwwmscapexcom

Delivers two products Modeler and Structures + SmartMidsurfacetrade

Adams 2015 The Adams 2015 release delivers new functionality and major enhancements in many areas especially for AdamsCar Automotive engineers will benefit from new out-of-the-box customized solutions for model setup and vehicle event simulations The new features also give users the ability to create higher fidelity subsystems in their vehicle models Highlights of the release include

Extends Vehicle Simulation Scope for Automotive Engineers

The 2015 product release lineup delivers new event simulations for vehicle modeling coupled physics extended material modeling methods an all-new release of MSC Apex and a range of advanced engineering simulation technologies for streamlining the analysis workflow In addition to the releases mentioned below please expect later this year to see new 2015 releases of Marc MSC Nastran amp Patran SimManager and additional releases of Digimat Simufact and Actran New Release Highlights

Higher Fidelity Modelingbull AdamsMachinery Compatibility in AdamsCar - High fidelity

gear and motor modeling in car amp drivelinebull Nonlinear FE Part Support for AdamsCar ndash Geometric

nonlinearity for vehicle subsystems modeling and simulationbull Adams-Marc Co-simulation Enhancements ndash Easier and faster

Multibody Dynamics-Nonlinear FEA Integrationbull New Vehicle Database ndash Provides availability of key vehicle types

out-of-the-box

New Vehicle Eventsbull Full-vehicle Suspension Parameter Measurement Machine

(SPMM) - Tune suspension parameters for desired vehicle behavior without costly iteration with physical prototypes

bull Static Vehicle Characteristics (SVC) ndash Computes and reports key metrics of the vehicle at static equilibrium

bull Tandem Axle Suspension Analysis (TASA) ndash Delivers support for tuning of multi-axle architectures

For details please visit wwwmscsoftwarecomproductadams

Volume V - Summer 2015 | 7

Digimat 60

Material Databanks

MaterialCenter 2015

This latest Digimat 60 release brings a series of new features and improvements for modeling and analyzing composite materials from Short Fiber Reinforced Plastics (SFRP) to Discontinuous Fiber Composites (DFC) and Continuous Fiber Reinforced Composites (CFRP)

The new release also introduces Digimat-VA a unique software solution dedicated to accurate virtual characterization of CFRPs to dramatically reduce the cost and time associated with material characterization and qualification Digimat-VA which stands for Virtual Allowables offers a dedicated integrated workflow starting with easy and efficient creation of advanced multi-scale material models (including micro-level variability and progressive failure) FEA simulations of common test coupons and automatic post-processing for computing mean strength and AB-basis values

Any engineer concerned with characterizing a new composite material exploring the design space or better understanding widespread mechanical properties will find in Digimat-VA a productive solution to save time and money

For details please visit wwwe-xstreamcom

The MSC Material Databanks are collections of technical materials information in electronic format The databanks are developed and maintained through MSCrsquos partnerships with premier sources of materials information They provide a comprehensive source of material property data for use by engineers for design and analysis Benefits include bull Easy access to high-quality reliable material data from around the world to improve team efficiency and information workflow bull Improved quality and consistency with engineering data derived from a single sourcebull Reduced transcription errors with electronic data transferbull Increased accuracy of predictive analysis product design and simulation using certified material data records for CAD CAE

or PLM software

For details please visit wwwmscsoftwarecom

MaterialCenter 2015 is an out-of-the-box Material Process and Data Lifecycle Management solution with direct integration into many of the CAE pre- and post-processing tools commonly

used by engineers The integration provides direct support to retrieve a material model from MaterialCenter without leaving the native CAE pre- and post-processing application

MaterialCenter 2015 also enables users to create and edit material data directly from the browser environment Along with MaterialCenterrsquos Excel integration this provides a completely traceable system to ensure users are aware of all the modifications made to the data

MaterialCenter is the single point of entry for all of your materials related activities including physical test data entry and reduction multi-scale materials modeling approval workflow and the export of simulation ready data to analysis

For details please visit wwwmscsoftwarecomproductmaterialcenter

The material modeling platform for simulating a range of composites

Secure reliable and fast access to material data

Delivers material data integration and ease of use to dramatically improve engineering simulation workflows

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 8: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

4 | MSC Software

MSC IN THE NEWS

More people are living side-by-side with their appliances in smaller spaces so they want quieter machines but not completely silent machines They want enough sound to confirm the refrigerator is working or the washing machine has completed its cycle but no more At the same time that engineers are trying to strike that balance government agencies are mandating greater energy efficiency and ldquoend of liferdquo design that minimizes waste and maximizes re-use Throw cost style and size into the mix and engineers face a tangle of conflicting priorities Acoustic simulation can resolve that conflict by giving engineers insight for developing products with appropriate sound profiles while balancing other design considerations Integrating acoustic simulation technology into their design processes provides manufacturers with the insight necessary to know where the balance between consumer preference and government restrictions lies They donrsquot need the resources of a multinational corporation to do it They just need to know that they have options for understanding their productsrsquo acoustic behaviors without raising their costs

Acoustic Simulation Software Helps Appliance Engineers Meet Demands Appliance Design

httpbitly1ddtJRj

Lugging is a familiar ndash and unwelcome ndash challenge that symbolizes the tension between fuel economy and noise vibration and harshness (NVH) in motor vehicle design today Lugging occurs when a vehicle is operating at a high gear and a low engine speed ndash below 2000 RPM ndash and the driver hits the accelerator Engineers can adjust the vehiclersquos transmission to accelerate smoothly in high gear ndash a process called ldquoslippingrdquo ndash but doing so reduces the carrsquos fuel economy Therein lies the conflict Consumers want the smoother rides that slipping the transmission yields but automotive engineers are under enormous pressure to improve fuel efficiency to meet ever-stricter government mileage requirements Fordrsquos solution came through a combination of simulation and modeling technology and an open standard for co-simulation called Functional Mock-Up Interface (FMI) Ford created detailed 3D models of the drivetrain and the entire vehicle in MSC Softwarersquos Adams multi-body dynamics software Simulation results demonstrated that a slip of 40rpm slip was the optimal trade-off between NVH and fuel economy Simulation will help engineers develop vehicles that deliver the comfort and performance required to appeal to customers and the efficiency to meet increasingly stringent fuel economy standards

Ford Applies New Simulation Technology to Solve ChallengesDesign World

httpbitly1GizEzv

In February 2015 MSC Software acquired Simufact creators of metal forming and joining simulation software The software is a popular nonlinear CAE Tool used by the automotive OEM aerospace and machine part industries The tool is designed to reduce the trial and error associated with manufacturing a product on the shop floor In fact some Simufact customers have reported that they have been able to cut their physical testing in half and reduce the cycle time of a new part to a single week when using the software For MSC users however Simufact will help to complete the simulation process chain This will give engineers the ability to simplify the assessments of their ldquoas manufacturedrdquo designs

Nonlinear Forming amp Welding Simulation Brings ldquoAs Manufacturedrdquo Data to MSCEngineeringcom

httpbitly1AL3dFy

Simulation News amp Media Coverage

Volume V - Summer 2015 | 5

Software that is easier to use allows engineers more time to focus on simulation and analysis of the data rather than trying to adapt to new software learn proprietary coding languages or the worrying about how to map algorithms to the latest GPU or accelerator technology For instance aircraft noise has become a major concern and in some cases is an obstacle to growth in air transport as numbers of airports place restrictions on the amount of noise that can be generated by an aircraft Designers and engineers must work hard to reduce the noise of jet engines by placing acoustic liners in the nacelle a housing that holds engines or equipment on an aircraft to minimize the fan noise radiated from the engine One example of the use of MSC software for acoustic simulation looked at the use of nacelle liners on Airbus aircraft The company evaluated several different shapes and materials to understand the best performance Airbus found that it could dramatically reduce the time required to design and evaluate acoustic liners by moving to a simulation-based process using Actran acoustic simulation software developed by Free Field Technologies (FFT) a subsidiary of MSC

Simplifying SimulationScientific Computing World

httpbitly1JSrlcP

A new generation of materials management technology will open a window on lighter more efficient vehicles Composites reinforced plastics and lightweight steel and aluminum are being deployed across the automotive industry at record rates to improve fuel efficiency Automotive OEMs are integrating new materials into parts and assemblies in existing designs and developing completely reimagined platforms around them such as the BMW i3 and i8 New material systems provide significant benefits in specific weight and stiffness However because of their variability due to new manufacturing methods and engineersrsquo lack of familiarity with them new material systems demand significantly more and different types of testing ndash potentially increasing up-front cost This expansion of testing obligates OEMs to rethink how material systems are managed and how they must evolve to support wider uses of new materials Such a system must put materials in the forefront of engineering to use materials as an essential design variable to innovate The ability to model material properties quickly easily and in detail is essential to adopting new materials that will make automobiles lighter more fuel efficient and ultimately better for the environment

Materials to Reduce Vehicle WeightTodayrsquos Motor Vehicles

httpbitly1S4iudL

In February 2015 the United States Marine Corps put some of its engineers through an intensive nine-day training course on Adams In less than two weeks the students realized that learning Adams could put them on equal footing with engineers in the private sector Adamsrsquo powerful analysis capabilities are giving the USMC the ability to start bringing engineering work back in-house allowing them to quickly and accurately analyze any vehicle mishaps that may occur

Class Gives United States Marine Corps Engineers New Analytical Tool Defense Video amp Imagery Distribution System

httpbitly1PPUK9i

6 | MSC Software

PRODUCT NEWS IN-BRIEF

2015 New Product Releases

MSC Apex Diamond Python

The latest release of MSC Apex enhances the engineerrsquos workflow and daily productivity with many innovative modeling and analysis capabilities The MSC Apex Diamond Python release introduces

bull The fourth release of MSC Apex Modeler - A CAE Specific direct modeling and meshing solution that streamlines CAD clean-up simplification and meshing workflow

bull The second release of MSC Apex Structures - An add-on to MSC Apex Modeler which now expands MSC Apex to a fully integrated and generative structural analysis solution

bull New incremental Mid-surface modeling workflow (SmartMidsurface trade) for dramatic time savings

Diamond Python delivers a solver integrated solution for interactive and incremental structural analysis Modeling validating solving and exploring designs has never been this efficient and easy MSC Apex helps users to dramatically reduce the amount of time that it takes to build and validate models a task that does not add any value to the design process This frees users to focus on delivering not just acceptable designs but ones that are optimal - in an environment that is fun to use

For details please visit wwwmscapexcom

Delivers two products Modeler and Structures + SmartMidsurfacetrade

Adams 2015 The Adams 2015 release delivers new functionality and major enhancements in many areas especially for AdamsCar Automotive engineers will benefit from new out-of-the-box customized solutions for model setup and vehicle event simulations The new features also give users the ability to create higher fidelity subsystems in their vehicle models Highlights of the release include

Extends Vehicle Simulation Scope for Automotive Engineers

The 2015 product release lineup delivers new event simulations for vehicle modeling coupled physics extended material modeling methods an all-new release of MSC Apex and a range of advanced engineering simulation technologies for streamlining the analysis workflow In addition to the releases mentioned below please expect later this year to see new 2015 releases of Marc MSC Nastran amp Patran SimManager and additional releases of Digimat Simufact and Actran New Release Highlights

Higher Fidelity Modelingbull AdamsMachinery Compatibility in AdamsCar - High fidelity

gear and motor modeling in car amp drivelinebull Nonlinear FE Part Support for AdamsCar ndash Geometric

nonlinearity for vehicle subsystems modeling and simulationbull Adams-Marc Co-simulation Enhancements ndash Easier and faster

Multibody Dynamics-Nonlinear FEA Integrationbull New Vehicle Database ndash Provides availability of key vehicle types

out-of-the-box

New Vehicle Eventsbull Full-vehicle Suspension Parameter Measurement Machine

(SPMM) - Tune suspension parameters for desired vehicle behavior without costly iteration with physical prototypes

bull Static Vehicle Characteristics (SVC) ndash Computes and reports key metrics of the vehicle at static equilibrium

bull Tandem Axle Suspension Analysis (TASA) ndash Delivers support for tuning of multi-axle architectures

For details please visit wwwmscsoftwarecomproductadams

Volume V - Summer 2015 | 7

Digimat 60

Material Databanks

MaterialCenter 2015

This latest Digimat 60 release brings a series of new features and improvements for modeling and analyzing composite materials from Short Fiber Reinforced Plastics (SFRP) to Discontinuous Fiber Composites (DFC) and Continuous Fiber Reinforced Composites (CFRP)

The new release also introduces Digimat-VA a unique software solution dedicated to accurate virtual characterization of CFRPs to dramatically reduce the cost and time associated with material characterization and qualification Digimat-VA which stands for Virtual Allowables offers a dedicated integrated workflow starting with easy and efficient creation of advanced multi-scale material models (including micro-level variability and progressive failure) FEA simulations of common test coupons and automatic post-processing for computing mean strength and AB-basis values

Any engineer concerned with characterizing a new composite material exploring the design space or better understanding widespread mechanical properties will find in Digimat-VA a productive solution to save time and money

For details please visit wwwe-xstreamcom

The MSC Material Databanks are collections of technical materials information in electronic format The databanks are developed and maintained through MSCrsquos partnerships with premier sources of materials information They provide a comprehensive source of material property data for use by engineers for design and analysis Benefits include bull Easy access to high-quality reliable material data from around the world to improve team efficiency and information workflow bull Improved quality and consistency with engineering data derived from a single sourcebull Reduced transcription errors with electronic data transferbull Increased accuracy of predictive analysis product design and simulation using certified material data records for CAD CAE

or PLM software

For details please visit wwwmscsoftwarecom

MaterialCenter 2015 is an out-of-the-box Material Process and Data Lifecycle Management solution with direct integration into many of the CAE pre- and post-processing tools commonly

used by engineers The integration provides direct support to retrieve a material model from MaterialCenter without leaving the native CAE pre- and post-processing application

MaterialCenter 2015 also enables users to create and edit material data directly from the browser environment Along with MaterialCenterrsquos Excel integration this provides a completely traceable system to ensure users are aware of all the modifications made to the data

MaterialCenter is the single point of entry for all of your materials related activities including physical test data entry and reduction multi-scale materials modeling approval workflow and the export of simulation ready data to analysis

For details please visit wwwmscsoftwarecomproductmaterialcenter

The material modeling platform for simulating a range of composites

Secure reliable and fast access to material data

Delivers material data integration and ease of use to dramatically improve engineering simulation workflows

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 9: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Volume V - Summer 2015 | 5

Software that is easier to use allows engineers more time to focus on simulation and analysis of the data rather than trying to adapt to new software learn proprietary coding languages or the worrying about how to map algorithms to the latest GPU or accelerator technology For instance aircraft noise has become a major concern and in some cases is an obstacle to growth in air transport as numbers of airports place restrictions on the amount of noise that can be generated by an aircraft Designers and engineers must work hard to reduce the noise of jet engines by placing acoustic liners in the nacelle a housing that holds engines or equipment on an aircraft to minimize the fan noise radiated from the engine One example of the use of MSC software for acoustic simulation looked at the use of nacelle liners on Airbus aircraft The company evaluated several different shapes and materials to understand the best performance Airbus found that it could dramatically reduce the time required to design and evaluate acoustic liners by moving to a simulation-based process using Actran acoustic simulation software developed by Free Field Technologies (FFT) a subsidiary of MSC

Simplifying SimulationScientific Computing World

httpbitly1JSrlcP

A new generation of materials management technology will open a window on lighter more efficient vehicles Composites reinforced plastics and lightweight steel and aluminum are being deployed across the automotive industry at record rates to improve fuel efficiency Automotive OEMs are integrating new materials into parts and assemblies in existing designs and developing completely reimagined platforms around them such as the BMW i3 and i8 New material systems provide significant benefits in specific weight and stiffness However because of their variability due to new manufacturing methods and engineersrsquo lack of familiarity with them new material systems demand significantly more and different types of testing ndash potentially increasing up-front cost This expansion of testing obligates OEMs to rethink how material systems are managed and how they must evolve to support wider uses of new materials Such a system must put materials in the forefront of engineering to use materials as an essential design variable to innovate The ability to model material properties quickly easily and in detail is essential to adopting new materials that will make automobiles lighter more fuel efficient and ultimately better for the environment

Materials to Reduce Vehicle WeightTodayrsquos Motor Vehicles

httpbitly1S4iudL

In February 2015 the United States Marine Corps put some of its engineers through an intensive nine-day training course on Adams In less than two weeks the students realized that learning Adams could put them on equal footing with engineers in the private sector Adamsrsquo powerful analysis capabilities are giving the USMC the ability to start bringing engineering work back in-house allowing them to quickly and accurately analyze any vehicle mishaps that may occur

Class Gives United States Marine Corps Engineers New Analytical Tool Defense Video amp Imagery Distribution System

httpbitly1PPUK9i

6 | MSC Software

PRODUCT NEWS IN-BRIEF

2015 New Product Releases

MSC Apex Diamond Python

The latest release of MSC Apex enhances the engineerrsquos workflow and daily productivity with many innovative modeling and analysis capabilities The MSC Apex Diamond Python release introduces

bull The fourth release of MSC Apex Modeler - A CAE Specific direct modeling and meshing solution that streamlines CAD clean-up simplification and meshing workflow

bull The second release of MSC Apex Structures - An add-on to MSC Apex Modeler which now expands MSC Apex to a fully integrated and generative structural analysis solution

bull New incremental Mid-surface modeling workflow (SmartMidsurface trade) for dramatic time savings

Diamond Python delivers a solver integrated solution for interactive and incremental structural analysis Modeling validating solving and exploring designs has never been this efficient and easy MSC Apex helps users to dramatically reduce the amount of time that it takes to build and validate models a task that does not add any value to the design process This frees users to focus on delivering not just acceptable designs but ones that are optimal - in an environment that is fun to use

For details please visit wwwmscapexcom

Delivers two products Modeler and Structures + SmartMidsurfacetrade

Adams 2015 The Adams 2015 release delivers new functionality and major enhancements in many areas especially for AdamsCar Automotive engineers will benefit from new out-of-the-box customized solutions for model setup and vehicle event simulations The new features also give users the ability to create higher fidelity subsystems in their vehicle models Highlights of the release include

Extends Vehicle Simulation Scope for Automotive Engineers

The 2015 product release lineup delivers new event simulations for vehicle modeling coupled physics extended material modeling methods an all-new release of MSC Apex and a range of advanced engineering simulation technologies for streamlining the analysis workflow In addition to the releases mentioned below please expect later this year to see new 2015 releases of Marc MSC Nastran amp Patran SimManager and additional releases of Digimat Simufact and Actran New Release Highlights

Higher Fidelity Modelingbull AdamsMachinery Compatibility in AdamsCar - High fidelity

gear and motor modeling in car amp drivelinebull Nonlinear FE Part Support for AdamsCar ndash Geometric

nonlinearity for vehicle subsystems modeling and simulationbull Adams-Marc Co-simulation Enhancements ndash Easier and faster

Multibody Dynamics-Nonlinear FEA Integrationbull New Vehicle Database ndash Provides availability of key vehicle types

out-of-the-box

New Vehicle Eventsbull Full-vehicle Suspension Parameter Measurement Machine

(SPMM) - Tune suspension parameters for desired vehicle behavior without costly iteration with physical prototypes

bull Static Vehicle Characteristics (SVC) ndash Computes and reports key metrics of the vehicle at static equilibrium

bull Tandem Axle Suspension Analysis (TASA) ndash Delivers support for tuning of multi-axle architectures

For details please visit wwwmscsoftwarecomproductadams

Volume V - Summer 2015 | 7

Digimat 60

Material Databanks

MaterialCenter 2015

This latest Digimat 60 release brings a series of new features and improvements for modeling and analyzing composite materials from Short Fiber Reinforced Plastics (SFRP) to Discontinuous Fiber Composites (DFC) and Continuous Fiber Reinforced Composites (CFRP)

The new release also introduces Digimat-VA a unique software solution dedicated to accurate virtual characterization of CFRPs to dramatically reduce the cost and time associated with material characterization and qualification Digimat-VA which stands for Virtual Allowables offers a dedicated integrated workflow starting with easy and efficient creation of advanced multi-scale material models (including micro-level variability and progressive failure) FEA simulations of common test coupons and automatic post-processing for computing mean strength and AB-basis values

Any engineer concerned with characterizing a new composite material exploring the design space or better understanding widespread mechanical properties will find in Digimat-VA a productive solution to save time and money

For details please visit wwwe-xstreamcom

The MSC Material Databanks are collections of technical materials information in electronic format The databanks are developed and maintained through MSCrsquos partnerships with premier sources of materials information They provide a comprehensive source of material property data for use by engineers for design and analysis Benefits include bull Easy access to high-quality reliable material data from around the world to improve team efficiency and information workflow bull Improved quality and consistency with engineering data derived from a single sourcebull Reduced transcription errors with electronic data transferbull Increased accuracy of predictive analysis product design and simulation using certified material data records for CAD CAE

or PLM software

For details please visit wwwmscsoftwarecom

MaterialCenter 2015 is an out-of-the-box Material Process and Data Lifecycle Management solution with direct integration into many of the CAE pre- and post-processing tools commonly

used by engineers The integration provides direct support to retrieve a material model from MaterialCenter without leaving the native CAE pre- and post-processing application

MaterialCenter 2015 also enables users to create and edit material data directly from the browser environment Along with MaterialCenterrsquos Excel integration this provides a completely traceable system to ensure users are aware of all the modifications made to the data

MaterialCenter is the single point of entry for all of your materials related activities including physical test data entry and reduction multi-scale materials modeling approval workflow and the export of simulation ready data to analysis

For details please visit wwwmscsoftwarecomproductmaterialcenter

The material modeling platform for simulating a range of composites

Secure reliable and fast access to material data

Delivers material data integration and ease of use to dramatically improve engineering simulation workflows

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 10: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

6 | MSC Software

PRODUCT NEWS IN-BRIEF

2015 New Product Releases

MSC Apex Diamond Python

The latest release of MSC Apex enhances the engineerrsquos workflow and daily productivity with many innovative modeling and analysis capabilities The MSC Apex Diamond Python release introduces

bull The fourth release of MSC Apex Modeler - A CAE Specific direct modeling and meshing solution that streamlines CAD clean-up simplification and meshing workflow

bull The second release of MSC Apex Structures - An add-on to MSC Apex Modeler which now expands MSC Apex to a fully integrated and generative structural analysis solution

bull New incremental Mid-surface modeling workflow (SmartMidsurface trade) for dramatic time savings

Diamond Python delivers a solver integrated solution for interactive and incremental structural analysis Modeling validating solving and exploring designs has never been this efficient and easy MSC Apex helps users to dramatically reduce the amount of time that it takes to build and validate models a task that does not add any value to the design process This frees users to focus on delivering not just acceptable designs but ones that are optimal - in an environment that is fun to use

For details please visit wwwmscapexcom

Delivers two products Modeler and Structures + SmartMidsurfacetrade

Adams 2015 The Adams 2015 release delivers new functionality and major enhancements in many areas especially for AdamsCar Automotive engineers will benefit from new out-of-the-box customized solutions for model setup and vehicle event simulations The new features also give users the ability to create higher fidelity subsystems in their vehicle models Highlights of the release include

Extends Vehicle Simulation Scope for Automotive Engineers

The 2015 product release lineup delivers new event simulations for vehicle modeling coupled physics extended material modeling methods an all-new release of MSC Apex and a range of advanced engineering simulation technologies for streamlining the analysis workflow In addition to the releases mentioned below please expect later this year to see new 2015 releases of Marc MSC Nastran amp Patran SimManager and additional releases of Digimat Simufact and Actran New Release Highlights

Higher Fidelity Modelingbull AdamsMachinery Compatibility in AdamsCar - High fidelity

gear and motor modeling in car amp drivelinebull Nonlinear FE Part Support for AdamsCar ndash Geometric

nonlinearity for vehicle subsystems modeling and simulationbull Adams-Marc Co-simulation Enhancements ndash Easier and faster

Multibody Dynamics-Nonlinear FEA Integrationbull New Vehicle Database ndash Provides availability of key vehicle types

out-of-the-box

New Vehicle Eventsbull Full-vehicle Suspension Parameter Measurement Machine

(SPMM) - Tune suspension parameters for desired vehicle behavior without costly iteration with physical prototypes

bull Static Vehicle Characteristics (SVC) ndash Computes and reports key metrics of the vehicle at static equilibrium

bull Tandem Axle Suspension Analysis (TASA) ndash Delivers support for tuning of multi-axle architectures

For details please visit wwwmscsoftwarecomproductadams

Volume V - Summer 2015 | 7

Digimat 60

Material Databanks

MaterialCenter 2015

This latest Digimat 60 release brings a series of new features and improvements for modeling and analyzing composite materials from Short Fiber Reinforced Plastics (SFRP) to Discontinuous Fiber Composites (DFC) and Continuous Fiber Reinforced Composites (CFRP)

The new release also introduces Digimat-VA a unique software solution dedicated to accurate virtual characterization of CFRPs to dramatically reduce the cost and time associated with material characterization and qualification Digimat-VA which stands for Virtual Allowables offers a dedicated integrated workflow starting with easy and efficient creation of advanced multi-scale material models (including micro-level variability and progressive failure) FEA simulations of common test coupons and automatic post-processing for computing mean strength and AB-basis values

Any engineer concerned with characterizing a new composite material exploring the design space or better understanding widespread mechanical properties will find in Digimat-VA a productive solution to save time and money

For details please visit wwwe-xstreamcom

The MSC Material Databanks are collections of technical materials information in electronic format The databanks are developed and maintained through MSCrsquos partnerships with premier sources of materials information They provide a comprehensive source of material property data for use by engineers for design and analysis Benefits include bull Easy access to high-quality reliable material data from around the world to improve team efficiency and information workflow bull Improved quality and consistency with engineering data derived from a single sourcebull Reduced transcription errors with electronic data transferbull Increased accuracy of predictive analysis product design and simulation using certified material data records for CAD CAE

or PLM software

For details please visit wwwmscsoftwarecom

MaterialCenter 2015 is an out-of-the-box Material Process and Data Lifecycle Management solution with direct integration into many of the CAE pre- and post-processing tools commonly

used by engineers The integration provides direct support to retrieve a material model from MaterialCenter without leaving the native CAE pre- and post-processing application

MaterialCenter 2015 also enables users to create and edit material data directly from the browser environment Along with MaterialCenterrsquos Excel integration this provides a completely traceable system to ensure users are aware of all the modifications made to the data

MaterialCenter is the single point of entry for all of your materials related activities including physical test data entry and reduction multi-scale materials modeling approval workflow and the export of simulation ready data to analysis

For details please visit wwwmscsoftwarecomproductmaterialcenter

The material modeling platform for simulating a range of composites

Secure reliable and fast access to material data

Delivers material data integration and ease of use to dramatically improve engineering simulation workflows

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 11: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Volume V - Summer 2015 | 7

Digimat 60

Material Databanks

MaterialCenter 2015

This latest Digimat 60 release brings a series of new features and improvements for modeling and analyzing composite materials from Short Fiber Reinforced Plastics (SFRP) to Discontinuous Fiber Composites (DFC) and Continuous Fiber Reinforced Composites (CFRP)

The new release also introduces Digimat-VA a unique software solution dedicated to accurate virtual characterization of CFRPs to dramatically reduce the cost and time associated with material characterization and qualification Digimat-VA which stands for Virtual Allowables offers a dedicated integrated workflow starting with easy and efficient creation of advanced multi-scale material models (including micro-level variability and progressive failure) FEA simulations of common test coupons and automatic post-processing for computing mean strength and AB-basis values

Any engineer concerned with characterizing a new composite material exploring the design space or better understanding widespread mechanical properties will find in Digimat-VA a productive solution to save time and money

For details please visit wwwe-xstreamcom

The MSC Material Databanks are collections of technical materials information in electronic format The databanks are developed and maintained through MSCrsquos partnerships with premier sources of materials information They provide a comprehensive source of material property data for use by engineers for design and analysis Benefits include bull Easy access to high-quality reliable material data from around the world to improve team efficiency and information workflow bull Improved quality and consistency with engineering data derived from a single sourcebull Reduced transcription errors with electronic data transferbull Increased accuracy of predictive analysis product design and simulation using certified material data records for CAD CAE

or PLM software

For details please visit wwwmscsoftwarecom

MaterialCenter 2015 is an out-of-the-box Material Process and Data Lifecycle Management solution with direct integration into many of the CAE pre- and post-processing tools commonly

used by engineers The integration provides direct support to retrieve a material model from MaterialCenter without leaving the native CAE pre- and post-processing application

MaterialCenter 2015 also enables users to create and edit material data directly from the browser environment Along with MaterialCenterrsquos Excel integration this provides a completely traceable system to ensure users are aware of all the modifications made to the data

MaterialCenter is the single point of entry for all of your materials related activities including physical test data entry and reduction multi-scale materials modeling approval workflow and the export of simulation ready data to analysis

For details please visit wwwmscsoftwarecomproductmaterialcenter

The material modeling platform for simulating a range of composites

Secure reliable and fast access to material data

Delivers material data integration and ease of use to dramatically improve engineering simulation workflows

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 12: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Figure 1 Conventional workflow for

MBD-Acoustics integration

Figure 2 New workflow for highly

integrated method

8 | MSC Software

MULTIBODY DYNAMICS - ACOUSTICS SIMULATIONCO-SIMULATION SPOTLIGHT

IntroductionThe reduction of the development cycle and resources needed for designing quality products is always a major industrial challenge The integration of different CAE technologies allows making a step forward to this aim For example by enabling Multibody Dynamics (MBD) engineers to access preliminary acoustic data in their familiar MBD environment it allows them to detect unsatisfactory designs even without being acoustic specialist or with the direct support of an acoustic engineer Moreover trying to connect the two worlds can lead to loss of information and requires additional manual work for the engineers On the contrary with an integrated solution the data exchange between MBD and acoustic departments would be limited only to some advanced acoustic results

This article will discuss how Adams and Actran the MBD and Acoustic solutions of MSC Software are combined and integrated together enabling MBD engineers with the possibility of an insight into the acoustic

behavior of moving mechanism early on in the design process Moreover the acoustic engineers can still get more valuable information from the further post-processing of acoustic results

Multibody Dynamics Coupled with Acoustic analysisIt is generally difficult to predict the noises coming from a moving system like transmission system or gearbox One there are complicated moving mechanisms inside the system and different ways in which the parts interact with each other causing varying contact forces and vibrations Two understanding how the dynamic performance can influence the acoustic waves radiated from the gearbox casing is also a big challenge

Without the ability to accurately predict how the system dynamics will impact its noise performance engineers donrsquot have an efficient method to redesign their systems to improve acoustic behavior

By

Dr

Die

go C

opie

llo

Pro

duc

t M

arke

ting

Man

ager

A

ctra

n amp

Yiju

n Fa

n P

rod

uct

Mar

ketin

g M

anag

er

Ad

ams

amp E

asy5 The traditional workflow for such analysis

involves three interfaces Multibody dynamics (MBD) tool finite element analysis (FEA) tool and acoustic software First Engineers would need to perform the dynamic analysis in an MBD tool to get the dynamic loading on the gear casing surface and since that time-domain results usually canrsquot be read into Acoustic software directly they would need to convert the complete structure response in the frequency domain after that they can finally read the surface vibration into the acoustic software and use it as a boundary condition This workflow is fairly laborious and could require several CAE engineers to cooperate together every time therersquos a change in the design

MSC Software has recently developed a new methodology allowing the engineers to perform the modeling within the Adamsrsquo interface and get initial results and impressions of the acoustic behavior without manually exporting the results into acoustics software to perform noise analysis Typical acoustic results are computed via Actran and displayed in Adams interface including the acoustic pressure evolution in time at selected positions around the model and audible wave files for listening to the sound

Such new workflow greatly reduces the time and cost to conduct acoustic analysis on moving mechanisms like a gearbox enabling engineers to do more iterations on the new system design in the same period of time comparing to the conventional method Indeed the new methodology fully automates this workflow into a single simulation environment by embedding Actranrsquos new time domain acoustic solver into Adams This allows MBD engineers to perform a first iteration on acoustic results including the evaluation of the sound quality provided by a specific

Noise Prediction of Moving Mechanisms

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 13: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Figure 3 Gearbox model with three gear pairs amp flexible casing

Figure 4 Acoustic analysis setup in MBD environment

Figure 5 Acoustic Pressure evolution in time for the surrounding microphones

Figure 6 Spectrogram at one of the microphones surrounding the gearbox

Figure 7 SPL of orders 25 and 50 VS RPM

Volume V - Summer 2015 | 9

product design Thereafter and only if deemed necessary acoustic engineers can perform a more detailed analysis by investigating acoustic maps in the time domain or by converting only the most relevant results in the frequency domain

The Gearbox ExampleWith the aim of illustrating the MBD amp Acoustic integrated solution let us consider a gear box for example the motion of the gearwheels causes the vibration of the gearbox which affects then the physical behavior of the gearwheels leading to a strongly coupled problem The vibrating gearbox also transmits energy to the surrounding fluid and the acoustic waves radiate from it Contemporarily the acoustic waves affect the structural vibration as well However if on the one hand the Multibody dynamics and structural simulation domains are usually strongly coupled and shall be solved contemporarily on the other hand the feedback from the acoustic waves to the structure can be neglected when considering an acoustic radiation occurring in air This assumption allows the engineers to split the analysis of a vibrating structure into two subsequent steps the MBD analysis is run first and outputs the structural vibration on the structural domain These vibrations are used as boundary condition for the acoustic analysis which can be efficiently performed by means of Actranrsquos time-domain solver especially for

Advanced in the integration of CAE technologies enable a reduction of development time and resources

transient phenomena Let us also assume a gearbox composed by three gear pairs The input wheel is subject to a rotation ranging between 0 and 3000 RPMs

To evaluate the acoustic response we can consider a number of microphones distributed around the gearbox For example the microphones could be spatially distributed accordingly to the standard ISO 3744

In the Adams model the gearbox casing is considered flexible to capture its surface response The rest of the gearbox (like gears shafts bearings) are rigid parts Although the gears are not flexible parts it is still possible to calculate the tip relief and crowning effects which can impact the dynamic loading on the gearbox casing

After the Adams model is set up a 5-seconds dynamic analysis is conducted with the rotational speed of the input shaft ramping up from 0 to 3000rpms From the analysis we got outputs for all the loads and contact forces of each component as well as the displacement velocity and acceleration of each systemrsquos part

Following the MBD simulation and while still in the Adams environment an acoustic toolkit is launched to set up the parameters for the acoustic analysis like the acoustic mesh radius of the infinite elements speed of the sound fluid density output format acoustic environment (the material) and so on

What this toolkit does is that it will convert the MBD results into boundary conditions for acoustic model and perform the acoustic analysis in the background using the new Actran time domain solver Specifically the casing acceleration (or equivalently the displacement or the velocity) and the surface mesh of the casing are used to feed the acoustic simulation tool As the meshing requirements for the structure model are more restrictive than the acoustic ones the structural and acoustic meshes are incompatible This also implies that a projection procedure from the structural mesh to the acoustic one is needed When the acoustic simulation is done in the Adamsrsquo environment you can go to the MBD postprocessor and get some of the acoustic results of this gearbox casing like the acoustic pressure evolution in time for the

surrounding microphones at each microphone location and sound file (wav)

Figure 5 shows an example of the acoustic response in time domain of all the surrounding microphones this first result allows the identification of instants and areas where the acoustic pressure could exceed unwanted values which means some potential noise issues Moreover these data can be converted in audio files to get the audio quality of a certain gearbox design directly in a single simulation environment enabling MBD engineers to detect unsatisfying results from an acoustic perspective

Time domain data can be further converted in the frequency domain thanks to Actranrsquos utility ICFD Thereafter results can be post-processed in ActranVI to get a thorough understanding of the acoustics For example Figure 6 depicts the waterfall diagram of the noise at a microphone surrounding the gearbox case The main noise contribution is given by the 25th and 50th orders highlighted by two straight lines in the picture These orders are linked to the first gearwheel since it features 25 teeth Between 800 and 1300 Hz the noise levels are much higher This is due to the excitation of specific structural modes by the first gearwheel

Figure 7 depicts the Sound Pressure Level (SPL) versus the machine RPM automatically extracted by Actranrsquos WaterfallViewer from the plot of 6 This allows to better understand the impact of the different orders on the acoustic performance Indeed at low machine rotational speed the 50th order has a major contribution to the radiated noise whereas the 25th mainly impacts the system at higher rotational speed

ConclusionsAdvances in the integration of CAE technologies enable a reduction of development time and resources This article provides an example of these benefits by illustrating how the integration Adams and Actran improves the workflow for CAE engineers Specifically multibody dynamic and acoustic time domain analyses are integrated into Adamsrsquo environment enabling MBD engineers to perform preliminary acoustic performance evaluations of their products These evaluations also include the investigation of the noise quality thanks to the generation of audio files Finally and only on most relevant cases advanced post-processing can be performed by acoustic engineers in Actranrsquos environment u

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 14: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Figure 1 Physical testing of skid against a curb load case

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATION

10 | MSC Software

CO-SIMULATION SPOTLIGHT

Bas

ed o

n an

inte

rvie

w w

ith A

nder

s W

irje

Tec

hnic

al E

xper

t at

End

uran

ce A

ttrib

ute

amp C

hass

is C

AE

Dep

t

Volv

o

Avehicle might be subjected to misuse peak load or strength events such as driving over a curb or skidding against a curb a few times during its life These

durability load cases play a major role in the product development process since they potentially drive the design for several components At Volvo the ldquodriving over a curbrdquo and ldquoskid against a curbrdquo strength events are classified into two categories Level 1 and 2 Level 1 represents extreme customer usage and the requirement is that all functions remain intact with no visible or noticeable deformation of any component of the vehicle Level 2 covers customer misuse and a certain amount of damage is accepted with a safe failure mode Structural deformations are acceptable but there should be no separation or breakage For level 2 it is desirable that a predetermined inexpensively replaceable component deforms and protects neighboring components a design principle known as chain of failure

ChallengeThe capability to perform peak load simulation with a high level of confidence is of great

importance to setting the design loads for components and studying vehicle behavior in these events Volvo uses Adams multibody dynamics software to simulate Level 1 load cases for driving over a curb and skidding against a curb The components of interest are modeled as linear flexible bodies in Adams This allows for linear material response for flexible bodies so this method is only valid up to small plastic strains which is a good fit for Level 1 load cases

On the other hand Level 2 load cases involve plasticity and buckling of flexible bodies for which there has not been a way in Adams to simulate with sufficient levels of accuracy up to now The skid against a curb load case is verified with physical testing with a known mass hitting the vehicle at a specified velocity and impact angle These tests require prototype hardware that is expensive to build and only available later in the product development cycle ldquoWe wanted the capability to simulate Level 2 load cases in order to be able to evaluate design of suspension components earlier in the development cycle without having to build hardware for each design alternativerdquo said Anders Wirje Technical Expert CAE Durability at Volvo

SolutionValidationMSC recently introduced the Adams-Marc co-simulation capability that makes it possible for the first time to include geometrically and materially nonlinear structural behavior in multibody dynamics simulation Any Adams model and any Marc model can be used in co-simulation with this tool Post processing is done separately Adams results in Adams and Marc results in the Marc postprocessor or using Computational Engineering Internationalrsquos (CEI Inc) EnSight post-processor which can import both Adams and Marc results

When setting up the co-simulation model for the skid against curb load case the Marc model contains the lower control arm and bushings connecting the LCA to the subframe whereas the rest of the half-vehicle model are included in the AdamsCar model Due to the extreme nature of a peak load event component modeling is absolutely critical to simulation accuracy All components have to be described within their full range of excitation Key components and behavior to model include

bull Contacts between curb and tire amp between curb and rim

bull Elastomers ie bushings

bull Camber stiffness of the suspension

bull Flexibility and plasticitybuckling of structural components

Adams runs a dynamics analysis while Marc runs a quasi-static analysis which means that mass and inertia of the component is not accounted for It would also be possible to run a transient analysis in Marc that would take mass effects into account Adams leads the co-simulation and then feeds its results to Marc Marc interpolates the Adams results to catch up and passes the results to Adams which extrapolates them in taking the next step The simulated event has a duration of 07 seconds in clock time The communication interval is 5e-4 seconds in clock time The

Evaluating Suspension Components Earlier in DesignVolvo Car Looks Into New Technology to Simulate Complex Load Cases

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 15: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Results of Adams-Marc co-simulation of Level 1 skid against curb event show no buckling or plasticity

Results of Adams-Marc co-simulation of Level 2 skid against curb event shows buckling and plastic deformation matching physical testing results

Lateral force on front bushing based on linear elastic simulation (blue trace) and fully non-linear Marc component (red trace)

Close-up view of Adams-Marc co-simulation of Level 2 skid against curb event

Strain mapped onto lower control arm in Level 2 skid against curb event

Volume V - Summer 2015 | 11

The ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle

total simulation time was a very reasonable 40 minutes on a Dell laptop with 16 Gigabytes of RAM and a 27 GHz CPU

The Adams ndash Marc co-simulation of the Volvo S80 front suspension accurately predicted the behavior of a Level 2 skid against a curb load case The low velocity impact (Level 1) and high velocity impact (Level 2) cases showed the same behavior as the physical tests

ResultsBenefitsThe ability to accurately simulate Level 2 load cases will make it possible to substantially improve the product development process ldquoFrom the early stages of the development process we will be able to evaluate the performance of alternative designs in terms of their performance under Level 2 loadsrdquo Wirje said ldquoThe ability to quickly and easily look at alternatives at a time when we are not locked into any particular approach should make it possible to meet performance requirements with a lighter suspension that can improve the fuel economy of the vehicle At the same we should be able to reduce the cost and time involved in suspension development by performing product development more accurately from the beginning so fewer prototype verification cycles are required Of course full physical verification will be performed at the end of the projectrdquo

About Volvo Car GroupVolvo Car Group manufactures and markets sport utility vehicles station wagons and sedans Sales for 2014 hit a record of 465866 cars up 89 percent from 2013 Volvo Cars has been under the ownership of Zhejiang Geely Holding of China since 2010 u

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 16: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

12 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Based on an interview with Dr Steve Jia Chief Engineer Litens Automotive Group

Litens Automotive Grouprsquos patented TorqFiltr torque modulator uses an arc spring isolator mechanism to decouple the accessory drive system inertia from the engine torsional

vibrations The Litens torque modulator controls the system resonant frequency by tuning the spring stiffness to the system inertia Because the spring stiffness is softer than traditional rubber isolators vibrations from the engine are mostly absorbed before being transmitted to the accessory drive belt This results in isolation of all components in the accessory drive and any accessory drive resonance has very small peak amplitudes since there is very little excitation

The product is dimensionally rather small but incorporates a complex mechanism consisting of a series of components that transmit power to each other through complicated frictional contacts rather than fixed connections ldquoThis device provides an enormous design challengerdquo said Dr Steve Jia Chief Engineer for Litens Automotive Group ldquoWe need to fully understand the

behavior of the design under dynamic loading conditions The product must be customized to deliver optimal performance for many different automotive engines In the past this involved a time-consuming and expensive trial and error processrdquo

ChallengeLitens developed the ability to accurately simulate the operation of its torque modulator including how the design behaves how components move and react against each other and what happens under dynamic loading conditions with MSC Marc nonlinear finite element analysis software Simulation provides substantial cost savings by accurately predicting performance of a proposed design without the considerable expense and lead time required to build and test a prototype However the computational resource requirements are considerable because a nonlinear finite element analysis is performed on each component Time to perform a typical simulation is 30 hours which limits the degree to which nonlinear analysis can be used in the

design process

ldquoWe were looking for an approach that would allow us to simulate the performance of our torque modulators including material and geometric nonlinearities in a fraction of the time so that we could integrate advanced nonlinear analysis into the design processrdquo Dr Jia said ldquoWe had the idea of combining multibody dynamics (MBD) simulation at the system level with nonlinear finite element analysis at the component level for components with large deformation to achieve a fast solution and accurate resultsrdquo MBD software has previously been integrated with linear FEA software but not with nonlinear FEA which is needed to provide accurate results for components with large deformations and material nonlinearities such as the right and left side springs used in the torque modulator

SolutionValidationldquoMSC is the leader in nonlinear analysis with Marc and the leader in MBD software with Adams so they were the obvious choice

System Analysis 15x Faster with Co-SimulationLitens Automotive Group achieves 90 reduction in computation time

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 17: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Volume V - Summer 2015 | 13

The Adams-Marc co-simulation capability more than satisfies our guideline of lsquoreasonable results in a reasonable timersquo With up to a 90 reduction in computation time optimization using advanced nonlinear FEA becomes practical Such development provides a great benefit and is crucial for our product development and we are proud to work together with MSC in advancing the technologyrdquo

to approach with our request to integrate these two technologiesrdquo Dr Jia said MSC engineers coupled Marc and Adams so that the interaction between the motion behavior in Adams and the nonlinear behavior in Marc is taken into account in the simulation at both the system and component level and solved at each integration time step Deflections calculated by Adams are taken into account at each time step in Marc and dynamic loading conditions are transferred from Marc to Adams Marc determines stress and deformation at the component level with geometric material and contact nonlinearities taken into account The Adams-Marc co-simulation capability was introduced in a beta release of Adams 2014 The beta release was validated on the Litens torque modulator before the software was released to the general public in Adams 2014

ResultsLitens CAE engineers set up the typical simulation so that only the left and right springs are modeled as flexible bodies in Marc and all other components are modeled as rigid bodies Six contact points are established between the shell of the torque modulator and the springs and these points are used by Adams to provide displacements to Marc and by Marc to provide forces back to Adams Under these conditions Adams-Marc co-simulation analyzes the torque modulator in only two hours 115 of the time required for Marc simulation A small difference of 10 in results was seen with co-simulation and this was expected since normal Marc simulation analyzes all components as flexible bodies while the co-simulation models most components as rigid bodies The Marc simulations have previously been found to be very close to physical measurements The co-simulation results for key values such as the inner drive angle as a function of input torque were found to vary by less than the 10 from the Marc simulation over two revolutions of the input shaft

ldquoThis small difference in results is acceptable considering the dramatic reduction in computation time provided by co-simulationrdquo Dr Jia said ldquoThis technology will make it

possible for the first time to utilize advanced nonlinear FEA as an integral part of the design process We see this advancement as similar in significance to the advancement several decades ago in computing power which made it possible to integrate FEA into the design process It is expected that Adams-Marc co-simulation in the early stages of the design process to evaluate different design alternatives will significantly speed up the design process Once we find a design that looks promising we will run a more accurate Marc simulation to validate its performancerdquo

About Litens Car GroupLitens is a global organization serving the automotive market with high quality service and products for power transmission systems Litens was the first company to develop and produce in volume an automotive automatic tensioner and single belt accessory drive After 35 years Litens has established its global leadership in automotive belt drive systems and component design applications The company is engaged in the development of innovative products to provide its global customer base with unique engineered solutions to vehicle performance and NVH challenges u

Adams Model of the Center Drive and Marc Model of the Two Springs

The Litens torque modulator controls the system resonant frequency by tuning the spring

stiffness to the system inertia

Comparison of dynamic spring load for left spring for Marc simulation vs Adams-Marc co-simulation

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 18: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

14 | MSC Software

MULTIBODY DYNAMICS - CONTROLS CO-SIMULATIONCO-SIMULATION SPOTLIGHT

By

Mar

io F

elic

e amp

Jac

k Li

u of

For

d M

otor

Com

pan

y amp

Wul

ong

Sun

of

MS

C S

oftw

are

Noisevibrationharshness (NVH) and fuel economy often must be traded off against each other during the vehicle design process For example lugging

is a condition that typically occurs when the vehicle is in high gear with an engine speed of below 2000 rpm When the driver steps on the gas pedal under these conditions the engine struggles to give motion to the vehicle while generating relatively little torque so acceleration is low Lugging produces high levels of low frequency inputs because of the low firing frequency at low engine speeds and high loads These low frequency inputs are frequently experienced by the driver and passenger as seat track vibration steering wheel vibration and interior cabin boom sound

One of the primary methods by which engineers attempt to control lugging is through the torque converter which transmits and amplifies the torque from the engine to the transmission using fluid coupling The torque converter consists of a pump turbine impeller and stator contained within a cavity filled

with transmission fluid in addition to a lockup clutch and damper assembly The clutch is electronically controlled to provide the desired level of slip When required the clutch locks up and provides a direct connection between the engine and transmission resulting in near 100 efficiency and the best fuel economy In lock-up mode engine torque fluctuation is transmitted directly to the transmission potential causing the drivetrain to generate vibration and noise Slipping the torque converter increases dampingreducing sensitivity of the driveline vibration to the engine torque excitation and improvingNVH performance On other hand slipping increases losses due to fluid coupling and clutch friction which decreases fuel economy

ChallengeWhen developing a new vehicle model engineers are responsible for meeting a wide variety of often conflicting performancetargets Fuel economy and NVH are two of the most important categories of targets With regards to lugging NVH engineers are typically responsible for holding torsional vibration

amplitudes at the transmission output shaft below a target value The NVH team naturally would prefer a large amount of slip in order to help meet their targets while the team responsible for fuel economy would like slip to be as low as possible to meet their targets Up to now it has not been possible to determine torsional vibration amplitudes with high levels of accuracy until a prototype vehicle is built and tested in the late stages of the product development process However at this late stage the design is frozen and changes are quite expensive and could potentially delay production Ford was looking for a method to simulate the effects of different torque converter designs so that engineers could make intelligent tradeoffs upfront in the design and development stages

Tackling Conflicting Performance RequirementsFord Leverages Adams FMI Co-Simulation Method to Optimize Tradeoff between Fuel Economy and NVH

Adams and AMESim FMI co-simulation Torque converter assemblyDrivetrain model

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 19: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Torsional vibration at transmission output shaft vs engine rpm vs slip rpm

Steering Wheel and Seat Track Vibration are drastically reduced by slipping Torque Converter

Volume V - Summer 2015 | 15

We ran the model for different values of desired slip rpm across a broad range of engine rpm The simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economy

SolutionValidationFord engineers addressed this challenge by taking advantage of a new capability of MSC Softwarersquos Adams to support the Functional Mock-Up Interface (FMI) tool independent open standard for model exchange or co-simulation The FMI standard makes it possible to create a virtual product from a set of models of the physical laws and control systems assembled digitally The FMI instance of a model is called a Functional Mock-Up Unit (FMU) An FMU is a formatted file containing an XML formatted model description file dynamic link libraries and model data files FMI can be used for model exchange or co-simulation The Adams FMI support extends the AdamsControls Co-simulation support of Matlab and Easy5 to all software utilizing the FMI Co-simulation standard

In this case Ford engineers used an Adams 3D drivetrain and full vehicle model as the co-simulation master with an AMESim 1D converter slip controller model as the co-simulation slave with the goal of optimizing converter slip to meet the vehicle lugging NVH target while maximizing fuel economy A drivetrain model was created in AdamsDriveline including an I4 Gasoline Turbocharged Direct Injection (GTDI) engine with three mounts a torque converter with a lockup clutch a six-speed gearbox with internal shafts and planetary gear sets and a front driveline with differential link-shafts half-shafts constant velocity joints and wheels The driveline model was incorporated into a full vehicle model using AdamsCar The vehicle model includes the chassis suspension steering brake and wheel subsystems The AMESim torque converter model is a

proportional-integral-derivative (PID) controller that provides the normal force on the converter clutch based on the difference between the actual slip and the desired slip

ResultsWe ran the model for different values of desired slip rpm across a broad range of engine rpmrdquo Mario Felice said ldquoThe simulation results showed that a slip of 30 rpm or lower would fail to meet the NVH target while a slip of 40 rpm or greater would meet the target The simulation showed that 40 rpm slip was the optimal value that would meet the NVH target and would result in the best trade off with fuel economyrdquo Engineers further studied the reduction in torsional vibration amplitudes generated by the clutch damper behavior and the torque converter slip They also compared vibration at the steering wheel and seat track with 0 rpm and 40 rpm slip The results showed that steering wheel and seat track vibration are drastically reduced by slipping the torque converter ldquoNext steps will include increasing the sophistication of the torque converter model by modeling the hydraulic system to provide more accurate predictions of normal force as a function of timerdquo Felice said ldquoWe also plan to validate the model with physical testing results Then we will integrate the co-simulation into the design process so that the torque converter design can be optimized early in the product development cyclerdquo

About FordThe Ford Motor Company is an American multinational automaker that sells automobiles and commercial vehicles under the Ford brand and luxury cars under the Lincoln brand u

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 20: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

16 | MSC Software

MULTIBODY DYNAMICS - NONLINEAR FEA CO-SIMULATIONCO-SIMULATION SPOTLIGHT

Each year an estimated 1 million people suffer from painful bedsores in US hospitals across the country These wounds are the result of long-term confinement to a bed

or wheelchair and often become seriously infected or develop gangreneNot only are bedsores incredibly painful but they can also be deadly linked to a four-fold increase in death with a hospital mortality rate of 23-37 percent Compounding the problem patients who develop bedsores also experience a five-time longer hospital stay putting them at much greater risk of developing other ailments Then of course there are financial implications conservative estimates peg the cost of bedsores in US hospitals at $55 billion per year (All sources httpleedergroupcombulletinsbed-sores)

Finding a way to prevent bedsores before they start is a high priority for hospitals nursing home and long-term care facilities as well as bed manufacturers Conventional means of studying possible solutions typically involve long prototyping processes and the use of human test subjects who are asked to lie in a bed for an extended period to see if they develop a bedsore

Instead MSC Softwarersquos Senior Engineer Mark Carlson and his team have developed a simulation test bedmdashboth literally and figurativelymdashfor assessing the impact of potential bed designs on bedsore formation in a matter of hours instead of months with absolutely no risk to human health The

simulation combines the non-linear finite element solution capabilities in MSC Marc with the multi-body dynamics analysis power of MSC Adams and the 3D post-processing visualization provided by EnSight from CEI The analysis has been able to uncover critical previously unattainable insights into the bedsore problem This helps equipment manufacturers build better beds that can help prevent bedsores from forming in the first place

More than Skin DeepOne of the critical challenges in studying bedsore development is understanding how where and why they develop Anecdotally Carlson and his team knew that the buttocks and heels are the primary locations for bedsore formation Bed manufacturers have been experimenting for years with different types of bed surfaces foam materials positioningangling and other parameters to help better distribute the stresses caused by pressure and gravity across the body

The problem is conventional testing typically involves two methods which have some limitations First manufacturers ask human test subjects to lie on a pressure sensitive pad which indicates how the contact patches manifest externally on the surface of the skin Researchers have long theorized that bedsores are more than just a surface problemmdashthey actually manifest under skin deep in the tissues of the flesh muscles and even bone interfaces Second lab tests using body part

By

Ms

Kar

a G

ray

CE

I amp M

ark

Car

lson

M

SC

Sof

twar

e

Simulations give insight into Bedsore ProblemsMSC Co-Sim Technology Combines with EnSight 3D Visualization to Solve Bedsore Mystery

molds in a compression test machine can study the forces applied by those parts onto the bed but only for those specific individual partsmdashjust the heel or the torso for example This kind of test makes no consideration for the changes sometimes dramatic which could occur when entire human bodies of varying sizes and anthropometric characteristics are positioned across the entire bed

MarcAdams Co-Sim Reveals Hidden InsightsTo study the problem more holistically Carlson and team developed an advanced co-simulation solution that not only allowed researchers to study the problem more thoroughly but also much faster to accelerate material and equipment design innovation testing and market delivery

Carlson began with Adams to simulate the rigid component geometry of the human body using the Life Modtrade plugin (httpwwwlifemodelercomproductslifemod) from Life Modeler of San Clemente Calif to model the anthropometric data for various parts sizes and characteristics of the human body from the pre-loaded Life Modeler geometry database Adams was able to simulate the effects of bed settling due to gravity across the fifteen different body segments accounting for accurate range of motion calculations as well as the other complex dynamics and kinematics present in the various human joints

But gravity settling is only part of the

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 21: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Soft Tissue Behavior Included at the Calf to Foam Interface

Tissue Stress amp Comfort Analysis 50th Percentile Male on Multi-Foam Mattress

Finite Element Contact Stress on the Polymer Insert

Close up of the calf contact stress

Volume V - Summer 2015 | 17

equationmdashunderstanding the contact patches and associated stresses caused by those loading conditions in relationship to the bed was the next step With MSCrsquos nonlinear finite element solver Marc the team was able to develop a mathematical model of the bed including simulation of a wide array of foam materials foam layering configurations and other properties In addition the team was able to create its own simulated foam materials and configurations for scenario testing

The Co-Sim solution running the two solvers simultaneously to include the complex physical contact interactions along with accurate representation of the human motion was critical to understanding the complete picture of the conditions under which bedsores develop even beneath the skinrsquos surface More importantly the team was able to better understand as well as practically quantify the sensitivities of attribute combinations and evaluate how even small changes in bed design positioning foam material and other parameters could have significant effect on contact stresses even into the deep tissue layers below the surface With the time synchronous co-simulation solution the team was able to test hundreds of combinations with varying anthropometric characteristic bed geometries and complex foam materials in very short order

A Clearer Picture with EnSightWhile both Marc and Adams have their own built-in post-processing capability they still generate separate data sets To merge the two Carlson and his team used CEIrsquos EnSight 3D visualization software from Computational Engineering International (CEI Inc) of Apex NC to view the data sets concurrently

ldquoLooking at Adams only yoursquod see the human body sinking into nothingness and with Marc yoursquod see the finite elemental deformations in the bedmdashthe contact pointsmdashbut no body Once we time-sync the two and import the results into EnSight you get a clear picture of the combination of both data sets at oncerdquo Carlson said ldquoEnSight is so flexible and easy to use that we can also plot data at the same time as we visualize look at each data set separately or combine them into a single immersive 3D viewrdquo

In addition to EnSight the team used CEIrsquos EnLiten file viewer to share the 3D simulations with others who may not have EnSight Carlson says the ability to demonstrate the research and results in a visually compelling way that everyone can access makes a

tremendous impact in understanding and humanizing the results

ldquoThe enhanced communication we achieved with EnSight and EnLiten is hugerdquo he said ldquoNot only in any presentations I might put together but also in the fact that I can send someone a full 3D EnLiten model which they can study on their own interact with manipulate views and angles turn parts and plots off Itrsquos free and they can use it independently of the simulation and visualization softwarerdquo

A Positive PrognosisWith the research enabled through the MarcAdams co-simulation hospital bed and other equipment manufacturers can gain much greater visibility into whatrsquos going on internally with the body in relationship to external forces and how to solve related challenges

ldquoThis capability is like installing sensors inside the body and on the surface that the body

is resting on to get a picture of how the two interact That just wasnrsquot possible beforerdquo Carlson said ldquoAnd itrsquos so much faster and less expensive than building prototypes bringing in real people for testing and exposing them to the risk of complications and then having to go back to the drawing board for every variable change With Marc Adams and EnSight working together we can set up several variations to run simultaneously and have results the same day versus waiting weeks or months for physical test or clinical trial resultsrdquo

Originally developed as a customized solution the MarcAdams co-simulation tool is now available as a pre-packaged general purpose product EnSight and itrsquos free 3D viewer EnLiten are compatible with MSCrsquos entire suite of solvers including Marc Adams Dytran and Nastran for stunning and compelling 3D visualization and communication

To learn more visit wwwmscsoftwarecom and wwwensight10com u

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 22: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

TECH TIPSMSC Software

Figure 1

Figure 2

Figure 3

Figure 4

Defining Axis of Rotation of a Rigid BodyBy Joe Satkunananthan Sr Manager Global Services Post Sales Support Americas MSC Software

When a rigid body is required to be rotated about an axis how do we calculate the direction cosines of rotation axis In the example below a cylindrical surface defined as a rigid body is to be rotated about an axis that goes through the points (125 075 150) and (785 565 1025) as shown in Figure 1

In order to rotate this geometry about its axis the center of rotation and direction cosines need to be inserted into Contact Body Control Parameter menu in Mentat shown in Figure 2 (Contact Body Properties gt Body Control Parameters) The direction cosines of the rotation axis can be calculated from the coordinates of the two points through which the axis goes through

As Mentat only needs the vector of the rotation axis you can also get away by following the approach below

1 Select Distance from Tools menu (you can also type the command lsquodistrsquo in the dialog window at the command prompt) (Figure 3)

2 Select 2 points that would show the direction of the vector

You would get 2 lines of output as shown below

In addition to the distance between the selected two points Mentat displays ∆x ∆y and ∆z The second line shows the angles (in degrees) with respect to each of the axes You can calculate the direction cosines by finding cosine of each of the angles You can also just enter the numbers in the parenthesis (66 49 and 875) to define the rotational axis (Figure 4)

18 | MSC Software

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 23: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Useful Tools for Contact AnalysisBy Christian Aparicio Product Marketing Manager MSC Software

Contact analysis is used to simulate the interaction of two or more separate parts or when one part contacts itself This type of analysis is useful for determining the load transfer and load path between components In order to perform a contact analysis contact bodies and the other bodies which they contact must be identified

In the latest release of Patran we have introduced new functionality to expedite the process of creating the necessary contact bodies and pairs for a contact analysis

How to quickly create deformable contact bodies in Patran Contact bodies as the name implies are the parts of your model that will be in contact with other parts or itself

To enter the tool go to Tools gt Modeling gt Contact BodiesPairshellip

A new form appears Do the following

1 Set Create to Deformable Bodies

2 Set Method to Properties

3 Set Create From to Select Properties

a Click on the small icon that is to the right

b Select which properties are to be considered when creating the contact bodies

4 Click Apply

Patran will then determine the contact bodies list them in the model tree and indicate the contact bodies with a magenta circle on the screen

How to quickly create contact pairs in Patran Once the deformable contact pairs are created a definition is needed to indicate which contact bodies touch other contact bodies This definition is known as a contact pair The same tool mentioned in the previous tip can also be used to create contact pairs

In the same tool as before

1 Set Create to Body Pair

2 The Distance Tolerance is used as follows if one contact body is within proximity or a certain distance of another contact bodies the pair of contact bodies is expected to touch For example if the face of contact body 1 is 2mm from the face of contact body 2 a Distance of Tolerance greater than 2mm would be need in order for the application to generate a contact pair

3 You may select All Bodies which selects all Deformable and Rigid contact bodies or Deformable Only

4 For Create Form the Select Bodies options allows you to select which contact bodies will be used to determine contact pairs

5 Click on Apply

The end result is a list of contact pair definitions This example had 4 deformable bodies so there are 3 contact pairs

Volume V - Summer 2015 | 19

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 24: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

The FE_PART is a wholly Adams-native modeling object with inertia properties which can undergo very large deformation or geometric nonlinearity FE_PART is based on an MSC-authored adaptation of Absolute Nodal Coordinate Formulation (ANCF) This Adams object can model 2D or 3D beam-like structures The 3D formulation is a fully geometrically nonlinear representation that can account for stretching shearing bending and torsion The 2D formulation is a geometrically nonlinear representation where the centerline of the beam-like structure is assumed constrained to a plane parallel to the modelrsquos global XY YZ or ZX plane The 2D Beam can stretch or bend in plane and solves faster than the 3D Beam

What are the benefits

bull No need for an FEA-Package to generate the FE_PART

bull No need for subdivision of masses as in Adams Discrete Flexible Link

bull Modification and parameterization is often easier than multi-MNF and Discrete Flexible Link

bull Modeling a distributed load via ldquoFE_Loadrdquo is far less time consuming than using discrete force vectors or MFORCES

bull Support for stress and strain recovery in AdamsPostProcessor (X-Y plots)

bull Reduced noise in nonlinear contact where a geometry ldquowrapsrdquo around another since the geometry is not discretized

bull No ldquoseamsrdquo in the stressstrain results due to discretization

bull 2D formulation option for faster analysis on planar problems

Industrial Applications

bull Automotive

- Anti-roll bar

- Coil springs

- Leaf Springs

bull Heavy Machinery

- Cable Applications

bull Aerospace

- Structures with large deformation

How to Implementbull Create an FE_PART using the FE_PART

wizard

bull Select material properties and beam formulation (3D 2D)

bull Generate a centerline for the FE_PART beam-like structure

- Create a matrix based on the

centerline x y z data

- Create a curve using the matrix

- Create a bspline elements using t he curve

bull Use the bspline as the centerline for the FE_PART

bull Use the Curve Control Point from the bspline

bull Modify node spading or angle of rotation if needed

bull Create a new section based on default sections

bull Determine faceting tolerance for mesh refinement

bull Use Adams Durability plugin to recover stresses and strains at any FE_NODE

How to apply distributed loads FE_LOAD special force is used to define a distributed applied load (force and moment) per unit length unit area or unit volume The nature of the force depends on the FE_PART this load

acts upon For example if the FE_PART is a beam or cable then the load is automatically set to have units of force and moment per unit length

For a general distributed load shown below the FE_LOAD statement can be defined as follows

Comparison between a traditional Anti-Roll Bar and an FE_PART Anti-Roll BarUnder a given loading a geometrically linear element undergoes higher torque than a geometrically nonlinear element This is seen in the graph below the FE_PART anti-roll bar shows a smaller twisting torque than the simple anti-roll bar

More to read

Please refer to the publically available FE_PART document article DOC10651 for more details

The New ANCF Object FE_PARTBy Maziar Rostamian Technical Representative MSC Software

20 | MSC Software

FE_LOAD1 FE_PART=3 FX= 0 FY= -30SIN(PIS) FZ= 0 TX= 0 TY= 0 TZ= 0

Application of FE_Part for Anti-Roll Bar Undergoing Large Deformations

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 25: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

MSC Platinum SUPPORT

Support Services amp Features Standard Support Plan Platinum Support Plan

SimCompanion Access (Knowledge Base Videos

Community Forums)

Technical Support Availability

Technical Support Response Time

Expert Mentoring

e-Learning

Technical Support Account Manager

Annual Roadmap Session

VPD Community Forums

24x7 24x7

24x7 24x7

Live On-Demand Live On-Demand

Web Email Phone Web Email Phone

Business hours

4 Business hours

Extended hours

Current + Last Major

1 Business hour

Current + Last 3 Major

Eligible

Eligible

Included

Included

SimAcademy Webinars

Technical Support Channels

To learn more visit

wwwmscsoftwarecom Platinum-Support

Technical Support for Software Versions

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 26: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

MSC Apex is a next generation simulation platform that is easy to use easy to learn and intuitive for engineers It is a fully integrated and generative structural analysis solution for product designers and researchers New to

the latest Diamond Python release is a unique incremental mid-surfacing workflow additional attribute capabilities and expanded Analysis Readiness and Generative Behavior New Incremental Mid-Surfacing ndash SmartMidsurfacetrade

Challenge Existing methods in prepost processors while automated often produce mid-surface geometry that is far from complete A user then needs to devote substantially more time to repair the geometry before the mid-surface model is complete

Solution MSC Apex features a first-to-market incremental mid-surface approach that gives users more control and options early in the process for extracting mid-surfaces The benefit is that this semi-automated approach produces mid-surface models closer to completion earlier in the process saving the user time

Additional Attribution Capabilities

Challenge The traditional process of assigning thickness and offset properties is exhaustive Users have to manually measure every thickness and calculate each offset Automated methods exist but are limited to cross sections of uniform thickness

Solution MSC Apex includes an automatic method to generate these thickness and offset properties rapidly but what is new

in Diamond Python is that this automated process is now applicable to non-uniform cross sections

Expanded Analysis Readiness and Generative Behavior

Challenge Before performing an analysis there is the likelihood that an error exists in the model and would cause a computationally expensive analysis to fail mid-way through The model is then inspected carefully for the error and repaired On average the troubleshooting process could require a time consuming 4 iterations

Solution MSC Apex includes an integrated solver that is the basis of an Analysis Readiness capability that inspects the model prior to analysis and prompts the user if any errors are found ndash for example say elements are found to be distorted and unacceptable for analysis As the model is repaired Analysis Readiness dynamically inspects the new changes and certifies the model is ready to be analyzed Instead of making multiple attempts and devoting expensive computational time to failed

To learn more about the new incremental mid-surface workflow and other capabilities mentioned please visit wwwmscapexcom and request a free trial

The New MSC Apex Diamond Python Release Delivers Dramatic Time Savings

22 | MSC Software

FEATURE STORY

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 27: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

MSC APEX TRANSFORMS THE WAY ENGINEERS PERFORM SIMULATION BY REDUCING CRITICAL CAE MODELING amp PROCESS TIME FROM DAYS TO HOURS

Volume V - Summer 2015 | 23

Smart MidSurfaceTMAccelerated Mid-Surface Model Construction Workflow

01 Identify Mid- Surface PairsUse pairing technology to automatically identify guides for mid-surface extraction

04 Continue repairing with direct modeling amp meshingUse direct modeling to further repair geometry that may already be meshed Slivers or cracks may easily be resolved and the mesh can be quickly regenerated automatically

02 Use Flexible Incremental ToolsAddRemove solid faces to pairs and merge pairs to incrementally guide extraction of mid-surfaces and maintain continuity across mid-surface junctions

05 Automatically create thickness and offset assignmentsUse Auto Thickness and Offset to create numerous property definitions for shell elements and export to the bdf file format

03 Extract Mid- Surfaces and RepairCreate complete mid-surface models by extracting extending mid-surfaces and trimming mid-surfaces Extraction is applicable to uniform or non-uniform thicknesses and planar or curved solid faces

06 Validate for AnalysisPerform an Analysis Readiness check and ensure models have necessary definitions for successful analysis

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 28: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Robert Lind Director of Engineering TLG Aerospace

ldquoMSC Apex takes what used to be time consuming amp frustrating geometry tasks using traditional programs amp turns them instead into efficient and satisfying tasksrdquo

Problems with original CAD geometry that needed to be cleaned up before analysis

Non congruent surfaces(gaps interference non-mating surface geometry)

44 locations

176 minutes

4 minuteslocation

58 locations

348 minutes (approx 58 hrs)

6 minuteslocation

OML curvature does not match stiffeners frames intercostals and beams

Total cleanup time for Pre-mod configuration

290 minutes

584 minutes (approx 98 hrs)

40 minutes132 minutes

Facets from complex surfaces drive node locations and poor element quality

4 locations

60 minutes

15 minuteslocation

Pre-Mod Configuration

Post-Mod Configuration

24 | MSC Software

What was the ProjectWings USA Inc a flight services company based in Janesville Wisconsin contracted with TLG Aerospace LLC to analyze a proposed modification to light aircraft

TLG was asked to analyze the aircraft before and after the modification to determine whether or not the modification would have a significant impact on the fuselage stiffness

What was the ChallengeThe original CAD geometry was created to the normal level of precision achieved in the design process TLG engineers then faced the time-consuming task of cleaning up the geometry to the higher standards required for finite element analysis and meshing As is typical with design geometry the CAD model contained broken surfaces surfaces that were not stitched together and redundant overlapping surfaces

TLG estimated that 348 minutes would have been required to manually make these corrections using traditional surface geometry tools The geometry also contained non-congruent surfaces including gaps interferences and non-mating surface geometry in 44 locations An estimated 4 minutes would have been required to clean up each location for a total of 176 minutes

Total cleanup time for the pre-mod configuration was 97 hours The post-mod configuration required a similar cleanup effort however a majority of this work from the pre-mod configuration could have been applied to the post-mod configuration

TLG engineers made the assumption that 30 of the total time required for cleaning up the

pre-mod configuration using traditional surface geometry tools or 29 hours would have been required for the post-mod configuration So the total cleanup time would have amounted to 126 hours TLG engineers also assumed that the meshing time for both the pre-mod and post-mod configuration would have been equal to the cleanup time so total geometry cleanup and meshing time would have amounted to 252 hours

MSC APEX TESTIMONIAL TLG AEROSPACE

Analyzing Design Modifications FasterTLG engineers reduce geometry cleanup and meshing time by 75

The MSC Apex Solution ndash Dramatic Time SavingsTLG Aerospace engineers addressed these challenges by performing the cleanup and meshing with MSC Apex which features a complete set of direct modeling tools to improve geometry cleanup and meshing productivity

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 29: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

W Scott Taylor Sr Mechanical Engineer Dynetics Technical Services Inc

ldquoThe technology innovation represented in MSC Apexrsquos capability suite and ease of use was head and shoulders above any other stand-alone CAD healer or integrated CAD-CAE meshing software I usedrdquo

Volume V - Summer 2015 | 25

What was the ProjectThe National Aeronautics and Space Administrationrsquos (NASArsquos) Space Launch System (SLS) will be the most powerful rocket in history launching crews of up to four astronauts in the Orion spacecraft to explore multiple deep space destinations

The RS-25 served as the Space Shuttle main engines and operated with 100 mission success during 135 missions The RS-25 is being modified to serve on the SLS by increasing its power from 491000 to 512000 pounds of vacuum thrust among many other improvements

What was the ChallengeEngineers who have been modifying the design of numerous fuel pump components used on the RS-25 and many rocket engine systems up to and including the SLS have based their analysis efforts on preexisting CAD design models These models have been received either by direct third party translators or open standards like STEP

As a case in point a recent demo is based on CAD geometry from a third party parametric solid modeling program that was altered to be generic and generally representative of the kind of complex airfoil geometries such as engine and fuel pump turbine blades The geometry produced by the third party program required considerable cleanup work before it could be meshed for structural analysis

The MSC Apex Solution ndash Dramatic Time SavingsTaylor used the advanced geometry modification utilities in MSC Apex Modeler to greatly simplify the process of repurposing the CAD geometry

In this application of MSC Apex on a generic turbine blade geometry that has been encountered and analyzed by engineers for decades the cleanup of geometric pathologies and arbitrary segment lines was reduced ldquofrom two days to one hourrdquo said W Scott Taylor Senior Mechanical Engineer Dynetics Technical Services Inc who is working on contract at MSFC

MSC APEX TESTIMONIAL DYNETICS

From Two Days to One HourDynetics Technical Services Inc achieves dramatic time savings

Engineers sketched new surface boundaries

Suppress edges functions used to remove undesirable edges in a single step

Ideal mesh quality is seen on leading (left) and trailing (right) edges

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 30: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

CAD model inside MSC Apex

26 | MSC Software

OverviewDEMA SpA is a major aerospace supplier that provides work packages for many major aircraft programs such as the Boeing 787 Airbus A380 and A321 ATR 42-72 Augusta Westland AW139 and Bombardier CS100 DEMA recently designed and built an innovative avionics bay pressurized door for a commuter jet DEMA engineers developed an innovative design concept in which the door is assembled from sheet metal using a machinable plate that saves weight by eliminating the need for mechanical joints DEMA needed to analyze the ability of the door to meet in-flight structural requirements in spite of multiple damage scenarios that might be incurred during service operations or could result from manufacturing variation in order to determine whether or not the structure maintains a sufficient safety margin These damage scenario analyses are used as the basis for inspection protocols that are performed on a regular basis to ensure that the door is flight-ready

The damage scenarios included reductions in the thickness of the pockets and reductions in the thickness and height of the vertical stiffeners The analysis procedure begins with analyzing the door at the as-designed thickness and height If the calculated static margin is less than or equal to 005 then no damage is permitted in this area If the calculated static margin is greater than 005 than the section is analyzed with 10 damage If the calculated static margin at 10 damage is greater than or equal to 005 then 10 damage is allowed in this area If the calculated static margin is less than or equal to 005 then the section is analyzed with 5 damage If the calculated status margin with 5 damage is greater than or equal to 005 then 5 damage is permitted in this area If the calculated static

MSC APEX CASE STUDY DEMA

Aero Supplier Achieves Dramatic Time Savings MSC Apex reduces time required to analyze aircraft avionics door for damage scenarios by 60

margin at 5 damage is less 005 then no damage is allowed in this area

ChallengeFour damage scenarios needed to be analyzed 1) 5 reduction in stiffener height and pocket thickness 2) 10 reduction in stiffener height and pocket thickness 3) 5 reduction in stiffener thickness and pocket thickness 4) 10 reduction in stiffener thickness and pocket thickness The door geometry had to be edited and the new geometry then had to be meshed and analyzed for each scenario The normal procedure was to first analyze of the baseline geometry based on the computer-aided design (CAD) model that contains the geometry definition The next step was to modify the CAD geometry

to replicate the first damage scenario Modifying geometry can often be difficult with conventional parametric CAD because only features configured in the original definition as parametric can be easily modified In some cases it is necessary to re-create the geometry from scratch because of inherent limits on editing parametric geometry

The resulting geometry was then meshed in the CAD program and exported to Patran where the model was completed with the addition finite elements such as MPC or CBUSH and then constrained and loaded with the appropriate load cases Finally MSC Nastran finite element analysis software was used to perform the simulations ldquoGenerically in the past each scenario would have required 16 hours for geometry modification and 4

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 31: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Volume V - Summer 2015 | 27

Antonio Miraglia Stress Lead for DEMA

ldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo

hours to prepare the mesh for analysis The four scenarios required for the door would have taken a total of 80 hours to evaluaterdquo said Matteo Capobianco structural analyst in charge of these activities

SolutionValidationldquoWe decided to evaluate the MSC Apex Modeler because we were looking to reduce the amount of time required for geometry modificationrdquo said Danilo Malacaria Head of Research and Innovation for DEMA MSC Apex Modeler uses a direct modeling approach in which the geometry is directly created as features or individual operations without requiring a network of constraints between the features and without reference to its history Users can edit geometry interactively by simply selecting entities of interest such as a face edge or vertex and push pull or drag them to implement any modifications For models that have already been meshed modifications to the geometry will cause the mesh to be immediately regenerated with the geometry DEMA engineers modified the door geometry inside the MSC Apex environment by dragging the zones impacted by the reductions to proper dimensions The mesh was then automatically updated

ResultsldquoEditing the geometry for one scenario took only 4 hours a 75 reduction from the traditional methodrdquo said Antonio Miraglia Stress Lead for DEMA ldquoPrepping the model took four hours the same as the traditional method A total of 8 hours were thus required to model each scenario and 32 hours were required for all four scenarios a 60 reduction from the time required in the pastrdquo

Pocket thickness modification inside MSC ApexMid-Surface extraction of vertical stiffeners

Finite element mesh inside MSC Apex

DEMA is planning to implement MSC Apex Structures an add-on module that provides linear structural analysis capabilities This module will save additional time in the future because the elements loads and constraints will updated along with the geometry changes in the MSC Apex environment ldquoWe project that the use of MSC Apex Structures will reduce the time required for prepping the model to 25 hours for each scenario reducing the total time needed to model all four scenarios to 26 hours a 675 reduction from the previous methodrdquo Malacaria said

About DEMA SpADEMA SpA manufactures and supplies aerospace assemblies and components such as aircraft fuselage sections passenger floors cockpits tail cones fan cowls ramps cargo doors slide boxes horizontal stabilizers helicopter fuselages helicopter tail booms and helicopter rear fuselages The companyrsquos areas of expertise include engineering design configuration management weight and stress reduction materials and processes sheet metal processing industrial engineering manufacturing and composite part production Founded in 1993 DEMA has about 800 employees and the headquarter is based in Somma Vesuviana Napoli - Italy

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 32: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

INNOVATIONSPREIS-IT

BEST OF 2015

INDUSTRIE amp LOGISTIK(finalist)

The Award-Winning

28 | MSC Software

Download the Free Trial TodayTo learn more visit wwwmscapexcom

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 33: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Comparison of mesh geometry between two models

30 | MSC Software

PARTNER SHOWCASE

IntroductionEffective collaboration is a key requirement for efficient design of products in a globalized environment Use of simulation in product development has grown from specific component level to much detailed assembly level to predict design behavior Simulation studies and results are being used at various levels of the product development life cycle to make designs without having to build a large number of physical prototypes

Best in class companies using simulation as competitive advantage to bring products to market faster are making constant efforts to

bull Improve collaboration among global teams

bull Manage CAE investments efficiently

bull Work diligently to maximize the utilization of the CAE investments

Different types of simulations are performed using different tools resulting in a large number of vendor specific data formats Managing several CAE data formats is always a challenge More affordable HPCCloud computing resources are helping CAE analysts to solve increasingly complex simulations that were not possible to solve previously However

such activities are resulting in huge simulation results files and posing new sets of challenges to CAE teams in managing the data Large CAE results data files may reside globally at different locations

Collaboration and visualization of the data across teams and locations is a challenging job Devising smart ways of finding mining and visualizing important information is essential for the utilization of simulation results An effective filtering data reduction and easy to use visualization solution is necessary for handling large simulation data files and improving collaboration of CAE data in a global product development environment

This article discusses a lightweight collaborative CAE visualization solution called VCollab

VCollab CAE data filtering and lightweight post processing solutionVCollab is a collection of smart tools which provide a common Visual Collaboration platform for CAE data and helps in democratizing the visualization of simulation data

By

Pra

sad

Man

dav

a C

EO

V

isua

l Col

lab

orat

ion

Tech

nolo

gies

Inc

Smart amp Collaborative 3D CAE Visualization Solution for MSC Nastran Marc amp SimManager

Visual Collaboration Technologies Inc is an MSC Partner whose unique CAE Visual Collaboration Solutions were incorporated into SimManager allowing the simulation community to reduce visualize mine and share CAE data

These smart tools include

CAX a compact CAE Data format A vendor neutral CAE file is more suitable for storing and communicating results from many different CAE tools VCollab uses a proprietary compact data format called CAX CAX can store CAD FEA CFD and other simulation data in a highly compact format VCollab provides tools to convert MSC Nastran and Marc models and results files into CAX format

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 34: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

VCollab Presenter embedded in MS Office documents (3D Presentation)

Comparison of CAE result between two models at hotspot locations

Volume V - Summer 2015 | 31

Effective collaboration is the key requirement for efficient design of products in a globalized environment

VCollabrsquos CAX-Writer API can also be used to create CAX files from any simulation data

Lightweight CAE Data model In general CAE tools generate many results which may not be required for storing processing or for communicating with others Filtering of only required results from the large CAE Data file can reduce file size For example often only outer skin results of a set of load cases could be sufficient for decision making Only few parts in a large assembly may have failed and the analysts need to communicate only those parts information to the designers VCollab provides a tool called VMoveCAE for such filtering capability from many different CAE result file formats The output from VMoveCAE is a common lightweight CAE result file in CAX format VMoveCAE can also be used to extract required CFD information as sections iso-surfaces and flow lines from result files of popular CFD tools Geometry from different CAD models can be converted to compact CAX format using VMoveCAD VMoveCAE converts MSC Nastran BDF OP2 XDB files and Marc t16 as well as t19 files to CAX files In general CAX file sizes can be reduced up to 95 or better for solid meshes and 60 or better for surface meshes

CAE Metadata Filtering In general SPDMPLM systems associate metadata with the stored CAE files such that required files can be searched quickly and effectively For example when maximum von misses stress for the model is stored as metadata it is possible to search for models based on von mises stress criteria It may not be feasible to extract such CAE parameters while searching VCollab provides such a tool to extract certain CAE parameters (in XML format) from CAE files of different formats

CAX Files as 3D Reports CAX files can store many CAE views with color plots XY-plot vectors and labels as viewpoints Anyone can display these CAE viewpoints with a click of a button in a VCollab Viewer as selection of 2D power point slides This way MSC Nastran or Marc models and results can be converted to CAX file with viewpoints and can be easily shared as a 3D CAE report either thru an e-mail or a browser or a PowerPoint file or thru a SPDMPLM environments

Post-Processing and 3D Report Generation Simulation experts are the people best qualified to process CAE results They extract only required information and create reports In general 2D images and PowerPoint or pdf reports are created and shared VCollab supports a 3D report sharing capability in the form of CAX VCollab Pro is the CAX viewer which can be used for post-processing and viewpoint generation The analysts can view any result saved in CAX filter parts based on results probe results add noteslabels and create XY-graph for the relevant information VCollab supports many additional functions such as automatic hotspot label generation to simplify the task of analysts Any CAE view can be stored as a viewpoint Based on the analysis the analysts can further filter parts or result instances to reduce CAX file size or to share only required information It is also possible to split an assembly into multiple CAX files

Multi model and multi-disciplinary Visualizations and Comparisons VCollab Pro supports multiple CAX files from different CAE tools or from CAD files One can view and compare a CAD model with CAE mesh model or compare two CAE models from different stages of analysis VCollab Pro can also display geometrical difference between models as a deviation color plot and compare results from two models and display comparison labels for the hotspots

Export to other formats In addition to CAX for sharing CAE analysts can use VCollab to export CAE data into many other popular formats based on the purpose of sharing Using VCollab CAE analysts can automatically generate PowerPoint files from viewpoints

eliminating the need for manually saving images Analysts can use VCollab to export CAE models and results from MSC Nastran and Marc into 3D PDF or JT for easier sharing and integration of CAE data with CAD systems

Visualization of CAE Results (3D report) for Improved CAE Data Visual Collaboration The shared CAX files with CAE viewpoints can be viewed using VCollab Presenter VCollab presenter is the CAX viewer which can be embedded into web browsers Most of the SPDM systems are web based tools and can embed presenter as a simple to use CAE viewer CAE result with viewpoints can provide a simple and easy CAE visualization environment across PLMSPDM domain

Sharing and Visualization of MSC Nastran and Marc Results in Microsoft Office and Web BrowsersLarge MSC Nastran and Marc result models can be easily converted into lightweight CAX files with CAE viewpoints These CAE viewpoints may have only required results views hotspot labels graphs and any other comments from the analyst VCollab Presenter is the CAX viewer which can be embedded into Microsoft Office documents such as PowerPoint presentation Word document and Excel sheet This will enable 3D visualization while sharing these documents PowerPoint presentations with 3D models can be very effective in CAE review meetings The CAX files can also be displayed in web browsers using embedded VCollab Presenter This can be used to share and visualize CAE data in the intranet

Integration of VCollab with SimManagerVCollab is a lightweight CAE post processing solution that delivers the biggest value when it is integrated with a web based PLM or SPDM system where teams can access the CAE models and results through a browser for decision making

To be continued on page 35

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 35: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

32 | MSC Software

SPECIAL SPOTLIGHT

What has happenedSimufact a familiar acquaintance and partner joins MSC Software MSC and Simufact are linked through a common history It quickly becomes apparent This acquisition is more than just a business takeover ldquoWe have been collaborating closely with MSC from the beginning of our 20-year historyrdquo says Michael Wohlmuth CEO Founder and Managing Director of Simufact ldquoSimufact now steps into a New Erardquo

Who is SimufactSimufact is an expert in manufacturing simulation providing simulation solutions for metal forming and joining as well as

welding The company is headquartered in Hamburg Germany with approximately 50 employees over 75 of whom are experienced engineers Simufact has a direct global presence as well as a wide reseller network and many prestigious

By

Volk

er M

ensi

ng

Sim

ufac

t E

ngin

eeri

ng

Simufact Welcome to the MSC familyOn Thursday February 12th 2015 the signatures are renderedHands are shaken Faces are smiling Somebody says ldquoWelcome to the MSC familyrdquo 1+1 = 3 Somebody states ldquoA New Era beginsrdquo

customers including Airbus Audi Bosch Daimler Ford GKN Schaeffler Group SMS Meer ThyssenKrupp VW ZF and many others

Drivers and Strategic GoalsDominic Gallello explains ldquoWe are acquiring Simufact because our customers are increasingly concerned about simulating the as-manufactured product rather than just the initial design By connecting Simufactrsquos manufacturing process oriented tools to design simulation we can better assist our customers with their drive for lsquofirst time rightrsquo

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 36: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Volume V - Summer 2015 | 33

The CAE approach ldquodesign as manufacturedrdquo requires an even closer connection between CAD-based product design CAE- verified and optimized prototyping and proper manufacturing The declared goal is to consider manufacturability in the early phase of product design Prototypes developed by the use of CAE technologies are only half as valuable when they subsequently cannot be manufactured

ldquoAnother benefit to engineers is that Simufactrsquos tools are uniquely effective at simulating the manufacturing process chain because of a strong connection to MSCrsquos simulation products which result in significant reductions in shop-floor tryouts and associated costrdquo Dominic Gallello adds

The advantages of virtual prototyping find their seamless continuation in virtual manufacturing process design Some of the ways in which Simufact customers benefit include

bull Higher economic efficiencybull Improved qualitybull More robust processesbull Preserving and increasing process

knowledgebull Better figures in series production

- Extended tool life - Less waste - Reduced material usage - Reduced energy use - Higher machine utilization rates

Products and Fields of ApplicationSimufactrsquos product lines Simufactforming and Simufactwelding are able to simulate a broad spectrum of forming and joining processes and the most common welding processes

Simufactforming is established software for the simulation of industrial forming processes The software modules cover the complete spectrum of forming technologies including Hot Forging Cold Forming Rolling Ring Rolling Sheet Metal Forming Open Die Forging Mechanical Joining and Heat Treatment It guarantees a realistic portrayal of the processes with full 3D functionality and 3D representation of all tools amp parts High quality results are guaranteed since Simufactforming is based on MSCrsquos Marc and Dytran solver technologies which enable the representation of complex nonlinear physics of the forming process with high precision

Simufactwelding is high performance software for welding process simulation allowing for elastic-plastic material behavior to be modeled As one of the most important tasks the software succeeds in realistically predicting the distortions and residual stresses that occur during welding while considering phase transformations and controlling these in the component Simufactwelding considers microstructural properties in the heat-affected zone its form allows conclusions about the properties of the weld seam in particular its strength The user gains valuable clues to identify

welding defects such as hot cracks in the simulation to avoid them in practice

Simufact software not only simulates single production steps but the modules can be combined - even across both product lines - and thus consistently simulate a complete process chain

Outlook and Take AwaySimufact continues its operation as a 100 subsidiary of MSC Software under the very capable leadership of its co-founders Michael Wohlmuth (CEO) and Dr Hendrik Schafstall (CTO) as well as their CFO Frieder Carle The well-established Simufact brand is a strong addition to MSCrsquos solution portfolio The acquisition strengthens MSC`s as-manufactured approach Simufactrsquos product offerings share a common technology backbone with MSCrsquos solvers facilitating the simulation of manufacturing processes on the product as designed Simufactrsquos technology positions MSC as a leader in simulating advanced manufacturing processes u

For more information visit wwwmscsoftwarecomproductsimufact

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 37: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

34 | MSC Software

SPECIAL SPOTLIGHT

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell

Optimizing MSC Nastran Nonlinear with Multi-Core TechnologyIntelreg and MSC Software Team Up to Optimize Performance of MSC Nastran Solution 400

The MSC Nastran Advanced Nonlinear module (SOL 400) allows engineers to perform structural and thermal nonlinear analysis via implicit

methods Engineering problems that exhibit nonlinear material behavior contact and geometric nonlinearity may be solved SOL 400 is targeted at customers familiar with the linear static in MSC Nastran as it allows simple conversion of linear models to nonlinear models

Pardiso PowerIn MSC Nastran 20140 Intel and MSC Software teamed up to improve the performance of the Advanced Nonlinear module by incorporating the PARDISO solver from the Intelreg Math Kernel Library (Intelreg MKL) into MSC Nastran for use in SOL 400 The Intel MKL PARDISO sparse direct solver has exhibited unparalleled performance on todayrsquos multi-core computing architectures and has been a part of the Intel Math Kernel Library for multiple generations

The Intel MKL PARDISO sparse direct solver is also used in two other products at MSC Software Since 2008 the PARDISO sparse direct solver has been used in the Marc Advanced Nonlinear FEA Product of MSC Software and as of 2014 it is also used in the premier Acoustics Simulation Package

Actran from MSC Software Developers at MSC Software have worked closely with Intel MKL developers on getting the best performance out of PARDISO

The advantage of the Intel MKL PARDISO solver is it obtains optimal performance on the newest architecture from Intel which today is the Haswell Applications containing floating-point loops that can already be vectorized using Intelreg Streaming SIMD Extensions (Intelreg SSE) instructions are likely to see significant gains just by recompiling for Intelreg Advanced Vector Extensions (Intelreg AVX) due to the greater width of the SIMD floating-point Intel AVX instructions Applications that call performance libraries such as the Intelreg Math Kernel Library that contain many functions optimized for Intel AVX may see gains even without rebuilding The benefits of recompilation are likely to be significantly less for applications containing mostly scalar code integer code with very heavy access to memory or heavy use of double precision divide and square root operations The same is true for applications with hot loops or kernels that do not vectorize however the Intel AVX instruction set contains some new features that help to vectorize certain loops that were difficult to vectorize using SSE instructions The latest Intelreg Compilers also contain new features that allow more loops to be vectorized See

By

Mik

e La

ffert

y T

echn

ical

Com

put

ing

Mar

ketin

g M

anag

er

Inte

l Am

eric

as

en-usarticlesrequirements-for-vectorizable-loops for an indication of what sort of loops can be vectorized and en-us for more detailed information about vectorization

Parallel Direct Sparse Solver for Clusters is a powerful tool set for solving system of linear equations with sparse matrix of millions rowscolumns size Direct Sparse Solvers for Clusters provides an advanced implementation of the modern algorithms and is considered as expansion of Intel MKL Pardiso on cluster computations For more experienced users Direct Sparse Solvers for Clusters offers insight into the solvers sufficient to finer tune them for better performance Direct Sparse Solvers for Clusters is available starting with Intel MKL 112

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 38: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Volume V - Summer 2015 | 35

Continued from page 31

A Matter of ScaleIntel MLK PARDISO provides a much

needed parallel performance improvement

for SOL 400 PARDISO has much better

SMP scalability than the existing MSC

sparse direct solver For example in Figure

1 the PARDISO solver ran 3x faster than

the MSC default solver MSCLDL using 16

Integrating VCollab with MSC Nastran Marc amp SimManager

Figure 1 Scaling of Matrix Solution (left) and Total Wall Clock Time (right) for Intel MKL PARDISO sparse direct solver versus the MSCLU sparse direct solver

VCollab is tightly integrated with SimManager to provide CAE data enrichment as well as CAE data viewing amp processing capabilities As shown in the figure below SPDM systems will associate and manage CAX files along with other required CAE files so that only required CAE information can be stored in the SPDM system VMoveCAE will generate CAX files and CAE information that can be used to generate required metadata from different CAE result files VCollab Pro is used to create CAX files with Viewpoints These lightweight files can be stored in a SPDM system or they can also be stored in PLM systems as reports associated with design data VCollab Presenter is well integrated into the SimManager window to provide CAE visualization for the CAX files in the SPDM system

An ability to quickly extract and visualize key simulation information from MSC Nastran and Marc using the VCollab lightweight simulation solution through the SimManager framework would help the CAE analyst in hisher decision making and improve effi-ciency Such an integrated solution will help digital product development in many ways

Summary bull VCollab is a Smart amp Collaborative 3D

CAE Visualization Solution for MSC Nastran Marc and SimManager

bull Productivity of CAE analysts is improved as they can now work with compact CAX files instead of huge native CAE files for quick processing and automated 3D report generation

bull CAE analysts create 3D CAX files with their viewpoints and share only the

relevant post processed information with designers These 3D reports can be managed and visualized across the globe using SimManager

bull The CAX file created from MSC Nastran and Marc is used to transfer CAE data into any PLM system to store or collaborate with design and other communities

bull Simple to use common CAE smart viewers support most of the CAE displays and help with reviewing and quick decision making around work in progress CAE data Such a system improves the productivity of analysts reduces the load on the CAE IT infrastructure and improves collaboration among the global teams u

cores for the model displayed in Figure 2 At 16 cores the matrix factorization phase ndash which is about 40 of the total solution time is solved twice as fast using Pardiso With 32 cores even faster run times are possible

The FutureFor the next release MSC Software is teaming up with Intel developers on

both extending the reach of Intelrsquos MKL PARDISO sparse direct solver in MSC Nastran to cover linear solution sequences like SOL 101 103 107 108 and 111 Additional improvements to performance for SOL 400 with respect to the PARDISO solver are also planned Besides work with the PARDISO sparse direct solver there are also plans for acceleration of the MSC Nastran Sparse Direct Solver MSCLDL using the Intel PHI This will provide the first Intel PHI capability for the MSC Nastran product We lastly note that Intel and MSC Software continue to have a strong relationship with mutual benefit to both companies u

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 39: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

2015 CONTEST WINNERS

SPECIAL SPOTLIGHT

Top 3 University Winners Top 3 Industrial Winners

Adams demonstrates ability to accurately evaluate new logging machine design

MSC Products Illustrated Adams

Individuals from industry and academia were invited to participate in the 2015 ldquoSimulating Realityrdquo contest by submitting a video or image demonstrating how they used MSC Software technology to develop interesting products and future design innovations

We are proud to announce the Winners

Predicting combat boot performance from underbody blast using nonlinear FEA analysis

MSC Products Illustrated Marc

Evaluating new orthopedic implant for knee replacement in high-demand conditions

MSC Products Illustrated Marc

Adams Simulation Solves Stability Problem in Rotary Wing Unmanned Aerial Vehicle

MSC Products Illustrated Adams

Using Adams and AdamsMachinery simulations engineers can accurately predict the results of a driveline testing that normally takes several months in only two weeks

MSC Products Illustrated Adams

Leveraging Marc nonlinear FEA capabilities to simulate dynamic extrusion of copper at high velocity

MSC Products Illustrated Marc

KTH-Royal Institute of Technology

Imperial College London

Radboud University Medical Center

Saab Aeronautics

Bias Engineering

TECHDYN Engineering

The images or videos and related descriptions submitted by participants were to meet one or more of the following criteria in connection with use of MSC technology

bull Showcase innovative industry applicationsbull Demonstrate resulting business benefitsbull Showcase great impact on society or industrybull Demonstrate leading edge product design

About the Contest

36 | MSC Software

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 40: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

University Winners Showcase Industrial Winners Showcase

Nonlinear FEA simulation for bushing insertion helps optimize part for assembly process thereby reducing scrap cost

MSC Products Illustrated Marc

Hutchinson AVS NA

Simulating the mechanical fight control systems of a light transport aircraft to accurately predict the stretch values

MSC Products Illustrated MSC Nastran

CSIR National Aerospace Labratories

Utilizing Adams to test the dynamical balance of an Air-jet weaving machine

MSC Products Illustrated Adams

RWTH Aachen University

Using AdamsMachinery to model crane transmission and cable systems and study the containers orentation during the hoisting

MSC Products Illustrated Adams

Tai Yuan Institute of Technology

Investigating how the toe anglecamber angle reacts by varying the hardpoints position of the rear multilink suspension system

MSC Products Illustrated Adams

University of Applied Sciences Suumldwestfalen

Developing advanced ABS control strategies for off-road terrain

MSC Products Illustrated Adams

University of Pretoria

Studying teh mechanical performance of modular Total Knee Arthroplasty (TKA) prosthesis using finite element analysis

MSC Products Illustrated Adams

Indian Institute of Technology Bombay

Performing dynamic analysis of motorbike to find out the conact forces between tire and ground when driving over an obstacle

MSC Products Illustrated Adams

Altem Technologies (P) Ltd

Leveraging flexible multibody dynamic analysis to simulate a 6-DOF insect flight considering fluid-structure interaction of flapping wings

MSC Products Illustrated Adams

Korea Advanced Institute of Science amp Technology

Studying vehicle chassis behavior in differnt road inputs using Adams

MSC Products Illustrated Adams

Instanbul Technical University

Adams helps engineers perform bump road test and reduce bus rollover risk

MSC Products Illustrated Adams

Anadolu Isuzu Otomotiv AS

Performing advanced dragline dynamics analysis to catch the major kinematics and dynamics behavior of the dragline front end

MSC Products Illustrated Adams

Bucyrus

Adams helps reduce time to design child safety latch system

MSC Products Illustrated Adams

Keikert AG

Conducting engine cam dynamic analysis to study and reduce the tappet clearance when the engine is revving at high rotational speed

MSC Products Illustrated Adams

Mahindra Two Wheelers

Performing virtual testing of commercial vehicle handling events with flexible frame platform and cab

MSC Products Illustrated Adams

Scientific Research Laboratory of Intellectual Systems Transport

Leveraging Adams Tracked Vehicle (ATV) Toolkit to reconfigure mobile robotics into a humanoid formation without loss of balance

MSC Products Illustrated Adams

Ford Motor Company

Volume V - Summer 2015 | 37

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 41: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

圀漀甀氀搀 礀漀甀 氀椀欀攀 琀漀 欀渀漀眀 琀栀攀 漀甀琀挀漀洀攀 漀昀 礀漀甀爀 洀愀渀甀昀愀挀琀甀爀椀渀最 瀀爀漀挀攀猀猀 戀攀昀漀爀攀 最漀椀渀最 琀漀 瀀爀漀搀甀挀琀椀漀渀㼀 䤀琀猀 琀椀洀攀 琀漀 氀攀愀爀渀 洀漀爀攀 愀戀漀甀琀 匀椀洀甀昀愀挀琀

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 42: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Volume V - Summer 2015 | 39

SPECIAL SPOTLIGHT

The numbers are staggering In 2015 approximately 50 percent of engineers will be eligible for retirement When they leave theyrsquoll take years of critical

knowledge and experience with them As the next generations move in it will be essential to train them both quickly and effectively to avoid major impact on workflow and bottom line This combined with significant budget cuts that leave fewer and fewer training dollars could have serious implications Many corporations are turning to cost effective e-Learning solutions to meet the training needs of their employees

At MSC we have witnessed firsthand the effects of training and travel budget cuts with a decline in public instructor led training attendance When we surveyed our customers 51 of them stated that they had never taken an MSC Software training course all of them indicated an interest and need for training on MSC Software tools Digging a little deeper 47 indicated that course fees and travel costs had prevented them from being able to

attend a training course with other reasons ranging from schedule conflicts and not being able to take time from work In response to this trend MSC invested in a Learning Management System the MSC Learning Center capable of delivering on demand online training courses (e-Learning)

MSC Learning Centerrsquos e-Learning subscription is for the engineer who quickly needs to be productive with MSC Software technologies It provides an innovative and creative approach to instruction with unprecedented access to resources and information Besides offering flexibility and cost savings it allows engineers to proceed through a training curriculum ldquoat their own pace in their own placerdquo

Since the launch of e-Learning at MSC in early 2014 we have responded to customer feedback and made significant progress in improving our content both from a delivery and value perspective

We have transitioned from a product-based subscription to an all-inclusive subscription

By

Chr

isto

phe

r A

nder

son

eLe

arni

ng A

ssoc

iate

Man

ager

M

SC

Sof

twar

e

This means that you now get access to all available product-based subscriptions in one ldquomasterrdquo subscription for the same price no need to have multiple subscriptions to meet your training needs

In 2014 we added 18 online courses and certification exams

We have invested in a new e-Learning course viewer that contains keyword search page preview in the table of contents and faster navigation

Throughout 2015 we will be adding training content for the Marc Patran and Easy5 product lines

We invite you to experience MSC e-Learning courses free trial With the free trial you will be able to view the first few sections of each MSC Nastran and Adams online training course

To learn more visit wwwmscsoftwarecommsc-learning-center and click on the free trial link

If you have any questions about MSCrsquos e-Learning please contact Chris Anderson at christopherandersonmscsoftwarecom or contact your Account Manager

MSC Learning Centerrsquos e-Learning18 online MSC Nastran and Adams courses amp certification exams available with 14 more online courses and certifications under development including Marc Patran and Easy5

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 43: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Fig 1 3D Adams simulation for package folding machinery

Fig 3 D-RAPS robot in operating folding carton

Fig 2 Tuck-in operation by human fingertip and kinematic analysis From top left to the bottom right a) first flap folding b) second flap folding c) the third flap folding d) the

tuck-in of the third flap

40 | MSC Software

CUSTOMER SPOTLIGHT

Consumer products companies are continually developing innovative packaging methods The highly competitive nature of this industry requires ever

shorter development times and lower costs Packaging plays a particularly important role in the high-quality confectionary market where producers produce elaborate cartons with complicated folding procedures that can be compared to origami Most of these packages are not secured by glue but rather

with complicated tuck-in operations requiring that the carton be constructed with flaps and slots that mate to each other during the folding operation Complex packages are traditionally built by human operators because of the difficulty in developing automated machinery that can manage the complicated folding operations and also be readily adapted to new packaging styles as they are developed

ChallengeOne of the greatest challenges involved in the design of the carton and packaging equipment is understanding the behavior of the carton during the folding process The cardboard consists of a multiply ldile stiffness and low compression stiffness When the adjacent panels rotate around a crease the outer plies are stretched and the inner plies are compressed as shown in Figure 1

Task 1 - Tack InThe tuck-in operation where the end flap of the lid is secured by inserting it into a slot is the most complicated task of carton folding The tuck-in operation is complicated by the

Bas

ed o

n an

inte

rvie

w w

ith F

erna

ndo

Can

nella

Ita

lian

Inst

itute

of

Tech

nolo

gy

Simulating Complex Package Folding ProcedureIIT uses simulation to evaluate folding methods and new package designs

fact that the lid is divided into three links whose kinematics must be well understood to insert the end plate into the small slit The tuck-in operation on a relatively simple carton is shown in Figure 2 The fingers fold the first piece of the lid as shown in a then break the end flap crease as shown in b The tuck-in operation is shown in c and the completed package in d This complex operation can be completed without difficulty by a skilled person however it much more challenging to automate the process so it can completed at a high rate of speed while maintaining perfect quality This research was led during the ARCHAP project

SolutionValidationIIT engineers produced an Adams model of both the carton and robot to demonstrate how the folding operation could be performed The robot has three finger with two degrees of freedom each whose layout is shown in the Figure 3 Central finger provides yaw motion at the base and pitch motions on the following two joints The side fingers have only pitch motions so they can move on a planar surface Each moving element of the

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 44: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Fig 5 More complex folding operation 19 panels and 15

Fig 7 D-RAPS model created with Adams

Fig 9 Carton folding simulation matches real-life robot

Fig 8 Finger contact for from simulation

Fig 6 Carton folding trajectories for more complex folding operation

Fig 4 D-RAPS robot in operation folding carton

Volume V - Summer 2015 | 41

The physical finger displacements correlate very well with the actual robot displacements The carton folding sequence of the folding model also matched up perfectly to the actual robot

machine is connected kinematically to the carton model in order to fold the carton This was accomplished by using Adams to develop the inverse kinematic solution of the fingers The resulting joint angles were input to the multibody rotational and linear actuators to drive the simulation

Task 2 - Oragami Carton FoldingAutomated folding machinery on the other hand is commonly used for simple packages that are produced in large volumes Consumer products companies want to convert complex packages to automated production in order to improve quality and reduce the potential for repetitive motion injuries But conventional automated folding machines are very difficult to adapt to new designs So the industry is working on developing flexible automation systems based on programmable robots that can handle complicated packages and can accommodate new designs with software changes alone The Dexterous Reconfigurable Assembly and Packaging Systems (D-RAPS)was developed by Prof Jian S Dai (Kings College London London UK) for use as a carton folding test rig to evaluate the use of robots in complex packaging operations as shown in Figure 4

ResultsldquoThe physical finger displacements correlate very well with the actual robot displacementsrdquo said Ferdinando Cannella Head of IITrsquos Advanced Industrial Automation Lab of Advanced Robotic Department ldquoThe carton folding sequence of the folding model also matched up perfectly to the actual robot With the Adams simulation model validated against the physical D-RAPS robot researchers are now able to evaluate different folding methods and new package designs with the simulation model as opposed to having to use the actual robot One the best result is that we computed the contact forces that were impossible to measure on the physical prototype because the contact points were too small to install a pressureforce sensor and the motor typology was not suitable for this feature This is an enormous advantage because many students use the robot for their research so it is often very difficult to get time on the actual robot The Adams model of the robot built by PhD

candidate Mariapaola DrsquoImperio can be applied not only to package folding but also to a wide range of other robotic applications IIT and Kings College London researchers are also working on introducing flexible materials into the model which will increase the accuracy of the simulation and make it possible to accurately simulate even more complicated folding operationsrdquo

About the Italian Institute of TechnologyThe Italian Institute of Technology is a foundation established jointly by the Italian

Ministry of Education Universities and Research and the Ministry of Economy and Finance to promote excellence in basic and applied research and to contribute to the economic development of Italy The primary goals of the IIT are the creation and dissemination of scientific knowledge as well as the strengthening of Italyrsquos technological competitiveness To achieve these two goals the IIT will cooperate with both academic institutions and private organizations fostering through these partnerships scientific development technological advances and training in high technology u

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 45: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

42 | MSC Software

UNIVERSITY amp RESEARCH

This Adams tutorial package is designed as a supplemental curriculum kit for undergraduate Mechanical Engineering courses including Design of Machinery Dynamics Mechanisms and Mechanical Design There are 44 examples in this Adams tutorial package including some simple problems like ldquofour-bar linkagerdquo ldquospring-damper systemrdquo and also some real industrial examples like ldquoOpen differentialrdquo or ldquoGear Train Systemrdquo which are created based on a new powerful set of simulation modules in Adams called AdamsMachinery

Several examples were developed from specific textbook problems for example the four problems in section III were developed in reference to the textbook Design of Machinery (Fifth Edition) by Robert L Norton Design of

Machinery has proven to be a favorite of both students and educators across the globe It is currently used in over 100 schools in the US and Canada and in many more worldwide in both English and several other languages The book is praised for its friendly writing style clear exposition of difficult topics attractive appearance thorough and relevant coverage its emphasis on synthesis and design and its useful computer programs

Teach with AdamsWe are asking you to use this Adams tutorial package as supplemental learning material for your courses in your mechanical engineering program today as a way to further develop the skills of your students in engineering simulation and to prepare them for engineering careers in the future

The Adams Curriculum Kit 2nd Edition is Here

Download Today To learn more visitwwwmscsoftwarecomadams-tutorial-kit

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 46: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION

Integrated Solution to Compute Virtual Allowables Digimat-VA (ldquoVirtual Allowablesrdquo) is an efficient solution that empowers engineers tovirtually compare materials before going into the lengthy physical allowables process By generating virtual allowables engineers can start component design in parallelwith a physical allowable campaign

Digimat-VA provides a method to virtually test the behavior of composite coupons (unnotched open hole filled hole) in order to select and compute the allowables of composite materials

bull It defines a text matrix in a few clicks

WHY DIGIMAT-VA

bull It turns a test matrix into FEA runs to obtain virtual allowables

bull It creates multiscale material models based on composite datasheet

bull It models batch and process variability

bull It can go beyond recommended CMH17 procedures

AllowablesAt Your Fingertips

Page 47: MSC Software Magazine | Volume V Summer 2015 Issue · 2015-07-02 · MSC IN THE NEWS 4 Simulation News & Media Coverage PRODUCT NEWS IN-BRIEF 6 2015 MSC New Product Releases CO-SIMULATION