symposium on the integration of analysis in product … 2006... · symposium on the integration of...

Juan F. Betts, PhD, MBAManager,

Aeronautics, Space, & Defense Process Group

Symposium on the Integration of Analysis in Product DesignSymposium on the Integration of Analysis in Product DesignSimulation fusion for performance engineering

2 copyright LMS International - 2005

LMS, well positioned for accelerated growth

The industry largest R&D commitment to

Engineering Innovation

Talented people, 700 professionals

committed to customers’ success

More than 3000 manufacturing companies

actively use LMS products and services

100M€ Annual Revenue

Strong financial track record of double digit

profitable growth

25 Years of Engineering Innovation


A Global CompanyWorld-wide Sales & Customer Services Organization

LMS regional offices : 17

LMS NA - Detroit

LMS NA -Los Angeles

LMS NA -Washington D.C.

LMS ItaliaLMS France - Lyon

LMS France -Paris

LMS UK

LMS HQ -Leuven - BELGIUM

LMS Russia

LMS Deutschland

LMS China -Beijing

LMS China -Shanghai

LMS Singapore

LMS Japan

LMS Korea

LMS representatives offices - 25

ALAVA-LMS Partnership


Cost Structure by Industry Market Segment

B/E – Minimum break even sales volumeV* - Expected or realized sales volume

Sales Volume

Cost

Fixed Costs

Variable Costs

VA*

Automotive

VR*

Jet &Regional Air

VS*

Satellite

VL*

Launchers

Large Air

Vg*

Incre

asin

gly

Ris

k A

dvers

e


Simulation Fusion Value Proposition

End-to-End Solutions: From Concept Development to Operational. From system level to component level

CAD/CAE Integration: Seamless design/analysis with either CAD and/or FEA

Multi-physics Analysis: Account for the interface boundary physics and link to internal processes

Best in Class Point Solution: Structures, Acoustics, Durability, Multi-body dynamics, Optimization, structural tests, environmental test

Hybrid Engineering: Combine test and numerical analysis. Example: Heritage System with new component.

Risk

Co

st

Today

Desired

Strategic Change Program

Value

Value




CAD/CAE Integration:CAD/CAE Integration:CAD/CAE Integration: Seamless Seamless Seamless

design/analysis with either CAD and/or FEAdesign/analysis with either CAD and/or FEAdesign/analysis with either CAD and/or FEA

MultiMultiMulti---physics Analysis:physics Analysis:physics Analysis: Account for the Account for the Account for the

interface boundary physics and link to internal interface boundary physics and link to internal interface boundary physics and link to internal

processesprocessesprocesses

Best in Class Point Solution:Best in Class Point Solution:Best in Class Point Solution: Structures, Structures, Structures,

Acoustics, Durability, MultiAcoustics, Durability, MultiAcoustics, Durability, Multi---body dynamics, body dynamics, body dynamics,

Optimization, structural tests, environmental Optimization, structural tests, environmental Optimization, structural tests, environmental

testtesttest

Hybrid Engineering: Hybrid Engineering: Hybrid Engineering: Combine test and Combine test and Combine test and

numerical analysis. Example: Heritage System numerical analysis. Example: Heritage System numerical analysis. Example: Heritage System

with new component.with new component.with new component.

Risk

Co

st

Today

Desired


Value

Value


LMS, delivering solutions that support all phasesof the development process

Design / Loads Cycles

Physic

al P

erfo

rman

ce C

ertif

icat

ion

Component Verification/Certification

Assembly Verification/Certification

Vehicle Level Verification/Certification

Virtual

Perfo

rman

ce C

ertif

icat

ion

Assembly Analysis

Component Analysis

Concep

t Valid

ation

Targ

et Cascad

ing

Feasibility DefinitionInServiceConcept Development

Mar

ket S

tudy

Conce

pt Sel

ecte

d

Agre

emen

t With

Prim

ary

Par

tner

s

Auth

ority

To O

ffer

Progra

m L

aunch

Maj

or A

ssem

blies

Entry

Into

Ser

vice

Cer

tific

atio

n

First F

light

Maj

or B

ody S

ectio

ns

Com

ponent D

esig

n

Vehicle Level Analysis





MultiMultiMulti---physics Analysis:physics Analysis:physics Analysis: Account for the Account for the Account for the

interface boundary physics and link to internal interface boundary physics and link to internal interface boundary physics and link to internal

processesprocessesprocesses




testtesttest




Risk

Co

st

Today

Desired


Value

Value


Engineering CollaborationData Management

Simulation Process IntegrationDesign Optimization

Refinement

Engineering

Refinement

Engineering

LMS Virtual.LabSimulation fusion for performance engineering

Test

Detailed

Engineering

Detailed

EngineeringUpfront

Engineering

Upfront

Engineering

System PerformanceSimulation

Pre-& PostprocessingStructural Analysis Vehicle Modeling

CATIA CAE

ABAQUS

NASTRAN

ANSYS

LMS Virtual.Lab

Design

LMS Virtual.LabDesigner

CATIA V5-embedded simulation Stand-alone Integrated Simulation environment

Multi-CAD


FEA Stress AnalysisGeneral process overview: “As Is”

GeometryGeometry MeshingMeshing MeshMesh

ModificationModificationPostPost--

ProcessingProcessingAnalysisAnalysis

DefinitionDefinitionAssemblyAssembly SolverSolver

DrivingDriving

NASTRANNASTRAN

ABAQUSABAQUS

ANSYSANSYS......

Many different user environments and FEA tools

Poor integration with the product design Master geometry translation

Geometry re-working and cleaning

No or poor associativity of analysis at component or sub-assembly level Manual edition in input deck file

CatiaV5

Patran or V4 Nastran Patran

CAD translation

FEM translation

FEM translation


FEA Stress AnalysisGeneral process overview: “To Be”

GeometryGeometry CreateCreate

MeshMeshPrePre--

ProcessingProcessingPostPost--

ProcessingProcessingSolverSolver

DrivingDrivingAssemblyAssembly SolverSolver

CATIA V5CATIA V5CATIA V4CATIA V4

VirtualVirtual.Lab .Lab StructuresStructures forfor NASTRANNASTRAN

ReRe--runrun &&

OptimisationOptimisation

NASTRANNASTRAN

ABAQUSABAQUS

ANSYSANSYS......

OtherOther meshmesh without without geometrygeometry::

NASTRANNASTRAN, , ABAQUSABAQUS, , ANSYSANSYS, , IDEASIDEAS……

ParameterisedParameterised

AssociativeAssociative

GPSGPSFMSFMSFMDFMD......


Value PropositionStress Analysis

“Virtual.Lab Structures decreases the time for iterative stress analysis more than 70%”

“Virtual.Lab Structures decreases the time for initial stress analysis by 30%”

1. Integrated Environment1. Integrated Environment 2. Fast Iterative Analysis2. Fast Iterative Analysis

Over 60%Over 60% Average Time Saving Per Component AnalysisAverage Time Saving Per Component Analysis


Economic Impact Analysis Assumptions

Average fully costed cost of an engineer ~ $220K

The company has an internal rate of return ~ 5%

To complete an analysis it takes ~ 10 reruns

There is no break in the associativity of the stress analysis process

There are 200 stress engineers at the company

Note Note -- Although the cost advantage could be used to reduce workforce, Although the cost advantage could be used to reduce workforce, the real the real

competitive advantage is the agility the manufacturer gets like competitive advantage is the agility the manufacturer gets like for example being able for example being able

to producing more designs for the same cost or develop better opto producing more designs for the same cost or develop better optimized designstimized designs


Efficiency & Cost Advantage – Year 1

0%

10%

20%

30%

40%

50%

60%

70%

0 10 20 30 40 50 60 70 80 90 100

110

120

130

140

150

160

170

180

190

200

Number of Licenses

Eff

icie

ncy

0

5

10

15

20

25

30

Co

st

Savin

gs i

n O

ne Y

ear

(Mil

lio

ns)

Efficiency Cost Savings


Net Present Value

SolutionFunctionalityEvaluation

OperationalEfficiency

Gain

FullStrategicBenefit

$0

$50

$100

$150

$200

$250

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

Number of Licenses

Net

Pre

se

nt

Va

lue

(in

Mil

lio

ns)

at

r=5%

One Year

Five Years

Ten Years


Subsystem & Component Stress AnalysisMulti & Single Component FEA Stress Analysis

V5 Geometry

Meshing

Load & Restraint Application

Integrated Job Submission

Results Sorting

Results Reporting

CATIA Material Database

Loads Data

Material & Property Application

Set-up Analysis

Local User/Section Material Database

Connection Modeling

V4 Geometry

ConnectionTo

DatabaseConnection

ToDatabase

Internal Tools for Stress Calculations

Optimization









testtesttest




Risk

Co

st

Today

Desired


Value

Value


Aero-acoustic Analysis

High Lift Devices

Air Loads

CFD Analysis

Kinematics Model (Multi-body Model)

Flexible Body Model (Stress Model)

Durability Model (Fatigue Model)

Kinematics Correlation (Loads, Deflections)

Dynamics Correlation (Modes)

Wind Tunnel Testing

Failure Criteria Correlation (Stress, Fatigue)•Aerodynamic Loads•Dynamic Loads•Wing deformation•Low component stress•High durability

Low radiated noise


Fluid-Structure Dynamic InteractionDiscretized & Random Loading

∆Ω∆Ω

+=

∗

≠

∗

=

∗ ∑∑ jrik

ji

jiikik

ji

iirk MMppMMppww

∆Ω∆Ω

+=

∗

≠

∗

=

∑∑ jrik

ji

ijirik

ji

iikr MMSMMSW

[ ]∗

∞→= ji

Tij ppE

T

1limS

Fluid MeshAnd

Structural MeshDissimilar

[ ]∗

∞→= ii

Tii ppE

T

1limS

[ ]∗

∞→= rk

Tkr wwE

T

1limW










Risk

Co

st

Today

Desired


Value

Value


LMS Virtual.Lab, the award-winning solution for “Design-Right-First-Time” performance simulation

Structural Analysis Pre- Post processing Assembly Analysis Multi-solver FEM

Interior Acoustics Pre- Postprocessing Cabin noise,

Passenger comfort Sound synthesis

Noise & Vibration System synthesis Dynamic loads and

response synthesis Test/CAE Correlation

Mechanism Analysis Kinematic and

dynamic analysis Mecatronic systems Dedicated solutions

Suspension Landing gear …

Durability Analysis Component fatigue System level fatigue

Exterior Acoustics Pre- Post processing Near and far field

acoustic analysis


Example: Flaps Design


Wing flap application : Electro Hydrostatic Actuator

Actuator

Sensor

LMS Virtual.Lab Motion

Displacement

Rate

EHA (Electro Hydrostatic Actuator)

Force/Torque


Mechanical Simulation ProcessSystem-level simulation of Landing Gear

Kinematics Dynamic

Simulation

GeometryLoads

Calculation Subassembly

Loads Calculation

Integrated ac

Loads Calculation Component

Durability Calculation


Example: Landing Loads & Landing Gear Retraction







Hybrid Engineering: Combine test and numerical analysis. Example: Heritage System with new component.

Risk

Co

st

Today

Desired


Value

Value


System level performance

calculations Faster solution time full numerical models More accurate than full numerical models More flexibility than full test-based models

Numerical models For sub-systems of design

interest Guide design prior to hardware Design Space Studies,

optimization

Test-based models For existing / carryover / benchmark sub-

systems Faster than building numerical models Guaranteed to accurately match

hardware

Noise and Vibration Engineering Process

Hybrid assembly

Juan F. Betts, PhD, MBAManager,

Aeronautics, Space, & Defense Process Group

Thank you

symposium on the integration of analysis in product … 2006... · symposium on the integration of...

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