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Verification of Numerical Simulations GOM October 17, 2014

2-Frame Setup / Frame 2 2-Frame Setup / Frame 1

3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3

Page 2 Verification of Numerical Simulations GOM

GOM Industrial 3D Measuring Techniques Measurement systems

Full-field 3D Digitizing

3D Shape and Dimension Inspection

Material Testing

Dynamic Component Testing

Full-field 3D Strain Measurement

Deformation Analysis in Sheet Metal Forming

Mobile Optical CMM

Dynamic 3D Analysis




GOM Industrial 3D Measuring Techniques Measurement systems

Material Testing 3D Coordinate Measurement Component Testing

ATOS

ATOS ScanBox

TRITOP

ARAMIS

PONTOS

PONTOS

ARAMIS

TRITOP ARGUS

Viewing and evaluation software




GOM Industrial 3D Measuring Techniques Measurement systems and results

Material Testing 3D Coordinate Measurement Component Testing




GOM Industrial 3D Measuring Techniques Company Overview

Benefits of optical metrology

Optical metrology enables and supports High information density Fast measurement and provision of results High degree of flexibility regarding task, place and parts High process safety

Optical metrology is used complementary or as an alternative to

3D CMM Checking fixtures, gauges Displacement- and acceleration sensors Extensometers Strain gauges

Verification of Numerical Simulations Webinar Overview




Following topics will be discussed during the Application Webinar Verification of Numerical Simulations

Introduction in GOMs optical measuring systems

Determination of input parameters for numerical simulations

Verification procedures for numerical simulations

Including example applications in

Sheet metal forming Composite component testing Biomedical applications Fluid dynamics in the Automotive and Aerospace industry

Supported numerical simulation software packages and formats

Verification of Numerical Simulations Overview

Verification of Numerical Simulations Optical Measuring Techniques




Verification of Numerical Simulations Example Applications




Verification of Numerical Simulations Overview Finite Element Simulation

Input Geometry (Mesh)

Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing




Verification of Numerical Simulations 3D-Shape Measurements

Reverse Engineering

FEA-Simulation

RevRev

CFD-Analysis

3D-Shape / STL-mesh




Verification of Numerical Simulations Dynamic Deformation and Strain Analysis

FEA-Verification

Material Parameters

Shape / Displacement / Strain




Boundary Conditions

Verification of Numerical Simulations Dynamic Deformation Analysis

Position / Displacement Dynamic

FEA-Verification




Boundary Conditions

Verification of Numerical Simulations Static 3D-Coordinate Measurements and Deformation Analysis

Position / Displacement Static

FEA-Verification




Verification of Numerical Simulations Sheet Metal Forming Analysis

FEA-Verification

Shape / Strain




Verification of Numerical Simulations GOM System Applications

Results Application for FEA

ATOS Geometry / Shape 3D coordinates

Full field, static Input for Mesh Generation, Verification of Shape Spring-back, Thickness

ARAMIS Deformation Coordinates, Displacements, Strain

Full field, dynamic Material Parameter Verification of Shape, Displacement, Strain

ARGUS Forming Analysis Coordinates, Displacements, Strain

Full field, static

Verification of Shape, Displacement, Strain

PONTOS Deformation Coordinates, Displacements, Velocity

Point wise, dynamic Boundary conditions, Verification of Position, Displacements

TRITOP Deformation Coordinates, Displacements

Point wise, static

Boundary conditions, Verification of Position, Displacements, (Geometry)

Verification of Numerical Simulations Determination of Input Parameters






Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing






Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing

Input Geometry





Input geometry for numerical simulation

Numerical simulations are initially depending on 3D input geometries which are usually taken from construction models (CAD)

Due to differences in the 3D shape of CAD data sets and prototypes the reliability of numerical simulations are sometimes questionable

Thus the accuracy and reliability of numerical simulations can be improved using the real parts geometry









Generation of input geometries for numerical simulations










Section based reverse engineered CAD model from scan data










Computational fluid dynamics






Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing






Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing

Material Parameters





Material parameter models as input for numerical simulation

The accuracy and reliability of numerical simulations are strongly depending on accurate material parameter models

With optical measuring techniques advanced material parameter models are developed utilizing different applications and testing procedures, such as

Tensile tests (quasi-static, high speed, etc.) Youngs modulus, R-value, N-value, Poisson ratio, etc.

Nakajima and bulge tests Forming limit curves and bi-axial yield curves

Torsion tests Bending tests Compression tests ...






Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing






Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing

Boundary Conditions





Boundary conditions as input for numerical simulations

Numerical simulations strongly depend on the input of boundary conditions which represent manufacturing and testing conditions







Inhomogeneous / unknown material behavior

E.g. Bones








E.g. Bones








E.g. Bones

PONTOS Measurement

FEA Input Geometry








E.g. Bones

FEA Result Meshes








E.g. Bones

Process parameters

Tool behavior and press motion during stamping, cutting, etc.

Verification of Numerical Simulations Common Verification Procedures




Verification of Numerical Simulations Verification Procedures

Point wise comparisons used for

Displacement transducers

Accelerometers

Strain gauges

Etc.





Point wise comparison

Section based comparison





Point wise comparison

Section based comparison Visual comparison of color plots




Summary

No automatism, manual work





Summary


Due to user interaction very fault-prone Definition of points, sections, etc. in correct corresponding positions in FEA and measurement results





Summary


Due to user interaction very fault-prone Definition of points, sections, etc. in correct corresponding positions in FEA and measurement results

Limitations

Comparison only possible for local areas

Points Sections

Visual comparison of color plots

Inaccurate matching between FEA and measurement results


Verification of Numerical Simulations Verification Procedure using 3D Data






Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing






Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing

FE Verification




Verification procedure in ARAMIS and ARGUS






Import of result data set from numerical simulation







The result data set from the simulation need to be exported into the correct format from the numerical simulation software package

Direct export functions available in LS-Dyna, Pamstamp and Autoform

Export scripts are available for ANSYS, ABAQUS and NASTRAN







3D coordinate system alignment

Usually the 3D coordinate system is not aligned between results from numerical simulation and measurement

Manual pre-alignment

Best-fit alignment








Surface Comparison

Deviations between FEA and measurement








Surface Comparison

Deviations between FEA and measurement

With small enough deviation between the two surfaces the comparison of further result data, such as displacement and strain, is useful








Surface Comparison

Result data comparison

Due to the issues that the nodes in the simulation are not at the same 3D positions as the measured 3D coordinates from the measurement a mapping of these two datasets is required to enable the direct comparison between FEA and measurement








Surface Comparison


Due to the issues that the nodes in the simulation are not at the same 3D positions as the measured 3D coordinates from the measurement a mapping of these two datasets is required to enable the direct comparison between FEA and measurement








Surface Comparison


Further post-processing and reporting functions are available in ARAMIS for measurement and FEA data

Point evaluations Section Statistics Interpolation Filtering etc.


Verification of Numerical Simulations Application Examples Rotor Blade




Test Specimen Carbon fiber rotor Blade length: 1540mm

Numerical simulation Linear simulation model Used to define positions for the application of strain gauges

ARAMIS is used in this application to

Verify the numerical simulation Verify strain gauge positions Replace strain gauges

Verification of Numerical Simulations Application: Rotor Blade Bending test




Rotor blade bending test

Positions of strain gauges





Rotor blade bending test Full-field strain evaluation in X-direction of coordinate system





Rotor blade bending test Full-field strain evaluation in X-direction of coordinate system

Strain gauge positions not in maximum strain areas

Non homogeneous strain distribution in root area of the rotor blade

Further measurement only focused on the root area






Measurement of rotor blade root using a smaller measuring area to raise the local resolution for a better understanding of the local deformation behavior

Strain in X-direction






Measurement of rotor blade root using a smaller measuring area to raise the local resolution for a better understanding of the local deformation behavior

Strain in X-direction

Non homogeneous local deformation behavior

Strain gauges were not applied on the areas of maximum deformation as predicted in the numerical simulation






Strain gauge were applied to measure in X-direction

Comparison ARAMIS against strain gauges






Verification of numerical simulation from rotor blade

Alignment


Initial Shape from FEA

incl. measurement results

(measurement projected to FEA surface)






Alignment Import FEA Strains


Result from ANSYS simulation Result from ARAMIS measurement






Difference between ANSYS simulation and ARAMIS measurement result


Difference between Simulation (ANSYS) and measurement (ARAMIS)




FEA-comparison module

Included in ARAMIS and ARGUS

Comfortable alignment and mapping

Determination of full field deviations for Geometry Displacements Strains (Major, Minor, )

Easy and comfortable FEA verification including result evaluation and reporting

Verification of Numerical Simulations Summary






Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing

Thank you for your attention

[email protected] www.gom.com

gom graziosi

Documents

frame setup frame

d shape

d analysis

d digitizing

results material testing

dynamic component

mobile optical cmm dynamic

composite component