pro/engineer advanced mechanica robust capabilities to support your product development needs victor...
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Pro/ENGINEER Advanced MechanicaRobust capabilities to support your product development needs
Victor Remmers
Holland Engineering Consultants BV
© 2006 PTC2
Pro/ENGINEER Advanced Mechanica
Agenda-
State of PTC Simulation Solutions
PTC Structural and Thermal Analysis Solutions
– Pro/ENGINEER Mechanica
– Pro/ENGINEER Advanced Mechanica
Advanced Mechanica Capabilities
– Supported Solutions Types
– Additional Modeling Entities
– FEM Modeling Capabilities
© 2006 PTC3
Developing innovative simulation solutions for over a decade
Significant ongoing investments in computer aided engineering (CAE)
–Supports a healthy ecosystem of more than 200 software development partners
Over 8000 customers in diverse industry verticals
Leading respected companies such as...
PTC as a Simulation Solutions Partner
© 2006 PTC4
PTC as a Simulation Solutions Partner
PTC continue to invest heavily in simulation solutions – The proof is in the results...
PTC is not resting on past accomplishments, but continues to lead with innovative simulation solutions
Wildfire 1.0
–The biggest release of Structural and Thermal Simulation ever (even pre-dating the RASNA acquisition) -Over 130 individual projects
Wildfire 2.0
–Redesigned user interface – leveraging the Wildfire user model
–Many new functionality features such as bolt fasteners
Wildfire 3.0–User customizable simulation process guides
–Continuing usability and functionality enhancements
–Much more...
© 2006 PTC5
Pro/ENGINEER Mechanica
Using Pro/ENGINEER Mechanica in the design process serves to reduce risk-
Are you spending Money?
Do you know if the design
works?No No No No
$ $ $ $
Prototype Mfg.
Concept Design
Detailed Design
Drawing / Detailing
Prototype Testing
Yes
$
Risk
Simulation early in the design process reduces risk, reducing time and improves quality
© 2006 PTC6
Pro/ENGINEER Mechanica
Pro/ENGINEER Mechanica satisfies the need to evaluate product performance during design by satisfying the following four key points-
Integration
Accuracy
Affordability
Scalability“I was amazed at how fast I was able to produce accurate stress results…”
- Derrick Rogers, Lead Technical Engineer Miss Budweiser Racing; also a Loads and Dynamics Engineer at Boeing Commercial Aircraft
Structural and Thermal Simulation is the BEST solution for functional simulation early in the design process if you use Pro/ENGINEER
© 2006 PTC7
Pro/ENGINEER Mechanica
Pro/ENGINEER Mechanica satisfies the needs of design level analysis
Intended for everyday use as a design based simulation tool
Functionality addresses more common use scenarios
However, the complexity of the products and problems engineers face is increasing...
More nonlinear capabilities are required
More solution types necessary
More exotic properties and modeling entities required
Pro/ENGINEER Advanced Mechanica has the capabilities
to address the broader range of problems posed by complex product design requirements
© 2006 PTC8
Why Advanced Mechanica from PTC?
Advanced Mechanica addresses the greater needs of dedicated and expert users while maintaining the basic benefits of Mechanica-
Leverage your existing skills and investment in Mechanica infrastructure
Unique solution technology for not just any answer, but the right answer
A broad set of capabilities that build on the base package making simulation accessible from engineers through analysts
The power to get the job done, without compromise
The Scalability to address the needs of designers through experts
© 2006 PTC9
The bottom line...
Without Mechanica, you won’t leverage the power of Pro/ENGINEER. Without Advanced, you can’t leverage the full power of Mechanica
Advanced Mechanica expands the types of problems you can simulate-
Validate product performance to improve quality and reduce cost
Understand product performance in real world conditions before money is committed for physical prototypes
–A prototype should validate your decisions, not be used for design
Use simulation to drive the design, not validate it late in the process
© 2006 PTC10
Pro/ENGINEER Advanced Mechanica
Advanced Mechanica extends the capabilities of Mechanica in the following areas-
Supported Analysis/Solution Types
Support for Advanced Materials Properties
Advanced Modeling Entities
Sophisticated FEM modeling tools
Advanced Mechanica provides the depth of capability to simulate to today’s complex requirements
© 2006 PTC11
Advanced Tools for Model Simplification
2D Model simplification enables you to dramatically reduce the time to solution for applicable models
Supported 2D Model types include-– Plane Strain – Unit Thickness
– Plane Stress – Thin Plate
– Axisymmetric
Benefits include-
– Extremely fast solution speed
• Fast non-linear solutions, including large deformation or contact
• Even models with contact defined solve in seconds!
– Ideal for design studies
– Very simple to set up
Solve complex problems in a fraction of the time needed for full 3D models!
© 2006 PTC12
Advanced Solution Types
“How long will my design take to reach steady state?”
Steady state thermal analysis can tell you how hot or cold a component will get – Transient Thermal will tell you how long it will take to get there
Transient Thermal Analysis
Setup is straightforward -
– Time dependant heat loads
– Time dependant convection coefficients
– Analysis definition is similar to that of steady state
Available results include –
– Graphs of Measures vs. Time
– Full results at user selected intervals
– Temperatures to apply to structural models at user selected intervals
© 2006 PTC13
Advanced Solution Types
Large Deformation Nonlinearity
The ability to perform analysis on components which undergo large deformations yet small strains (once the load is removed there is no permanent set)
Common Applications include the design of-
– Snap Fits
– Springs
Output can include –
– Graphs of displacement vs. force
– Full fringe result
Linear static solution
In Nonlinear Large Deformationanalysis stresses are 11% lower
Unique adaptive nonlinear and solution algorithms are tailored for non-specialist users
© 2006 PTC14
Advanced Solution Types
Advanced Mechanica supports the analysis of such models in both static and dynamic analyses
Prestress Static Analysis
– Static analysis which takes loading into account for stiffness
Prestress Modal Analysis
– Modal (natural frequency) analysis which takes loading into account or stiffness
– Prestress Modal also includes additional physical effects including-
• Spin Softening
• Stress Stiffening
In certain structures the stiffness is dependant on an applied load
– For example, a sheet of paper is flexible and cannot support much, if any weight; however if I pull along the edges, the paper can support considerable weight
© 2006 PTC15
Advanced Solution Types
Vibration analysis capabilities include-
Dynamic Time
– Used for evaluating the behavior of systems where the input is a time history of load; common applications include transient or shock loadings
• For example the design of an aftermarket exhaust pipe for an off-road motorcycle where a requirement is the ability to withstand a 10 ms, 20g half-sine shock load
Dynamic Frequency
– Used in evaluating the response of a structure to an input of loading vs. frequency; common applications include rotating machinery and engines - where the loading is highly periodic in nature
• For instance in the above example we may have test data of the accelerations vs. frequency form the engine, and we may need to evaluate the maximum displacements of the muffler assembly during a range of operating conditions.
Advanced Mechanica supports a broad range of dynamic analyses
Many products operate in environments where vibration plays a key factor in the performance of the design. The physical test equivalent for dynamic would be “shaker table” testing of components.
© 2006 PTC16
Advanced Solution Types
Vibration analysis capabilities include (Cont’d)-
Dynamic Random
– Some vibration environments are characterized as random; for example a plane flying through turbulent air or a truck driving on pavement. In both of these examples another plane flying the same path or truck driving the same road would experience similar, but not the exact, same accelerations.
• The input to random vibration analysis is a PSD (Power Spectral Density); basically the “probability” of encountering a level of acceleration for a given frequency.
• For example, we may be designing a control unit for an engine in a vehicle for which we have a PSD of the mount locations. The PSD will include the effects of the engine, the road, etc.. And Dynamic Random analysis can show us how the component will behave in this environment.
Dynamic Shock
– Used for simulating seismic loads
• For example an equipment rack which must be able to withstand an earthquake of a given magnitude
© 2006 PTC17
Advanced Mechanica Capabilities
Laminates and Non-Isotropic Materials
Not all materials behave the same in all directions. Once only used in aerospace, but now common in everything from sporting goods to automobiles, Advanced Mechanica enables you to define and use Anisotropic and Orthotropic materials with ease in your models
Additional Capabilities Include:
Advanced tools for modeling composite structures
– Ply editing for building up laminates
– Layup stiffness review
– Results by ply
Support for common failure criteria such as Tsai-Wu
Evaluate the performance of your designs with exotic materials
© 2006 PTC18
Advanced Mechanica Capabilities
Advanced Mass Idealizations
– The ability to enter in the full mass matrix including inertial terms, not just the mass value
– The ability to define mass idealizations “from component” where the mass matrix and orientation are taken from another component.
Advanced Springs Idealizations
– The ability to define springs by specifying the full stiffness matrix including the coupling terms
– Control over automatic coupling between bending and tensile loads
Advanced Shell Idealizations
– The ability to easily model composite structure
More sophisticated Idealizations
Advanced Mechanica builds on the robust set of idealizations provided in the basic package.
Additional capabilities include-
© 2006 PTC19
Advanced Mechanica Capabilities
Advanced Bolt Fasteners
– Build off of the capabilities in Basic Mechanica
– Additional Functionality Includes....
– The ability to easily define preload
– Greater control over specifying bolt stiffness
– Control over the degrees of freedom in the bolt connection
Weighted Link Connections
– The ability to couple a point to move as the average displacement of a set of geometry
– Powerful tool for attaching point loads and masses and distributing these over a model
More sophisticated Connection Capabilities
© 2006 PTC20
Advanced Mechanica Capabilities
Advanced FEM Mode Modeling tools
Sophisticated capabilities for interfacing between Pro/ENGINEER and 3rd party solvers such as NASTRAN or ANSYS
•Additional capabilities include-
Hierarchical FEM modeling
– The ability to “Assemble” FEM meshes to build system level models
Support for Rigid and Weighted Links
– NASTRAN RBE3 and RBAR support. ANSYS rigid like export
Access in FEM Mode to other Advanced Capabilities
– Access to advanced shells, masses, distributed mass, etc...
Scalability to pass your models to 3rd party solvers for performing
systems level analyses
© 2006 PTC21
Why Advanced Mechanica from PTC?
Leverage your existing skills and investment in Mechanica solution technology
Greater Solution Flexibility
Greater Solution Capability
Expand the breadth of your simulation coverage
Advanced Mechanica is the ONLY solution for sophisticated simulation inside of Pro/ENGINEER
© 2006 PTC22
What is new in MECHANICA Wildfire 3.0?
A Quick overview….
© 2006 PTC23
Structural and Thermal Usability Improvements
Remaining “Mechanica” objects merged into Pro/E
Including...
– Spot welds
– Rigid connections
– Contact regions
Enhanced capabilities include…
– Improved UI
– Object-Action interaction (direct editing)
– Layers support
– Model tree support
– Improved display and controls
– Much, much more...
Automatic Contact Definition
Select components and separation tolerance
Contacts are automatically created
© 2006 PTC24
Structural and Thermal Usability Improvements
New design study UI
The last of the “Old Style” UI to be removed
Usability improvements to...
– Optimization definition
– Sensitivity study definition
– Design Studies
No more design variable definition
– Use dimensions and parameters directly
Greater control of optimization settings
Feasibility studies added
© 2006 PTC25
Structural and Thermal Usability Improvements
Many smaller improvements....
Selection/Copy enhancements
– Copy and Paste of simulation modeling objects
– Multi-selection for delete
Hide/Unhide for simulation objects in model tree
Exploded views supported in modeling
– Contact definition is much simpler
– Define connections in exploded state
Results improvements
– Dynamic query labels don’t erase when spinning model
– Spin center control allows rotations about a user selected location
– Legend settings don’t reset when window is edited
© 2006 PTC26
Structural and Thermal Functionality Improvements
Volumetric assignment
Ability to assign materials by volume
– Volume regions in a part can have different properties
Ability to assign heat loads by volume
Inertial relief
This is the ability to run static analyses on “unconstrained” or “under constrained” models
– Users simply select a checkbox on the analysis definition dialog
Externally applied loads are balanced in the solver by equal and opposite body forces (accelerations)
© 2006 PTC27
Structural and Thermal Functionality Improvements
“Weighted” links in Mechanica
Similar in functionality to NASTRAN RBE3
A point is tied to move the average of the displacements of selected geometry
A great tool for “smearing out” singular effects over more of a model such as point loads
Advanced springs
Now advanced spring definition is supported inside of Pro/ENGINEER
Full stiffness and coupling matrix may be defined
– Users also have the option to disable the “auto coupling” of simple springs
© 2006 PTC28
Structural and Thermal FEM Improvements
FEM mode specific enhancements
Spot weld connections supported for ANSYS and NASTRAN
Rigid links enhancements (one to many)
New modeling entities output to ANSYS
– Rigid links
– Beam releases
Display only mode in Run dialog
– Allows preview of output without writing the model to file
Supported solvers include...
– ANSYS 9.0
– MSC.NASTRAN 2005 r1
© 2006 PTC29
Structural and Thermal Robustness Improvements
Robustness
Meshing robustness
– Very large model AutoGEM robustness (200K+ solids)
– FEM solid and tri surface meshing robustness
“Assembly modeling methodology” in FEM
– Mid-surface compressed models “joined” with rigid links
Tolerance report
Performance Improvements
Removal of the 8 Gb memory limit on 64 bit operating systems
Mechanica running on Linux
Windows XP 64-bit support
– Intel Xeon 64
– AMD Opteron 64
© 2006 PTC30
New Materials Definition UI/Database
Materials in Pro/E are completely overhauled
Materials in Pro/E are being enhanced to support Simulation requirements
Database will be open and extendable
– Including the ability to add user defined parameters to materials
– Each materials property has units associated
Part materials will be “seen” at assembly level in Mechanica
New functionality includes...
User defined material parametersAssign materials in family tablesAssign appearance by material
© 2006 PTC31
Process Guide for Structural Simulation
A user customizable “wizard” that can be used alongside the standard user interface
Defined by a user specified xml file
Each “process” consists of one or more tasks
Users simply follow the steps listed in the tasks
What problem does Process Guide address?
Some Product Development activities are very “process oriented”, such as manufacturing or analysis
It is not uncommon for an engineer to perform analysis only a few weeks a year
– If a design cycle is 9-12 months, only a few weeks of that time may be simulating the design...
Some analysis tasks consist of repeatable processes– These may be dictated by expert users or analysts
Pro/E’s simulation tools are robust and easy to use, but for infrequent users the difficulty is not in the “clicks and picks” but in the sequence of events
© 2006 PTC32
Process Guide for Structural Simulation
The process is made up of discrete tasks
“Experts” or consultants can define process templates
– These are an xml file with the data that will populate Process Guide
37 different actions and may be defined, including...
– Info links – links to online help, company intranets, etc...
– Action links – loads, constraints, idealizations, etc...
The resulting process file has some intelligence
If created entity is deleted, task is invalidated
Sub-steps may be created
Some tasks are order dependant
– Analysis must be run before results may be viewed
Each task may contain
Text
One action and multiple informational links
Embedded images
© 2006 PTC33
Thank You!