rod dreisbach the boeing company computational structures technology boeing
DESCRIPTION
First MIT Conference on Computational Fluid and Structural Mechanics Cambridge, Massachusetts USA June 12-15, 2001. Enhancing Engineering Design and Analysis Interoperability Part 3: Steps toward Multi-Functional Optimization. Rod Dreisbach The Boeing Company - PowerPoint PPT PresentationTRANSCRIPT
Enhancing Engineering Design and Analysis Interoperability
Part 3: Steps toward Multi-Functional Optimization
Rod DreisbachThe Boeing CompanyComputational Structures Technologywww.boeing.com
First MIT Conference on Computational Fluid and Structural MechanicsCambridge, Massachusetts USA
June 12-15, 2001
Russell PeakGeorgia TechEngineering Information Systems Labeislab.gatech.edu
2Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Maturation of product life cycle knowledge
ProductLifecycle
Knowledge
Virtual Product Definition(CAD)
Constrained Objects (COBs):Multi-Directional, Associative, Computer-Sensible, Knowledge-Based, EngineeringInformation Mapping
Virtual Functional Prototype(CAE)
COMPOSE:Concurrent Optimization ofMultifunctionalProductOperationalSpecificationEnvelopes
Product Design Requirements,Operational Specifications
Develop Product
Build Product
Maintain Product
Design C
onstraints
Des
ign
Con
stra
ints
CA
M D
ataDesign Constraints
Design Intent
(PIM)
Operational Data
3Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
e
se
tr
Pf
02
21
e
be
ht
PCf
),,( 13 hbrfK
Channel Fitting Analysis
Typical Current Approach: Optimize idealized parameters (vs. detailed design)
Analysis Model (with Idealized Features)
Detailed Design Model
Idealizations
1 : b = cavity3.inner_width + rib8.thickness/2 + rib9.thickness/2
“It is no secret that CAD models are driving more of today’s product development processes ... With the growing number of design tools on the market, however, the interoperability gap with downstream applications, such as finite element analysis, is a very real problem. As a result, CAD models are being recreated at unprecedented levels.” Ansys/ITI press Release, July 6 1999
http://www.ansys.com/webdocs/VisitAnsys/CorpInfo/PR/pr-060799.html
Need
fine-grained
CAD-CAE
associativity
4Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Multi-Functional Optimization (MFO)
Term as coined at Boeing
Multitude of operational functional requirements Concurrent consideration during product design
process Idealized design variables used in optimization
associated directly with product (detailed design)
5Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Progress onNecessary Components
Design-Analysis Integration– CAD-CAE Associativity– Connect diverse CAE models to same CAD model:
Varying discipline, behavior, fidelity, method, tool– Multi-directional
Object-Oriented View of Optimization Enhanced FEA Modeling for Built-Up Structure
6Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
X-Analysis Integration Techniquesa. Multi-Representation Architecture (MRA)
1 Solution Method Model
ABB SMM
2 Analysis Building Block
4 Context-Based Analysis Model3
SMMABB
APM ABB
CBAM
APM
Design Tools Solution Tools
Printed Wiring Assembly (PWA)
Solder Joint
Component
PWB
body3body2
body1
body4
T0
Printed Wiring Board (PWB)
SolderJoint
Component
AnalyzableProduct Model
b. Explicit Design-Analysis Associativity
c. Analysis Module Creation Methodology
I n f o r m a l A s s o c i a t i v i t y D i a g r a m
C o n s t r a i n e d O b j e c t - b a s e d A n a l y s i s M o d u l eC o n s t r a i n t S c h e m a t i c V i e w
P l a n e S t r a i n B o d i e s S y s t e m
P W A C o m p o n e n t O c c u r r e n c e
CL
1
m a t e r i a l ,E( , )g e o m e t r y
b o d y
p l a n e s t r a i n b o d y , i = 1 . . . 4P W B
S o l d e rJ o i n t
E p o x y
C o m p o n e n tb a s e : A l u m i n a
c o r e : F R 4
S o l d e r J o i n t P l a n e S t r a i n M o d e l
t o t a l h e i g h t , h
l i n e a r - e l a s t i c m o d e l
A P M A B B
3 A P M 4 C B A M
2 A B Bc
4b o d y 3b o d y
2b o d y
1h oT
p r i m a r y s t r u c t u r a l m a t e r i a l
ii
i
1 S M M
D e s i g n M o d e l A n a l y s i s M o d e l
A B B S M M
s o l d e rs o l d e r j o i n t
p w b
c o m p o n e n t
1 . 2 5
d e f o r m a t i o n m o d e l
t o t a l h e i g h t
d e t a i l e d s h a p e
r e c t a n g l e
[ 1 . 2 ]
[ 1 . 1 ]
a v e r a g e
[ 2 . 2 ]
[ 2 . 1 ]
cT c
T s
i n t e r - s o l d e r j o i n t d i s t a n c ea p p r o x i m a t e m a x i m u m
s j
L s
p r i m a r y s t r u c t u r a l m a t e r i a l
t o t a l t h i c k n e s s
l i n e a r - e l a s t i c m o d e l
P l a n e S t r a i n
g e o m e t r y m o d e l 3
a
s t r e s s - s t r a i nm o d e l 1
s t r e s s - s t r a i nm o d e l 2
s t r e s s - s t r a i nm o d e l 3
B o d i e s S y s t e m
x y , e x t r e m e , 3
T 2
L 1
T 1
T 0
L 2
h 1
h 2
T 3
T s j
h s
h c
L c
x y , e x t r e m e , s jb i l i n e a r - e l a s t o p l a s t i c m o d e l
l i n e a r - e l a s t i c m o d e l
p r i m a r y s t r u c t u r a l m a t e r i a l l i n e a r - e l a s t i c m o d e l
c o m p o n e n to c c u r r e n c e
s o l d e r j o i n ts h e a r s t r a i nr a n g e
[ 1 . 2 ]
[ 1 . 1 ]l e n g t h 2 +
3 A P M 2 A B B 4 C B A M
F i n e - G r a i n e d A s s o c i a t i v i t y
ProductModel Selected Module
Analysis Module Catalogs
MCAD
ECAD
Analysis Procedures
CommercialAnalysis Tools
Ansys
Abaqus
Solder Joint Deformation Model
Idealization/Defeaturization
CommercialDesign Tools
PWB
Solder Joint
Component
APM CBAM ABB SMM
Ubiquitous Analysis(Module Usage)
Ubiquitization(Module Creation)
CAE
Physical Behavior Research,Know-How, Design Handbooks, ...
7Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
COB-based Constraint Schematic for Multi-Fidelity CAD-CAE Interoperability
Flap Link Benchmark Example
Material Model ABB:
Continuum ABBs:
E
One D LinearElastic Model
T
G
e
t
material model
polar moment of inertia, J
radius, r
undeformed length, Lo
twist,
theta start, 1
theta end, 2
r1
12
r3
0L
r
J
rTr
torque, Tr
x
TT
G, r, , ,J
Lo
y
material model
temperature, T
reference temperature, To
force, F
area, A
undeformed length, Lo
total elongation,L
length, L
start, x1
end, x2
E
One D LinearElastic Model
(no shear)
T
e
t
r1
12 xxL
r2
oLLL
r4
A
F
edb.r1
oTTT
r3
L
L
x
FF
E, A,
LLo
T, ,
yL
Torsional Rod
Extensional Rod
temperature change,T
cte,
youngs modulus, E
stress,
shear modulus, G
poissons ratio,
shear stress, shear strain,
thermal strain, t
elastic strain, e
strain,
r2
r1)1(2
EG
r3
r4Tt
Ee
r5
G
te
1D Linear Elastic Model
material
effective length, Leff
linear elastic model
Lo
Extensional Rod(isothermal)
F
L
A
L
E
x2
x1
youngs modulus, E
cross section area, A
al1
al3
al2
linkage
mode: shaft tension
condition reaction
allowable stress
stress mos model
Margin of Safety(> case)
allowable
actual
MS
Analysis Modules of Diverse Behavior & Fidelity
(CBAMs) MCAD Tools
Materials LibrariesIn-House, ...
FEA Ansys
Abaqus*
CATIA Elfini*
MSC Nastran*
MSC Patran*
...
General MathMathematica
Matlab*
MathCAD*
...
Analyzable Product Model(APM)
Extension
Torsion
1D
1D
Analysis Building Blocks(ABBs)
CATIA, I-DEAS* Pro/E* , UG *, ...
Analysis Tools(via SMMs)
Design Tools
2D
flap_link
critical_section
critical_simple
t2f
wf
tw
hw
t1f
area
effective_length
critical_detailed
stress_strain_model linear_elastic
E
cte area
wf
tw
hw
tf
sleeve_1
b
h
t
b
h
t
sleeve_2
shaft
rib_1
material
rib_2
w
t
r
x
name
t2f
wf
tw
t1f
cross_section
w
t
r
x
R3
R2
R1
R8
R9
R10
6R
R7
R12
11R
1R
2
3
4
5
R
R
R
R
name
linear_elastic_model
wf
tw
tf
inter_axis_length
sleeve_2
shaft
material
linkage
sleeve_1
w
t
r
E
cross_section:basic
w
t
rL
ws1
ts1
rs2
ws2
ts2
rs2
wf
tw
tf
E
deformation model
x,max
ParameterizedFEA Model
stress mos model
Margin of Safety(> case)
allowable
actual
MS
ux mos model
Margin of Safety(> case)
allowable
actual
MS
mode: tensionux,max
Fcondition reaction
allowable inter axis length change
allowable stress
ts1
B
sleeve1
B ts2
ds2
ds1
sleeve2
L
shaft
Leff
s
rib1 rib2
material
effective length, Leff
deformation model
linear elastic model
Lo
Torsional Rod
G
J
r
2
1
shear modulus, G
cross section:effective ring polar moment of inertia, J
al1
al3
al2a
linkage
mode: shaft torsion
condition reactionT
outer radius, ro al2b
stress mos model
allowable stress
twist mos model
Margin of Safety(> case)
allowable
actual
MS
Margin of Safety(> case)
allowable
actual
MS
allowabletwist
Flap Link Extensional Model
Flap Link Plane Strain Model
Flap Link Torsional Model* = Item not yet available in toolkit (all others have working examples)
Parts LibrariesIn-House*, ...
LegendTool AssociativityObject Re-use
8Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Test Case Flap Linkage: Analysis Template Reuse of APM
flap_link
critical_section
critical_simple
t2f
wf
tw
hw
t1f
area
effective_length
critical_detailed
stress_strain_model linear_elastic
E
cte area
wf
tw
hw
tf
sleeve_1
b
h
t
b
h
t
sleeve_2
shaft
rib_1
material
rib_2
w
t
r
x
name
t2f
wf
tw
t1f
cross_section
w
t
r
x
R3
R2
R1
R8
R9
R10
6R
R7
R12
11R
1R
2
3
4
5
R
R
R
R
Linkage Extensional Model (CBAM)
Flap link (APM)
reusable idealizations
material
effective length, Leff
deformation model
linear elastic model
Lo
Extensional Rod(isothermal)
F
L
A
L
E
x2
x1
youngs modulus, E
cross section area, A
al1
al3
al2
linkage
mode: shaft tension
condition reaction
allowable stress
ts1
A
Sleeve 1
A ts2
ds2
ds1
Sleeve 2
L
Shaft
Leff
s
stress mos model
Margin of Safety(> case)
allowableactual
MS
x
FF
E, A,
LLo
T, ,
L
9Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Design Model
Idealized Model
Design-Idealization Relation
flap_linkflap_link
critical_section
critical_simple
t2f
wf
tw
hw
t1f
area
effective_length
critical_detailed
stress_strain_model linear_elastic
E
cte area
wf
tw
hw
tf
critical_section
critical_simple
t2f
wf
tw
hw
t1f
area
effective_length
critical_detailed
stress_strain_model linear_elastic
E
cte area
wf
tw
hw
tf
sleeve_1
b
h
t
b
h
t
sleeve_2
shaft
rib_1
material
rib_2
w
t
r
x
name
t2f
wf
tw
t1f
cross_section
w
t
r
x
sleeve_1
b
h
t
b
h
t
sleeve_2
shaft
rib_1
material
rib_2
w
t
r
x
name
t2f
wf
tw
t1f
cross_section
w
t
r
x
R3
R2
R1
R3
R2
R3
R2
R1R1
R8
R9
R10
6R
R7
R12
11R
1R
2
3
4
5
R
R
R
R
R8
R9
R10
R8
R9
R10
6R6R
R7R7
R12R12
11R11R
1R1R
2
3
4
5
R
R
R
R
2
3
4
5
R
R
R
R
2
3
4
5
R
R
R
R
Product Attribute
Idealized Attribute
Ri Idealization Relation
Ri Product Relation
Product AttributeProduct Attribute
Idealized AttributeIdealized Attribute
Ri Idealization RelationRi Idealization Relation
Ri Product RelationRi Product Relation
Extended Constraint Graph
Flap Link APMImplementation in CATIA v5
10Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
CATIAModel CATDAK XaiToolsAPI
VBScripts
AnalysisInputs
AnalysisOutputs
(Design Updates)VBScripts
CATDAK OverviewXaiTools CATIA Design-Analysis Knowledge Manager
TraditionalSolvers
AnalysisTemplates
Design & Idealizations(APM)
API = application programming interface
CAD-AnalysisTemplate Coordination
Analysis TemplateUsage (CBAMs)
11Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Updating CAD Model from Analysis Template Results
m ateria l
e ffec tiv e leng th , L eff
de fo rm ation m ode l
linear e las tic m ode l
L o
E xtens iona l R od(iso the rm a l)
F
L
A
L
E
x2
x1
youngs m odu lus , E
cross sec tion area , A
a l1
a l3
a l2
linkage
m ode: sha ft tens ion
cond ition reaction
a llo w ab le s tress
ts1
A
Sleeve 1
A ts2
ds2
ds1
Sleeve 2
L
Shaft
Le ff
s
s tress m os m ode l
M arg in o f S a fe ty(> case)
allow ableactua l
M S
x
FF
E , A ,
LL o
T , ,
L
m ateria l
e ffec tiv e leng th , L eff
de fo rm ation m ode l
linear e las tic m ode l
L o
E xtens iona l R od(iso the rm a l)
F
L
A
L
E
x2
x1
L o
E xtens iona l R od(iso the rm a l)
F
L
A
L
E
x2
x1
youngs m odu lus , E
cross sec tion area , A
a l1
a l3
a l2
linkage
m ode: sha ft tens ion
cond ition reaction
a llo w ab le s tress
ts1
A
Sleeve 1
A ts2
ds2
ds1
Sleeve 2
L
Shaft
Le ff
s
ts1
A
Sleeve 1
A ts2
ds2
ds1
Sleeve 2
L
Shaft
Le ff
s
s tress m os m ode l
M arg in o f S a fe ty(> case)
allow ableactua l
M S
M arg in o f S a fe ty(> case)
allow ableactua l
M S
x
FF
E , A ,
LL o
T , ,
L
12Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Progress onNecessary Components
Design-Analysis Integration– CAD-CAE Associativity– Connect diverse CAE models to same CAD model:
Varying discipline, behavior, fidelity, method, tool– Multi-directional
Object-Oriented View of Optimization Enhanced FEA Modeling for Built-Up Structure
13Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Thesis AbstractObject Oriented Paradigm for Optimization Model Enhancement
Doctoral ThesisGeorgia Institute of Technology, Atlanta.
http://eislab.gatech.edu/Selçuk Cimtalay
Nov. 2000
The modeling process that transforms a detailed product design and its multi-fidelity analysismodels into an optimization model is a non-trivial task requiring large amounts of diverseinformation, engineering theory, and experienced-based heuristics, as well as the support ofoptimization, design, and analysis tools. Engineering optimization can be viewed as aninformation intensive problem that requires engineering information solutions.
This research has focused on developing a new information representation of optimizationmodels, termed Enhanced Optimization Model (EOM). EOM represents an informationframework for an object oriented design methodology for optimization model construction,enhancement, classification and solution. EOM utilizes a combination of constraint graph andobject techniques to provide semantically rich mappings. EOM representation consists of aninformation model structure and protocol, and modeling languages for creating EOM objects.Specifically, EOM representation is developed as an information representation by focusing onthe optimization aspects to partition the optimization area into more trackable and modularobjects. Key distinctions are the explicit representation of the associativity between anoptimization model and its analysis and design models and the ability to support multi-fidelityoptimization models as the design progresses.
EOM concepts have been prototyped in Java in conjunction with optimizers (Bolink, CONMINetc.), analyzers (Ansys FE) and symbolic solvers (Mathematica). Structural analysis andelectronic packaging test cases illustrate the different characteristics and help to evaluate theEOM representation with respect to the thesis objectives. Results show that EOM representationenables the enhancement ability to capture optimization model building information, to modifythe models easily, and provide flexibility to designers.
14Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Nf
p
f
c
12
2
1
'
Design ToolsAnalysis Tools
Printed Wiring Assembly (PWA)
Printed Wiring Board (PWB)
SolderJoint
Component
AnalyzableProduct Model
Solution Method Model
Enhanced Optimization Model (EOM)
Math Opt ModelEngineeringOpt. Model
Find
Design variable Notation
solder joint height (h)
PWB material type
Maximize
Solder Fatigue life:
Solution Method Model
Analysis Building Block
Context-Based Analysis Model
Solder Joint
Component
PWB
body3
body2
body1
body4
T0
Previous work [Peak et al. 2000, Tamburini 1999, Wilson, 2000]
THESIS FOCUS
Partition of Engineering Entities
Nf
p
f
c
12 2
1
'
Maximize/ Minimize
f x pj( , )Xj design variablesp Constants design parameters
Subject to
h (x,p)i0
i=1,.........,n
g x pi ( , ) 0 i=n+1,......,q
Side constraints
x x xlow j up j= 1,........,n
x x u p1
X 1
X 2
F e a s i b l e R e g i o n
x x u p2
x xl o w 2
g x p1 0( , )
g x p2 0( , )
T1 T3
T2
one variable
T4 T5
multi variable
unconstrained
T6
one-variable
T7 T8
multi variable
constarint
Optimization Methods
Optimization tools
Optimization Methods
15Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Optimization Model Diversity
Min Weight
g (x)<0h(x) =0
subject toStressDesign variablesArea
Min Weight
OPTIMIZATION MODEL CLASS
Optimization Object 1 Optimization Object 2
Min Weight
subject to
X(H)
Min Weight
subject to
X(H,LL,LR)
OPTIMIZATION MODEL CLASS
Optimization Object 1 Optimization Object 2
Min Weight, Cost
subject to
Optimization Object 3
X(H,LL,LR,Mat)
g (x)<0h(x) =0
g (x)<0h(x) =0
2D PLANE STRAIN MODEL
1D EXTENSIONAL STRESS MODEL
Analysis Model(s)Enhancement and/or Addition
subject toStressBucklingDesign variablesArea, Material
y
xPP
E, A
LLeff
,
L
Objective, design variable, and/or constraint function enhancement
16Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Optimization Model Enhancement
MinimizeLAf
1 WeightSubject to
0)(1 AMSg stress Normal Stress Margin of Safety
Design variables
X={A}
MinimizeLAf
1 WeightSubject to
0)(1 AMSg stress Normal Stress Margin of Safety
Design variables
X={A, material}
OPTIMIZATION MODEL I
OPTIMIZATION MODEL II
17Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Minimization of Weight of a LinkageX(area) subject to (extensional stress)
Leff
product structure: linkage
material
effective length, Leff
deformation model
linear elastic model
Lo
Extensional Rod(isothermal)
F
L
A
L
E
x2
x1
youngs modulus, E
cross section area, A
al1
al3
al2
analysis context
goal: optimization
mode: shaft tension
condition: flaps down
linkage reaction
allowable stressMargin of Safety
(> case)
allowableactual
MS
ts1
A
Sleeve 1
A ts2
ds2
ds1
Sleeve 2
L
Shaft
Leff
s
y
xPP
E, A
LLeff
,
L
minimize weight
constraint
Design VariableA
weight,WW AL
MS 0
density,
MSstress
1
allowablestressMS
18Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Minimization of Weight of a LinkageX(area, material) subject to (extensional stress)
Leff
product structure: linkage
material
effective length, Leff
deformation model
linear elastic model
Lo
Extensional Rod(isothermal)
F
L
A
L
E
x2
x1
youngs modulus, E
cross section area, A
al1
al3
al2
analysis context
goal: optimization
mode: shaft tension
condition: flaps down
linkage reaction
allowable stressMargin of Safety
(> case)
allowableactual
MS
ts1
A
Sleeve 1
A ts2
ds2
ds1
Sleeve 2
L
Shaft
Leff
s
y
xPP
E, A
LLeff
,
L
minimize weight
constraint
Design Variablearea,A
weight,WW AL
MS 0
density,
MSstress
1
allowablestressMS
material
19Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Optimization Model Enhancement
M i n i m i z eLAf 1 W e i g h t
S u b j e c t t o0)(1 AMSg stress N o r m a l S t r e s s M a r g i n o f S a f e t y
0)(2 AMSg buckling B u c k l i n g M a r g i n o f S a f e t yD e s i g n v a r i a b l e s
X = { A }
MinimizeLAf
1 WeightSubject to
0)(1 AMSg stress Normal Stress Margin of Safety
0)(2 AMSg buckling Buckling Margin of SafetyDesign variables
X={A, material}
OPTIMIZATION MODEL III
OPTIMIZATION MODEL IV
20Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Minimization of Weight of a LinkageX(area) subject to (extensional stress, buckling load)
Leff
product structure: linkage
material
effective length, Leff
deformation model
linear elastic model
Lo
Extensional Rod(isothermal, buckling)
F
L
A
L
E
x2
x1
youngs modulus, E
cross section area, A
analysis context
goal: optimization
mode: shaft tension
condition: flaps down
linkage reaction
allowable stress
Margin of Safety(> case)
allowableactual
MS
ts1
A
Sleeve 1
A ts2
ds2
ds1
Sleeve 2
L
Shaft
Leff
s
y
xPP
E, A
LLeff
,
L
minimize weight
constraints
Design VariablesA
weight,W W AL
MS 0MSstress
Margin of Safety(> case)
allowableactual
MS
moment of inertia, I
L
EIPcr
2
1
allowablestressMS
1F
PcrMSbuckling
load,P
MSbuckling
Lo
Extensional Rod(Buckling)
PcrI
E
density,
21Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Minimization of Weight of a LinkageX(area, material) subject to (extensional stress, buckling load)
Leff
product structure: linkage
material
effective length, Leff
deformation model
linear elastic model
Lo
Extensional Rod(isothermal, buckling)
F
L
A
L
E
x2
x1
youngs modulus, E
cross section area, A
analysis context
goal: optimization
mode: shaft tension
condition: flaps down
linkage reaction
allowable stress
Margin of Safety(> case)
allowableactual
MS
ts1
A
Sleeve 1
A ts2
ds2
ds1
Sleeve 2
L
Shaft
Leff
s
y
xPP
E, A
LLeff
,
L
minimize weight
constraints
Design Variables A
weight,W W AL
MS 0MSstress
Margin of Safety(> case)
allowableactual
MS
moment of inertia, I
L
EIPcr
2
1
allowablestressMS
1F
PcrMSbuckling
load,P
MSbuckling
Lo
Extensional Rod(Buckling)
PcrI
E
density,
material
22Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Progress onNecessary Components
Design-Analysis Integration– CAD-CAE Associativity– Connect diverse CAE models to same CAD model:
Varying discipline, behavior, fidelity, method, tool– Multi-directional
Object-Oriented View of Optimization Enhanced FEA Modeling for Built-Up Structure
23Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Chip Package Products Shinko
Plastic Ball Grid Array (PBGA) Packages
Quad Flat Packs (QFPs)
24Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Traditional VTMB FEA Model CreationManually Intensive: 6-12 hours
FEA Model Planning Sketches - EBGA 600 Chip Package
VTMB = variable topology multi-body
25Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Advanced Product Information-Driven FEA Modeling: Challenges
Main challenges» Differences between design & analysis geometries» Variable topology multi-body geometries» FEA requirements: node matching,
aspect ratio» Relative body sizes
Degree of indirect inter-body coupling
» Mixed analytical bodies » Idealized inter-body interfaces» Loads & interfaces on non-explicit boundaries» Idealization-induced anomalies
Ex. - Shell mid-/outer-face matching
» Arbitrary shapes (complex 3D surfaces …)
26Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Multi-Representation Architecture Context
1 Solution Method Model
ABB SMM
2 Analysis Building Block
4 Context-Based Analysis Model3
SMMABB
APM ABB
CBAM
APM
Design Tools Solution Tools
Printed Wiring Assembly (PWA)
Solder Joint
Component
PWB
body3body2
body1
body4
T0
Printed Wiring Board (PWB)
SolderJoint
Component
AnalyzableProduct Model
Composed of four representations (information models) Provides flexible, modular mapping between design & analysis models Creates automated, product-specific analysis modules (CBAMs) Represents design-analysis associativity explicitly
27Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Approach Outline: Test Cases
Benchmark test cases– “diving board”– eWidget– simplified PBGA
Production test cases(representative production-like problems for industry)– Chip package (Shinko)
» Thermal analysis - Phase 2» Thermomechanical (stress) analysis - after Phase 2
– Air frame structural analysis (Boeing)– PWA/B (JPL/NASA,…)
» Thermomechanical, ...
28Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Chip Package Test Cases (for Shinko)
Light Comunication module Pre-Mold PKG Pre-Mold PKG
FC-BGA (Flip Chip BGA) QFP Exposed DPH PBGA with Heat Spreader
Light Comunication module Pre-Mold PKG Pre-Mold PKG
FC-BGA (Flip Chip BGA) QFP Exposed DPH PBGA with Heat Spreader
29Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
Airframe Structural Analysis Radar Support Structure (for Boeing)
Automatic FEA Pre/Post-processing & Solution (in vendor-specific Solution Method Model)
Design Model
30Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
PWA Thermomechanical Analysis(for JPL/NASA, ...)
Goal: Generalization of previous work [Zhou, 1997]
31Georgia Tech Engineering Information Systems Lab eislab.gatech.edu© 1993-2001 GTRC
SummaryProgress … Design-Analysis Integration (maturing)
– CAD-CAE Associativity– Connect diverse CAE models to same CAD model:
Varying discipline, behavior, fidelity, method, tool– Multi-directional
Object-Oriented View of Optimization (initial progress) Enhanced FEA Modeling for Built-Up Structure (in-progress)
Further work needed … High-level operational criteria,
such as Product Design Requirements and Objectives Need to leverage recent optimization tools
– Ex. iSIGHT, ProductCenter, etc.– Provide enhanced modularity & knowledge capture