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Simulia SCN 1311
Simulia SCN 1311
COMMUNITY NEWS
#06 NOVEMBER 2013
DANA ACCELERATES
PRODUCT DESIGN
WITH SIMULATION
LIFECYCLE MANAGEMENT
3 Welcome Letter
Colin Mercer, VP R&D SIMULIA, Dassault Systèmes
4 Product Update
MATRIX
New Releases of Abaqus 6.13 and Isight 5.8
5 News
Dassault Systèmes Acquires Safe Technology
6 Optimization Spotlight
10 Voith Improves Efficiency of Automatic
Transmission Components
8 Strategy Overview
The Quest for the Best
10 Case Study
Matrix Applied Computing Helps Springfree Optimize
the Backyard Trampoline
12 Cover Story
Dana Accelerates Product Design with
Simulation Lifecycle Management
15 Alliances
DANA
GRM Consulting
Dynardo
16 Optimization Spotlight
12 Georg Fischer uses Tosca Structure to
Improve Fuel Efficiency
18 Case Study
DNV uses Abaqus to Study Blowout Scenarios
20 Academic Update
University of Toronto Blue Sky Team uses Abaqus
GEORG FISCHER
16
SIMULIA Community News is published by Dassault Systèmes Simulia Corp., Rising Sun Mills, 166 Valley Street,
Providence, RI 02909-2499, Tel. +1 401 276 4400, Fax. +1 401 276 4408, simulia.info@3ds.com, www.3ds.com/simulia
Editor: Tim Webb Associate Editors: Kristina Hines, Jessica Nicholson Graphic Designer: Todd Sabelli
The 3DS logo, CATIA, SOLIDWORKS, SIMULIA, DELMIA, ENOVIA, GEOVIA, EXALEAD, NETVIBES, 3DSWYM and 3DVIA are either trademarks or
registered trademarks of Dassault Systèmes or its subsidiaries in the USA and/or other countries. Other company, product, and service names
may be trademarks or service marks of their respective owners. Copyright Dassault Systèmes, 2013.
Welcome Letter
30%
Photo: Daimler AG
Optimizing a planet carrier: weight reduction carrier maintained the required stiffness and lifetime, achieved
by creating a new design considerable material and weight savings, and resulted in more
Tosca Structure is a flexible, modular software system for non- economical production.
parametric structural optimization, e.g. topology, shape, and/ “The topology optimization of our planet carrier resulted in a lighter
or bead, using finite element analysis (FEA). Voith Turbo used and more robust design as well as significantly higher production
Tosca Structure to optimize a planet carrier component, part of efficiency,” Wöhrle said.
the gearing system in its DIWA automatic transmission. Planetary
gearing systems consist of one or more outer, or planetary, gears
that revolve around a central “sun” gear. The outer gears are
mounted on the planet carrier, which is a moveable arm that itself
rotates around the sun gear.
Starting with CAD data of the carrier, the engineers first
used Tosca Structure to define the available design space by
subtracting functional areas and joint spaces to connecting areas.
Restrictions placed on the optimization ensured that any design or
manufacturing requirements are kept. In this case the functional
stiffness of the planet carrier—required to guarantee bearing
durability and equal load on the tooth flanks—was maintained.
Tosca Structure then automatically identified areas that did not
contribute to the force flux and removed the materials within
these areas that were not essential. Because requirements for the
manufacturing process were taken directly into account during
optimization, the design proposal could then be easily transferred
to Voith Turbo’s own CAD system where modifications were made
in order to meet further casting parameters.
“By using Tosca Structure we found the best solution to
realize material savings and increase efficiency in the product
development process of our automatic transmissions,” said Bernd
Wöhrle, Technical Calculations Commercial Vehicles, Voith Turbo.
Voith uses SIMULIA’s Tosca Structure topology optimization software to
Weight savings also provide manufacturing benefits reduce the weight of components such as the planet carrier in their DIWA
The new design of the planet carrier generated significant savings automatic transmissions.
in material, with a weight reduction of more than 30%. The more
compact size of the revised planet carrier permits an additional
component to be placed in the molding box, allowing the same
number of castings to be produced with fewer casting processes.
Voith’s experience with Tosca Structure shows that even designs For More Information
that have already been manually optimized still contain significant www.voith.com
optimization potential. The updated design of the planet www.3ds.com/tosca
• Fluid topology
COMPLIMENTARY • Monte Carlo Analysis
• Structural shape OPTIMIZATION • Six Sigma
WORKFLOWS
• Bead • Taguchi Method
• Multidisciplinary
Optimization
Engineering a Safer Bounce and shaped like a wide letter ‘T,’ these have
a rounded, midline socket into which the
balled top of each fiberglass support rod fits
Matrix Applied Computing helps Springfree (see Figure 2). The lower ends of the rods
connect to the metal base of the trampoline.
optimize the backyard trampoline “The plastic edge fitting of my design had
always been the most complicated bit of
the eight or nine different versions I came
up with,” says Alexander. The cleat, which
is inserted into a reinforced pocket in the
mat, harnesses the downward tension of
each jump, ensuring that the ball at the top
of the rod stays wedged into the socket as
it moves up and down.
Once the Springfree was commercialized,
word about its benefits began to spread.
Parent- and safety-association awards
followed, sales bounced upwards and
production swung into high gear. The
company’s New Zealand-based injection
molding supplier, Action Plastics, was kept
busy manufacturing cleats at a rate that has
now reached some 2.5 million units per year.
As the molding tool used to manufacture
the cleat drew near the end of its lifetime
in 2013, “we had some pretty significant
inducements to build a new tool and
we realized it was a great time to look
at optimizing and improving the cleat
Figure 1. A Springfree trampoline is
put to the test by an enthusiastic user.
component,” says Hamish McIntyre,
engineering manager at Springfree New
Zealand Ltd. “Because the cleat was so
A sk a kid if they like trampolines and impact zones in the classic trampoline complex in terms of loading and mechanical
their eyes are sure to light up with design (which dates to the 1930s) that properties we decided we needed an
joy. But ask some parents and you may needed to be arranged so the user engineering consultant to help us out. We
get an entirely different response. Despite wouldn’t impact them: the springs located Matrix Applied Computing, through
tightened manufacturing standards, connecting the bounce mat to the a Ministry of Science and Innovation expert
covered springs and frames, and safety frame, the metal frame itself and, of search program, and selected them based
net enclosures, some 90,000 children course, the ground. on their advanced capabilities.”
are still injured on traditional trampolines Of particular interest to McIntyre was
Many prototypes later (starting from 1989)
every year in the United States alone. Still, Matrix’s familiarity with realistic simulation
Alexander arrived at his final, innovative
the equipment is becoming increasingly using Abaqus finite element analysis (FEA)
solution: move the frame below the
popular worldwide. software from SIMULIA, the Dassault
jumping surface, create a soft edge to the
Dr. Keith Alexander, an associate professor mat, and surround the whole thing with Systèmes’ 3DEXPERIENCE application.
of engineering at Canterbury University, tensioned, ultraviolet-resistant netting that
New Zealand, felt there had to be a safer would bounce users back towards the
way to enjoy the trampoline. “I always center if they went off-kilter. The result was
believed that, as an engineer, I should be the Springfree™ Trampoline (see Figure 1),
doing things that benefit people,” he says. first produced in 2003 and currently selling
When his wife nixed his plans to buy a at a rate of some 40,000 per year around
conventional trampoline for his daughter the globe.
Katie out of safety concerns, he decided
So if trampolines are your thing, the
to build a better one. He began by working
Springfree would certainly make a safer,
in his garage, later moving his research to
healthy, eye-catching addition to the
the University where help from his students
backyard. Yet it’s what you don’t see
plus government and private grants kept
that’s most unique: the high-tech cleats Figure 2. Closeup of the innovative support structure of
the momentum going. a Springfree trampoline shows how white rods connect
under the mat’s edge—60 or more per
via cleats to the upper, soft-edged jumping surface.
Analyzing “reams of data,” Alexander trampoline, depending on the model. Made Lower end of rods attach to the secure metal frame
determined that there were three main from fiberglass-reinforced polypropylene that sits on the ground. Protective netting not shown.
Robust Design Optimization using CAD- To support this process, BOSCH initiated
the development of a plugin by the
Abaqus/CAE Abaqus/Solver
-CatPart
parameter-based optimization techniques -CatProduct has published several examples of
has become increasingly important in *.odb successful applications using parametric
meeting product performance requirements Input parameter=
Designtable
Optiqus Catia
Dynardo (ETK)
CAD-based modeling and Abaqus
Plugin
as well as cost and time-to-market simulations for product optimization and
challenges. One of the main challenges optiSLang
Output parameter
from Abaqus tolerance investigation using sensitivity
of using CAE parameter-based RDO is *.pro studies, optimization and robustness
*_run.bat
the parameterization of the geometry. In Definition objective evaluations. These capabilities of CAE-
addition to CAE-based geometry variations & Constraints
based parametric modeling and process
using mesh morphing or shape functions, automation enable RDO technologies
Workflow of sensitivity analysis of a power unit.
leveraging CAD-based geometry variations, to be implemented as standard virtual
to accelerate design optimization, provides prototyping processes for optimizing
Bosch at the 7th Weimar Optimization
promising potential. product performance and robustness.
and Stochastics conference. In their
To investigate CAD-based geometric application, the parametric CAD model
variation, an automated process flow was created in CATIA, the FEA modeling
becomes necessary starting with a was in Abaqus, and RDO was performed For More Information
parametric geometry update followed by using optiSLang from Dynardo. optiSLang www.dynardo.de/fileadmin/
all required CAE simulations and result provides capabilities for performing Material_Dynardo/dokumente/
extraction. An example of this process sensitivity analysis and investigating design Presentation_Power_Unit.pdf
was presented by engineers from Robert optimization and robustness. (German language)
2.0
1.0
Figure 2. Tosca™ optimization of a steering knuckle. Optimized design with 32% weight reduction. 0.0
Optimizing a steering knuckle: "Tosca Structure allows us minimum amount of material required for
the safe function of the component.”
As light as possible—yet safe
to develop our products
In an automotive suspension system, the 32% lighter component yields
steering knuckle serves to attach the wheel efficiently and thus fulfills reduced CO2 emissions and wins
to other suspension components (Figure
1). GF Automotive engineers—looking to the demands for consistent an award
Following optimization results (Figure 2), the
eliminate weight from this component, lightweight designs.” steering knuckle, which initially weighed
while keeping the structure strong and
Roman Brauner, former project 4.39 kg (9.7 lbs), is now 2.98 kg (6.6
safe—performed an optimization exercise
engineer in product development lbs)—a 32 percent savings. Since each
using Tosca Structure software.
at GF Automotive chassis requires two components, the total
“Through the use of Tosca we get designs reduction is 2.82 kg (6.2 lbs) per vehicle.
best adapted to loading, for lightweight When looking at projected installation in 1.6
and notch stress-free components in iron Casting’s flexibility allows sophisticated million vehicles, weight savings from this
and light metal castings," said Roman optimized lightweight designs to be mass- component alone would cut an estimated
Brauner, former project engineer in product produced cost effectively and with high 11,600 tonnes (12,787 tons) of CO2
development at GF Automotive. quality. emissions over the life of the part.
The essential starting point for a successful The benefits of the optimization process are The new lighter steering knuckle has been
high-volume (or series) design is to first many. For one, the new design concept can implemented in large-series production
define the appropriate design space. be easily transferred from Tosca Structure to since 2012. It’s being used by VW in their
For the steering knuckle this included a CAD model with little added interpretation MQB platform, e.g. in the Golf VII and in
consideration of the axle, the wheel, and effort. the Audi A3, among others. The design has
the kinematics of the suspension assembly. Tosca Structure’s fully automated also received the prestigious environmental
The component’s product specifications optimization process also provides results ÖkoGlobe, awarding pioneering innovations
were then transformed into mechanical quickly. In the case of the steering knuckle, for sustainable mobility, in the category
requirements for the analysis. the software enabled engineers to easily of “raw materials, materials, and process
arrive at a manufacturable design by optimization.”
Optimization to reduce weight began with
the Tosca Structure topology module. The considering critical manufacturing processes "Tosca Structure allows us to develop
analysis created a lightweight, stiff and and steps—such as de-molding directions our products efficiently and thus fulfills
strong design concept considering all and clamping points for mechanical the steadily increasing demands of our
relevant operating load and load-abuse finishing—right in the optimization setup. customers for consistent lightweight
cases simultaneously—which is especially Value can be further added by selectively designs,” said Brauner.
important for a dynamically stressed combining the improved design with the *Tensile strength: The resistance of a material to
component such as a steering knuckle. right material and a revised manufacturing a force tending to tear it apart, measured as the
The software’s shape optimization module process. GF Automotive engineered a maximum tension the material can withstand
was next used to eliminate an additional new type of cast iron, SiboDur, developed without tearing.
100 grams of weight through modifications in-house. This material is characterized **Fatigue strength: The maximum stress a material can
to the part’s surface geometry. by better properties at break, tensile endure for a given number of stress cycles without
breaking.
strength*, and fatigue strength**. Given
Considering manufacturability and
these properties, the lighter optimized
material choices for mass production design geometry complies with all safety
For a supplier that relies heavily on casting requirements for the part.
such as GF Automotive, topology and
shape optimization are perfectly suited to “In addition to aluminum, innovative cast- For More Information
their manufacturing methods because of iron materials are the trend,” said Brauner. www.georgfischer.com
the inherent design freedom of the process. “In each case, the aim is to use only the www.3ds.com/tosca
suspension reinforcement bars (connecting also provided valuable mass estimates that “It was far beyond our capabilities to consider
both left and right suspensions). the team used in controlling the vehicle’s all of these various structures together without
center of gravity. The team further determined Abaqus,” says Sureshkumar. “The software
All models were meshed in Abaqus. For the
through theory, testing, and calculations that allowed a much more integrated analysis and
aerobodies, Abaqus automated this process
weight, aerobody shape, tires, and wheel modeled external loads extremely accurately.
around the complex curves and holes that
bearings were the most critical factors when Abaqus gave us confidence in the complex
are an integral part of their surfaces. For the
looking to reduce drag and enhance vehicle design decisions and tradeoffs we made.”
solid models, a Python script in the software
speed.
was used to define mesh elements and The sun and simulation: a winning
make updating easier as the design evolved. FEA also provided design insights that would combination
Tie constraints were next defined in the lower have been missed in prior years. Looking at As race day dawned in Darwin, design
aerobody model between the mesh and loading, for example, the student engineers decisions had all been made, composite
surfaces of the chassis sandwich panels, learned that a .75G braking scenario placed layups completed, decals applied, test drives
which were part of the model (see Figure 1). as much stress on the car as a 6G bump logged. After countless all-nighters, the
(see Figure 3). Equally surprising to the team gleaming B-7 stood poised, reflecting the
Python scripting capabilities in Abaqus also
was the fact that the front and rear roll bars spring sun, ready for the starting gun. It was a
helped automate the previously repetitive
contributed little to the chassis’ torsional remarkable achievement for a volunteer group
and time-consuming task of manually
rigidity, while the inherent stiffness of the of students, 19 of whom had been chosen to
applying loads to the models. Each load
aerobody (especially the driver fairing) played travel to Australia to support the car.
case involved calculating, further defining,
a major role.
and then reapplying reaction forces at five How the race was run depended on more
suspension clevises (connection points). than just sunny skies. “There’s a remarkable
Now parameters could be changed, node amount of strategy,” says Park. “Tactics
sets redefined, and loads reapplied in a depend not only on the weather, but on
matter of seconds. This method made the road conditions, other teams that impede
determination of contact regions much more your speed and, yes, even the occasional
accurate than was previously possible (see kangaroo crossing your path. We go as fast
Figure 2). as possible but take every precaution to make
Other features in Abaqus further enhanced sure that two years’ work doesn’t break down
accuracy and efficiency. Established in the middle of the Outback.”
layup definitions in the software provided While more than half of the entries in the
a convenient way to try out varying ply competitive Challenger class did break down
schedules for the chassis and to fine- during the race, B-7 didn’t, placing second
tune stiffness and strength for the upper among North American entries and achieving
and lower aerobody’s surface layups and the Blue Sky team’s goal of a spot in the Top
sandwich-board construction. With the aid 10. The B-7 completed the 3,021 km/ course
of FEA, the team was able to minimize B-7’s in 45 hours, 38 minutes with an average
weight, using only half as much carbon speed of 65.7 km/hr.
fiber as in the previous car. “Abaqus helped
us determine how much stress our lighter Figure 3. These screen shots (side view of the lower “The race was the climax of an incredible two-
aerobody chassis) show the resulting deformation year engineering journey,” notes Sureshkumar.
design could take,” says Park. “It highlighted from a 6G front bump of the sandwich panel chassis
potential problems early in the design without the aerobody skin (top) and with it (bottom),
process.” using the same deformation upper bound. This
For More Information
illustrates how the rigidity of the aerobody coupled
While simulation of varying ply schedules with the sandwich panel results in an order of www.blueskysolar.utoronto.ca
helped with weight-minimization, Abaqus magnitude decrease in deformation. www.3ds.com/abaqus
The Brain
Optimization
The Comparator
The Simulator
Abaqus
Data Matching
Figure 2