Anda di halaman 1dari 41
Title: Advanced Simulations with Creo Simulate 2.0 Author: Theo Wijers Date: November 2012

Title:

 

Advanced Simulations with Creo Simulate 2.0

Author:

Theo Wijers

Date:

November 2012

Title: Advanced Simulations with Creo Simulate 2.0 Author: Theo Wijers Date: November 2012
Agenda: Introduction Why Simulations? Theory of Non-Linearity: o Geometric: Large Displacements o Constraints: Contact o Material:

Agenda:

Introduction

Why Simulations?

Theory of Non-Linearity:

o

Geometric: Large Displacements

o

Constraints: Contact

o

Material: Elastoplastic, Hyperelastic

Combining Non-Linearities with Creo Simulate 2.0

Examples of combined Non-Linear Analyses

Examples of Advanced Dynamic Analyses

Discussion

Introduction | 3991 CN | Contact information: Sleepboot 11 T +31 (0)30 635 48 50 www.cemasters.nl

Introduction

| 3991 CN |
|
3991 CN
|

Contact information:

Sleepboot 11

T +31 (0)30 635 48 50

www.cemasters.nl

Office of CE Masters in Houten, NL

Houten |

The Netherlands

F +31 (0)30 635 48 51

Introduction Our Customers

Introduction

Our Customers

Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Introduction Our Customers
Why Simulations? CE Masters distinguishes 3 Levels of Engineering: 1. Engineering without Simulation 2. Engineering with

Why Simulations?

CE Masters distinguishes 3 Levels of Engineering:

  • 1. Engineering without Simulation

  • 2. Engineering with Simulation

  • 3. Integrated Engineering & simulation

Engineering without Simulation Pre-study, Idea Conceptual Generation Design Engineering Build Test Long & Expensive Design Loops

Engineering without Simulation

Pre-study, Idea Conceptual Generation Design Engineering Build Test Long & Expensive Design Loops Mechanical Product Development
Pre-study,
Idea
Conceptual
Generation
Design
Engineering
Build
Test
Long & Expensive
Design Loops
Mechanical Product Development
Engineering

Characteristics:

Insufficient insight in product behavior

Unable to compare design alternatives

Long and expensive design loops

Expensive physical prototypes

Not first time right

End result is compromise of design issues

Engineering without Simulation Pre-study, Idea Conceptual Generation Design Engineering Build Test Long & Expensive Design Loops

Long Time to Market Low Quality High Costs

Engineering without Simulation Pre-study, Idea Conceptual Generation Design Engineering Build Test Long & Expensive Design Loops

“Physical Testing”

Engineering with Simulation Pre-study, Idea Conceptual Generation “Physical Testing” Design Engineering Simulation Long, less expensive Design

Engineering with Simulation

Pre-study, Idea Conceptual Generation “Physical Testing” Design Engineering Simulation Long, less expensive Design Loops Build Test
Pre-study,
Idea
Conceptual
Generation
“Physical Testing”
Design
Engineering
Simulation
Long, less expensive
Design Loops
Build
Test
Mechanical Product Development
Engineering
Validation
Engineering with Simulation Pre-study, Idea Conceptual Generation “Physical Testing” Design Engineering Simulation Long, less expensive Design

“Virtual Testing”

Engineering with Simulation Pre-study, Idea Conceptual Generation “Physical Testing” Design Engineering Simulation Long, less expensive Design

Characteristics:

Simulation used as design check Simulation not integrated in development process Limited use of gained insight with Simulation No investigation of design alternatives Not first time right

End result is still compromise of design issues

Integrated Engineering & Simulation Pre-study, Idea Conceptual Generation Design Engineering Build Test Multiple Short Design Loops

Integrated Engineering & Simulation

Pre-study, Idea Conceptual Generation Design Engineering Build Test Multiple Short Design Loops Validation Mechanical Product Development
Pre-study,
Idea
Conceptual
Generation
Design
Engineering
Build
Test
Multiple
Short
Design
Loops
Validation
Mechanical Product Development
Simulation integrated with Engineering
Characteristics:

Early insight in product behavior

Ability to compare many design alternatives

Short and low cost design loops

Short Time to Market

Less physical prototypes

High Quality

First Time Right approach

Low Costs

Concept optimized and based on insight

Integrated Engineering & Simulation Pre-study, Idea Conceptual Generation Design Engineering Build Test Multiple Short Design Loops

“Insight driven Engineering”

Simulation Characteristics Principle Calculations and Analyses Analyses and Comparison of Design Alternatives Design Optimization Verification Pre-study,

Simulation Characteristics

Simulation Characteristics Principle Calculations and Analyses Analyses and Comparison of Design Alternatives Design Optimization Verification Pre-study,
Principle Calculations and Analyses Analyses and Comparison of Design Alternatives Design Optimization Verification Pre-study, Problem Solving
Principle Calculations and Analyses
Analyses and Comparison of Design Alternatives
Design Optimization
Verification
Pre-study,
Problem Solving
Idea
Conceptual
Generation
Design
Engineering
Build
Test
Multiple Short Mechanical Product Development Simulation integrated with Engineering
Multiple
Short
Mechanical Product Development
Simulation integrated with Engineering
Design Loops Validation
Design
Loops
Validation

Simple Calculations Small Models

Simulation Characteristics Principle Calculations and Analyses Analyses and Comparison of Design Alternatives Design Optimization Verification Pre-study,
Comparison Calculations Conceptual Models
Comparison Calculations
Conceptual Models
Simulation Characteristics Principle Calculations and Analyses Analyses and Comparison of Design Alternatives Design Optimization Verification Pre-study,

Complex Calculations Detailed Models

“Insight driven Engineering”

Theory of Non-Linearity Comparison of Linear Analysis with: Geometric Non-Linearity: Large Displacements Material Non-Linearity: Elastoplastic Material

Theory of Non-Linearity

Comparison of Linear Analysis with:

Geometric Non-Linearity:

Large Displacements

Material Non-Linearity:

Elastoplastic Material Property

Constraint Non-Linearity:

Contact Analyses

Theory of Non-Linearity Example: Manhole Cover Linear Analyses: o ¼ of model due to symmetry o

Theory of Non-Linearity

Example: Manhole Cover

Linear Analyses:

o

¼ of model due to symmetry

o

Material Steel (linear): Emod = 210.000 MPa

o

Constraint vertically at contact surface with base

o

¼ of total load: F = ¼ * 15 = 3,75 kN

Theory of Non-Linearity Example: Manhole Cover Linear Analyses: o ¼ of model due to symmetry o
Theory of Non-Linearity Example: Manhole Cover Linear Analyses: o ¼ of model due to symmetry o
Max. VM stress = 1324 MPa Results Linear Analysis Max. Displacement = 18,3 mm

Max. VM stress = 1324 MPa

Results Linear Analysis

Max. Displacement = 18,3 mm

Max. VM stress = 1324 MPa Results Linear Analysis Max. Displacement = 18,3 mm
Theory of Non-Linearity Geometric Non-Linearity: Large Displacements Characteristics: o The stiffness under loading is Non-Linear (i.e.
Theory of Non-Linearity Geometric Non-Linearity: Large Displacements Characteristics: o The stiffness under loading is Non-Linear (i.e.

Theory of Non-Linearity

Geometric Non-Linearity: Large Displacements

Characteristics:

o

The stiffness under loading is Non-Linear (i.e. the stiffness changes due to changed shape)

o

The analyses is executed with load steps

o

At each load step the stiffness matrix will be recomputed

o

(reaction)Load direction can change

When to use Large Displacements (rules-of-thumb):

o

Deformation larger than the (shell)thickness

o

Deformation visible to the naked eye

o

Deformation larger than 1/20 th of part’s largest dimension

Max. VM stress = 668 MPa Results Non-Linear Large Displacement Analysis Max. Displacement = 8,95 mm

Max. VM stress = 668 MPa

Results Non-Linear Large Displacement Analysis

Max. Displacement = 8,95 mm

Max. VM stress = 668 MPa Results Non-Linear Large Displacement Analysis Max. Displacement = 8,95 mm
Example: Manhole Cover Comparison Linear Analysis with Large Deformation analyses Theory of Non-Linearity

Example: Manhole Cover

Comparison Linear Analysis with Large Deformation analyses

Example: Manhole Cover Comparison Linear Analysis with Large Deformation analyses Theory of Non-Linearity

Theory of Non-Linearity

Example: Manhole Cover Comparison Linear Analysis with Large Deformation analyses Theory of Non-Linearity
Material Non-Linearity: Elastoplastic Material Characteristics: o Until the Yield point the material acts linear o Above

Material Non-Linearity:

Elastoplastic Material

Characteristics:

o

Until the Yield point the material acts linear

o

Above the Yield point the stress-strain curve

o

changes Different material laws available

When to use Elastoplastic material:

o

To calculate realistic deformation (elastic and/or plastic) when the Yield stress is exceeded

Theory of Non-Linearity

Material Non-Linearity: Elastoplastic Material Characteristics: o Until the Yield point the material acts linear o Above
Material Non-Linearity: Elastoplastic Material Characteristics: o Until the Yield point the material acts linear o Above

Material Non-Linearity:

Elastoplastic Material

Characteristics:

o

Until the Yield point the material acts linear

o

Above the Yield point the stress-strain curve

o

changes Different material laws available

When to use Elastoplastic material:

o

To calculate realistic deformation (elastic and/or plastic) when the Yield stress is exceeded

Theory of Non-Linearity

Material Non-Linearity: Elastoplastic Material Characteristics: o Until the Yield point the material acts linear o Above
Theory of Non-Linearity Material Non-Linearity: Elastoplastic Material Characteristics: o Until the Yield point the material acts

Theory of Non-Linearity

Material Non-Linearity:

Elastoplastic Material

Characteristics:

o

Until the Yield point the material acts linear

o

Above the Yield point the stress-strain curve

o

changes Different material laws available

When to use Elastoplastic material:

o

To calculate realistic deformation (elastic and/or plastic) when the Yield stress is exceeded

Theory of Non-Linearity Material Non-Linearity: Elastoplastic Material Characteristics: o Until the Yield point the material acts
Material Non-Linearity: Elastoplastic Material Characteristics: o Until the Yield point the material acts linear o Above

Material Non-Linearity:

Elastoplastic Material

Characteristics:

o

Until the Yield point the material acts linear

o

Above the Yield point the stress-strain curve

o

changes Different material laws available

When to use Elastoplastic material:

o

To calculate realistic deformation (elastic and/or plastic) when the Yield stress is exceeded

Theory of Non-Linearity

Material Non-Linearity: Elastoplastic Material Characteristics: o Until the Yield point the material acts linear o Above
Max. VM stress = 477 MPa Results Non-Linear Elastoplastic Analysis Max. Displacement = 119 mm

Max. VM stress = 477 MPa

Results Non-Linear Elastoplastic Analysis

Max. Displacement = 119 mm

Max. VM stress = 477 MPa Results Non-Linear Elastoplastic Analysis Max. Displacement = 119 mm
Example: Manhole Cover Comparison Linear Analysis with Elastoplastic analyses Theory of Non-Linearity

Example: Manhole Cover

Comparison Linear Analysis with Elastoplastic analyses

Example: Manhole Cover Comparison Linear Analysis with Elastoplastic analyses Theory of Non-Linearity

Theory of Non-Linearity

Example: Manhole Cover Comparison Linear Analysis with Elastoplastic analyses Theory of Non-Linearity
Theory of Non-Linearity Constraint Non-Linearity: Contact Characteristics: o Contact acts as a constraint in one direction

Theory of Non-Linearity

Theory of Non-Linearity Constraint Non-Linearity: Contact Characteristics: o Contact acts as a constraint in one direction

Constraint Non-Linearity: Contact

Characteristics:

o

Contact acts as a constraint in one direction

o

Number of load steps dependent on situation

o

At each load step the contact situation will be evaluated

When to use Contact:

o

When contact issues are expected which cannot be captured with constraints

o

When contact values are needed (i.e. contact forces, contact area, contact pressure, …)

Max. VM stress = 948 MPa Results Non-Linear Contact Max. Displacement = 27,8 mm

Max. VM stress = 948 MPa

Results Non-Linear Contact

Max. Displacement = 27,8 mm

Max. VM stress = 948 MPa Results Non-Linear Contact Max. Displacement = 27,8 mm
Example: Manhole Cover Comparison Linear Analysis with Contact analyses Theory of Non-Linearity

Example: Manhole Cover

Comparison Linear Analysis with Contact analyses

Example: Manhole Cover Comparison Linear Analysis with Contact analyses Theory of Non-Linearity

Theory of Non-Linearity

Example: Manhole Cover Comparison Linear Analysis with Contact analyses Theory of Non-Linearity
Theory of Non-Linearity Linear alternative for Non-Linear contact analysis modified constraint Surface constraint Edge constraint

Theory of Non-Linearity

Linear alternative for Non-Linear contact analysis modified constraint

Theory of Non-Linearity Linear alternative for Non-Linear contact analysis modified constraint Surface constraint Edge constraint
Theory of Non-Linearity Linear alternative for Non-Linear contact analysis modified constraint Surface constraint Edge constraint

Surface constraint

Edge constraint

Theory of Non-Linearity Non-Linear contact analysis Linear analysis with edge constraint

Theory of Non-Linearity

Non-Linear contact analysis

Linear analysis with edge constraint

Theory of Non-Linearity Non-Linear contact analysis Linear analysis with edge constraint
Example: Manhole Cover Comparison Linear Analysis with all separated Non-Linear Analyses Theory of Non-Linearity Which one

Example: Manhole Cover

Comparison Linear Analysis with all separated Non-Linear Analyses

Example: Manhole Cover Comparison Linear Analysis with all separated Non-Linear Analyses Theory of Non-Linearity Which one

Theory of Non-Linearity

Example: Manhole Cover Comparison Linear Analysis with all separated Non-Linear Analyses Theory of Non-Linearity Which one

Which one is correct?

None of the above!

Previous analyses show that all Non-Linearities are occurring at the same time: Large Displacements Elastoplastic Material

Previous analyses show that all Non-Linearities are occurring at the same time:

Large Displacements Elastoplastic Material Contact

Previous analyses show that all Non-Linearities are occurring at the same time: Large Displacements Elastoplastic Material

Combining Non-Linearities with Creo Simulate 2.0

Previous analyses show that all Non-Linearities are occurring at the same time: Large Displacements Elastoplastic Material
Max. VM stress = 245,2 MPa Results combined Non-Linearities Max. Displacement = 12,5 mm

Max. VM stress = 245,2 MPa

Results combined Non-Linearities

Max. Displacement = 12,5 mm

Max. VM stress = 245,2 MPa Results combined Non-Linearities Max. Displacement = 12,5 mm
Example: Manhole Cover Comparison Linear Analysis with all separated Non-Linear Analyses Combining Non-Linearities with Creo Simulate

Example: Manhole Cover

Comparison Linear Analysis with all separated Non-Linear Analyses

Example: Manhole Cover Comparison Linear Analysis with all separated Non-Linear Analyses Combining Non-Linearities with Creo Simulate

Combining Non-Linearities with Creo Simulate 2.0

Example: Manhole Cover Comparison Linear Analysis with all separated Non-Linear Analyses Combining Non-Linearities with Creo Simulate
Red areas: stresses exceed Yield limit (plasticity) Results combined Non-Linearities Permanent Plastic Displacement = 1,5 mm

Red areas: stresses exceed Yield limit (plasticity)

Results combined Non-Linearities

Permanent Plastic Displacement = 1,5 mm (after un-loading)

Red areas: stresses exceed Yield limit (plasticity) Results combined Non-Linearities Permanent Plastic Displacement = 1,5 mm
Examples of Non-Linear Analyses

Examples of Non-Linear Analyses

Examples of Non-Linear Analyses Helmet and Clip www.egghelmets.com Questions: o Can the ABS outer shell be

Examples of Non-Linear Analyses

Examples of Non-Linear Analyses Helmet and Clip www.egghelmets.com Questions: o Can the ABS outer shell be

Helmet and Clip

www.egghelmets.com

Questions:

o

Can the ABS outer shell be ejected from the mold?

o

Does the clip work and survive impact tests?

Examples of Non-Linear Analyses Helmet and Clip www.egghelmets.com Questions: o Can the ABS outer shell be
Examples of Non-Linear Analyses Helmet and Clip www.egghelmets.com Questions: o Can the ABS outer shell be
Examples of Non-Linear Analyses Von Mises stresses Ejection of ABS helmet outer shell o o Quasi

Examples of Non-Linear Analyses

Examples of Non-Linear Analyses Von Mises stresses Ejection of ABS helmet outer shell o o Quasi

Von Mises stresses

Ejection of ABS helmet outer shell

Examples of Non-Linear Analyses Von Mises stresses Ejection of ABS helmet outer shell o o Quasi
o o Quasi static approach; incremental ejection steps Contact analysis for each ejection step Ejection 15
o
o
Quasi static approach; incremental ejection steps
Contact analysis for each ejection step
Ejection 15 mm
Displacements
Mold/Ejector: Steel
Helmet Shell: ABS, POLYLAC PA-746H
Examples of Non-Linear Analyses Contact analyses for different clip concepts Different clip concepts o Initial clip

Examples of Non-Linear Analyses

Examples of Non-Linear Analyses Contact analyses for different clip concepts Different clip concepts o Initial clip

Contact analyses for different clip concepts

Different clip concepts

o

Initial clip design didn’t pass the test

o

Comparison of different clip concepts

Examples of Non-Linear Analyses Contact analyses for different clip concepts Different clip concepts o Initial clip
Examples of Non-Linear Analyses Contact analyses for different clip concepts Different clip concepts o Initial clip

Initial clip

Examples of Non-Linear Analyses Contact analyses for different clip concepts Different clip concepts o Initial clip
Examples Advanced Dynamic Analyses

Examples Advanced Dynamic Analyses

Examples of Advanced Dynamic Analyses Mounting Equipment for Communication Devices www.thalesgroup.com Questions: o Does the structure

Examples of Advanced Dynamic Analyses

Examples of Advanced Dynamic Analyses Mounting Equipment for Communication Devices www.thalesgroup.com Questions: o Does the structure

Mounting Equipment for Communication Devices

www.thalesgroup.com

Questions:

o

Does the structure survive vibrations with specific Power Spectral Density diagrams?

o

Does the structure survive shock impact?

Examples of Advanced Dynamic Analyses Mounting Equipment for Communication Devices www.thalesgroup.com Questions: o Does the structure
Examples of Advanced Dynamic Analyses Mounting Equipment for Communication Devices www.thalesgroup.com Questions: o Does the structure
Examples of Advanced Dynamic Analyses Mounting Equipment for Communication Devices www.thalesgroup.com Questions: o Does the structure
Examples of Advanced Dynamic Analyses Mounting Equipment for Communication Devices www.thalesgroup.com Questions: o Does the structure
Examples of Advanced Dynamic Analyses Dynamic Random Analysis Characteristics: o Calculate Eigen Frequencies o Dynamic Random

Examples of Advanced Dynamic Analyses

Examples of Advanced Dynamic Analyses Dynamic Random Analysis Characteristics: o Calculate Eigen Frequencies o Dynamic Random

Dynamic Random Analysis

Characteristics:

o

Calculate Eigen Frequencies

o

Dynamic Random Analysis for 3 orthogonal directions

Examples of Advanced Dynamic Analyses Dynamic Random Analysis Characteristics: o Calculate Eigen Frequencies o Dynamic Random
Examples of Advanced Dynamic Analyses Dynamic Random Analysis Characteristics: o Calculate Eigen Frequencies o Dynamic Random
Examples of Advanced Dynamic Analyses Dynamic Random Analysis Characteristics: o Calculate Eigen Frequencies o Dynamic Random
Examples of Advanced Dynamic Analyses Dynamic Random Analysis Characteristics: o Calculate Eigen Frequencies o Dynamic Random
Examples of Advanced Dynamic Analyses Dynamic Time Analysis (Shock) Characteristics: o o Calculate Eigen Frequencies Dynamic

Examples of Advanced Dynamic Analyses

Examples of Advanced Dynamic Analyses Dynamic Time Analysis (Shock) Characteristics: o o Calculate Eigen Frequencies Dynamic

Dynamic Time Analysis (Shock)

Characteristics:

o o Calculate Eigen Frequencies Dynamic Time Analysis for 3 orthogonal directions
o
o
Calculate Eigen Frequencies
Dynamic Time Analysis for 3 orthogonal directions
Examples of Advanced Dynamic Analyses Dynamic Time Analysis (Shock) Characteristics: o o Calculate Eigen Frequencies Dynamic
Examples of Advanced Dynamic Analyses Dynamic Time Analysis (Shock) Characteristics: o o Calculate Eigen Frequencies Dynamic
Examples of Advanced Dynamic Analyses Dynamic Time Analysis (Shock) Characteristics: o o Calculate Eigen Frequencies Dynamic
Thank you for your attention!

Thank you for your attention!

Modeling & Simulation tiles rubbish rubbish rubbish inininin rubbish isisisis rubbish out rubbish rubbish out rubbish

Modeling & Simulation tiles

rubbish rubbish rubbish inininin rubbish isisisis rubbish out rubbish rubbish out rubbish out out
rubbish
rubbish
rubbish inininin
rubbish
isisisis
rubbish out
rubbish
rubbish out
rubbish out
out
FEA makes aaaa FEA FEA makes FEA makes makes good engineer good good engineer good engineer
FEA makes aaaa
FEA
FEA makes
FEA makes
makes
good engineer
good
good engineer
good engineer
engineer
better
better
better
better
but but
but
but aaaa poor
poor
poor
poor
engineer
engineer
engineer
engineer
dangerous
dangerous
dangerous
dangerous
aaaa fool with aaaa fool fool with fool with with good tool isisisis good good tool
aaaa fool with aaaa
fool
fool with
fool with
with
good tool isisisis
good
good tool
good tool
tool
still still
still
still aaaa fool
fool fool
fool