Msoe RPC Impact

Managing Analysis in the
Design Process
What to watch for and what to
watch out for!
Presented by:
Vince Adams
Director of Analysis Services
IMPACT Engineering Solutions, Inc.
Tel: 847-599-5635
E-mail: vadams@impactengsol.com
2004 IMPACT Engineering Solutions, Inc.
1
1
About IMPACT
?
?
?
Founded in 1987, IMPACT Engineering Solutions Inc. has grown

into a market leader, providing technology based engineering
services
Focused on solid modeling since 1993
Key IMPACT Product Offerings:
?
?
?
?
?
?
Design Support
Staff Augmentation
Product Simulation
Professional Services
Analysis Services Division Initiated October 2002

Gurnee, IL Office Opened in November 2003
www.impactengsol.com
2
2
2
Analysis Capabilities and Expertise

?
?
?
?
?
?
?
?
Pro/MECHANICA Structure/Motion
CosmosWorks Structure/Motion
MSC.NASTRAN / NE-Nastran
FEMAP Pre & Post-Processing
ANSYS
CFDesign CFD Simulation
LS-DYNA Drop and Crash Testing
FE-Fatigue (nCode) Durability Analysis
Extensive combined engineering analysis experience in a variety of
materials and industries
3
3
3
Four Areas of Analysis Support

? Project Support
? Training
? Coaching/Mentoring
? Implementation/Consulting
4
4
4
About Vince Adams

?
?
?
Engineering Project and Group Leadership for

over 18 Years
Six (6) US and Foreign Patents
Focused on Use, Training, and Support of Finite Element
Analysis for Over 10 Years
Active in Leadership of Chicago/Milwaukee Pro/MECHANICA
Users Group (MUG), NAFEMS, FE-Forum FEA Advocacy
Forum, and Illinois/Wisconsin Cosmos User Group
Co-Authored Building Better Products with Finite Element
Analysis from OnWord Press
International Speaker/Lecturer on FE Concepts
5
5
5
Anatomy of a Design Decision
Decide
Decide
Commit
Validate
Optimize
Validate
Commit
6
6
6
Anatomy of a Design Decision

Tools
CAE
FEM/FEA
Lab Tests
Hand Calcs
Data
Good Design Decisions
Weight
Stress
Displacement
Temperatures
Natl Frequencies
Sensitivity
7
7
Simulation and the Bottom Line
8
8
8

Time-to-Market
On-Time
+6 months
Development
Budget
+50%
Impact on
Profitability
-4%
Within
Budget
-33%
Source: McKinsey & Co.
9
9
9

The single most costeffective way to speed
up product
development isto not
make mistakes.
More realistically, identify
mistakes sooner before
commitments are made based
on them
10
10
10

CAE has little or no impact on time-to-market or
establishment of market share...
Grant Thornton; The Enterprise-Wide Impact of Computer-Aided-Engineering

on Manufacturers (1996)
Management Roundtable; Product Development in the 1990s (1997)
FEA slows down the rapid product development process

and should only be used after careful consideration of its
need
Developing Products in Half the Time; Preston and Reinertsen (1998)
despite the efforts to create an integrated CAD/analysis

product-development process, FEA remains today in the
hands of specialists.
Industry Week Magazine; December 11, 2000
11
11
11
Implementation
WARNING #1:
Simulation Software Does
Not Provide a Competitive
Advantage
12
12
12
A Tale of Three Companies

?
In 1995, Company A, B, & C were at about the same point

in FEA integration
The Similarities Were Clear
?
?
?
?
?
All members of MECHANICA User Group (MUG)

Only analysis tool was Pro/MECHANICA
Primary CAD tool was Pro/ENGINEER
Similar product and engineering needs
Similar geographic / demographic location
In fact, the president of the MUG was from Company C

and well respected in the group.
13
13
13

?
Where Are They NowFEA-wise in 2005?

?
Company A has developed a core analysis group with primary

analysis tool shifting to Abaqus for high level nonlinear and
contact study
Company B has developed a core analysis group with primary
tool shifting to ANSYS for high level nonlinear work
Company C is still struggling to make Pro/MECHANICA an
integral part of the design processin some waystheyve
regressed.
Why?
14
14
14

Software Doesnt Provide a Competitive
Advantage
Deciding Better
Making Fewer Mistakes
Innovating Moreand More Efficiently
Using Tools Smarter than Competition
Provides Competitive Advantage!
How can you use FEA Smarter?
15
15
15
What is Finite Element Analysis?

?
A process which utilizes a mathematical approximation of

a structure or system to predict the behavior under
specified environments or loads.
Allows for rapid iterations and What If studies on:
Geometry
? Wall Thickness
? Material Properties
? Loading Conditions
? Operating Temperatures
? Vibration Response
and more!
?
16
16
16

?
In the simplest terms, FEA answers complex

questions about structural behavior...
Based on a Given Set of Assumptions!

?
What are assumptions in a typical FE Problem?
17
17
17

Y
1000 lbs.
2 in.
10 in.
(0,0,0)
1 in.
?
?
?
?
?
?
Thickness
Length
Width
Force
End Condition
Material Modulus
?
?
?
?
?
(0,0,0)
Displacement Small
Stress-Strain Linear
Force Doesnt Change Magnitude,
Orientation, Distribution
Gravity Negligible
Guy who Wrote Equation Got It Right!
18
18
18
Implementation
WARNING #2:
All FEA Solutions

are wrong
Usually the Answers are right
but the Questions are wrong
19
19
19
Key FEA Assumptions

?
?
Geometry
Mesh
?
?
? engr
Convergence
Idealizations
Mild Steel
E = 30,000,000 psi
Cast Iron, E = 17,000,000 psi
Boundary Conditions
? Properties
Also
? Linear & Static
?
Aluminium
E=10,000,000 psi
0.2%
?engr
20
20
20
Implementation
WARNING #3:
CAD integration does not
ensure FEA success
It may actually hinder success if a user
is misinformed!
21
21
21
Key FEA AssumptionsGeometry

?
CAD Solids Built without Considering Analysis

Needs
Manufacturing Reqd Features Prevented
Accurate FE Model Creation
Shell Model Constructed from Drawings
22
22
22
Implementation
WARNING #4:
Getting a Mesh Is Not the
Problem Anymore
Getting the Right Mesh Still Requires
User Input
23
23
23
Key FEA AssumptionsMesh
Tetrahedron Mesh
Plate Mesh
Beam Mesh
Brick Mesh
24
24
24

?
?
?
CAD Solids Used without

Question
Took Weeks to Complete
Resulting Solid Mesh on
Small Portion of Model
Rendered Incorrect Results
Beam Model of Entire
System Built & Optimized in
Hours
25
25
25

Relative Convergence
Pass 1 26,384 psi

Pass 2 40,843 psi; Change = 55%
Pass 3 44,503 psi; Change = 9%
26
26
26
Key FEA AssumptionsBoundary Conditions
27
27
27
Key FEA AssumptionsBoundary Conditions
Fixed Bearings 32 ksi
Pinned Brngs 98 ksi

28
28
28
Key FEA AssumptionsProperties

Powdered Metal Latch
Catch
Striker
Axle
Rotor
F
29
29
29
Key FEA Assumptions

Linear vs. Nonlinear Analysis
The following analyses of a plastic paper tray indicate the importance of using
nonlinear analysis where requiredthe nonlinear results match test data closely.
Linear Model
Nonlinear Model
Displacement
2.49 inches
0.61 inches
Von Mises Stress

3,127 PSI
1,295 PSI
30
30
30
Insufficient Understanding of Problem

Tension Spring
Threaded Rod
32
32
32
Insufficient Understanding of Problem

Tension Spring
Field Failure
Test & FEA Failure

33
33
33
Warnings to Users and Managers

?
?
?
?
?
?
?
Simulation Software Doesnt Provide Competitive

Advantage
All Finite Element Analysis Results are Wrong!
CAD Integration Doesnt Ensure FEA Success
Ease-of-Use Doesnt Imply Accuracy
FEA Requires You to be Smarter Than You Ever Were!
Knowing the Interface Doesnt Equate to Knowing FEA
Many Bad Analyses Can Be Traced to Careless
Engineering
SoWhy Bother?
34
34
34
Why Do Analysis
When Used Correctly and At The Right Time
?
?
?
?
?
Reduce Product Development Time

Reduce Product Development Cost
Improve Product Quality
Reduce Product Cost
Improve Product Safety
35
35
35
on
i
t
a
ul d
m
i
le
S
b
a
En sign
De
Detailed Design
Three Stage of FEA Implementation

Concept
n
sig on
e
D ati
ific
r
e
V
Prototype
Verification ure
l
Fai ation
ic
f
i
r
Ve
Production
Optimal Design
or
Best Alternative When Time and
Money Ran Out?
36
36
36
What is Simulation-Enabled Design?

Adjustment of Processes to Make it as Fast and Easy
as Possible to:
?
?
?
?
?
Reduce the Product Knowledge Gap

Make Fewer Mistakes
Waste Less Time
Improve Quality
Develop Optimal Designs
37
37
37
What is Simulation-Enabled Design?

?
How do you implement Simulation-Enabled Design?

?
?
?
?
Process Integration
Communication
Education
Quality Control of the FE Process & Data
Part of an Overall Commitment to Continuous

Improvement & Product Quality
38
38
38
Who Should Do Analysis?

?
?
?
?
?
CAD Prowess Shouldnt Qualify

Candidates
Champion vs. Designate
Giving a Carpenter a Scalpel
Doesnt Make Him a Brain
Surgeon
Is it Too Easy to Get Results?
Many Marginal Users Consider
Themselves Experts!
39
39
39
Who Should Do Analysis?

?
Should Designers be doing FEA?

?
?
?
?
Designers vs. Design Engineers

Is there a fundamental understanding of engineering
principles?
Dont assume these come with a BSME!
Can team/mgmt ensure quality solutions?

Is there QA support system in place?
40
40
40
QA in FEAThe IMPACT Way

?
?
?
?
?
Process Audits
Manager Training
Skills Assessment
Best Practices / Analysis Template Development
Internal User Group & Intranet Support
41
41
41
Analysis Skills Assessment

General Comments
?
?
?
Should provide feedback on improvement reqd

Should be Code Independent
Should be Non-Threatening
?
Fear of assessment should say something
Should have levels and categories

?
?
Beginner vs. Advanced

Linear Static, Nonlinear, Dynamics
42
42
42
IMPACT Skills Assessment Program

?
Four part program

?
?
?
?
?
?
?
?
Basic Engineering Mechanics

Basic FE Knowledge
Hands-On Sample Problems
Portfolio Review
Interactive participation by evaluator

Results indicate confidence levels
Typically customized for company/industry
Initially focused on linear static/modal/buckling
43
43
43
Results of Assessment
?
Candidates will be given qualification levels:

?
?
?
?
Qualified to Mesh Models

Qualified to Set-Up Boundary Conditions
Qualified to Interpret Results
Qualified to Mentor Others
Assessment report will provide recommendations

for improvement and frequency of subsequent
assessment
44
44
44
How Can You Maximize FEA Success?

?
?
?
?
?
?
?
Planning
Training
QA
Communication
Common Sense
Bracket Problem Uncertainty
Find an Unbiased Resource for Support
45
45
45

Msoe RPC Impact

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Msoe RPC Impact

Enviado por

Direitos autorais:

Formatos disponíveis

Managing Analysis in the

2004 IMPACT Engineering Solutions, Inc.

Founded in 1987, IMPACT Engineering Solutions Inc. has grown

Analysis Services Division Initiated October 2002

Analysis Capabilities and Expertise

Four Areas of Analysis Support

About Vince Adams

Engineering Project and Group Leadership for

Anatomy of a Design Decision

Anatomy of a Design Decision

Good Design Decisions

Simulation and the Bottom Line

Simulation and the Bottom Line

Source: McKinsey & Co.

Simulation and the Bottom Line

Simulation and the Bottom Line

Grant Thornton; The Enterprise-Wide Impact of Computer-Aided-Engineering

FEA slows down the rapid product development process

despite the efforts to create an integrated CAD/analysis

A Tale of Three Companies

In 1995, Company A, B, & C were at about the same point

All members of MECHANICA User Group (MUG)

In fact, the president of the MUG was from Company C

A Tale of Three Companies

Where Are They NowFEA-wise in 2005?

Company A has developed a core analysis group with primary

A Tale of Three Companies

What is Finite Element Analysis?

A process which utilizes a mathematical approximation of

What is Finite Element Analysis?

In the simplest terms, FEA answers complex

Based on a Given Set of Assumptions!

What are assumptions in a typical FE Problem?

What is Finite Element Analysis?

All FEA Solutions

Key FEA Assumptions

Cast Iron, E = 17,000,000 psi

Key FEA AssumptionsGeometry

CAD Solids Built without Considering Analysis

Key FEA AssumptionsMesh

Key FEA AssumptionsMesh

CAD Solids Used without

Key FEA AssumptionsMesh

Pass 1 26,384 psi

Key FEA AssumptionsBoundary Conditions

Key FEA AssumptionsBoundary Conditions

Fixed Bearings 32 ksi

Pinned Brngs 98 ksi

Key FEA AssumptionsProperties

Key FEA Assumptions

Von Mises Stress

Insufficient Understanding of Problem

Insufficient Understanding of Problem

Test & FEA Failure

Warnings to Users and Managers

Simulation Software Doesnt Provide Competitive

Reduce Product Development Time

Three Stage of FEA Implementation

What is Simulation-Enabled Design?

Reduce the Product Knowledge Gap

What is Simulation-Enabled Design?

How do you implement Simulation-Enabled Design?

Part of an Overall Commitment to Continuous