Aerospace Product Development. NX CAE A Modern Simulation Environment

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1 Aerospace Product Development NX CAE A Modern Simulation Environment Smarter decisions, better products.

2 Simulation in Aerospace Where is it going? Earlier and faster iterations More complex phenomena Larger models, systems Increasing amounts of data

3 Simulation Challenges Today Complex Workflows and Numerous Data Transfers Geometry Engine Dynamics Analysis 3D Master Model Analysis Data Internal Aero Analysis Transient Heat Transfer Analysis Aero Mechanics Analysis External Aero Analysis Life Analysis Analysis Engine Clearance Analysis Modal Analysis

4 Simulation Today Lack of a Cohesive Environment People Expert analysts Simulation Software Various pre/post tools Many solvers Simulation Processes Capture Re-use Simulation Data Work in progress Variants

5 Evolution of the Role of CAE Modern Simulation Environments CAE is evolving from being a set of black box tools for highly specialized individuals toward a group productivity environment that delivers strategic competitive advantages to the business by supporting simulation-driven design.

6 Modern CAE Environment Delivering Competitive Advantages People: Expert analysts Designers / Design Engineers Modern Simulation Environment Simulation Processes Capture Re-use Simulation Data Work in progress Variants

7 Modern CAE Environment Delivering Competitive Advantages Modern Simulation Environment People Expert analysts Designers / Design Engineers Training Support Smarter Decisions SPM Simulation Processes Capture Re-use SDM KBE Simulation Data Work in progress Variants

8 Elements of a Modern Simulation Environment Integrated Modeling and Solutions Multi-Discipline Simulation and Optimization System Level Modeling and Simulation Simulation Data and Process Management

9 Simulation in Aerospace Where is it going? Earlier and faster iterations Integrated Modeling and Solutions More complex phenomena Multi-Discipline Simulation and Optimization Larger models, systems System Level Modeling and Simulation Increasing amounts of data Simulation Data and Process Management

10 NX CAE A Modern Simulation Environment Simulation Modeling Structural Thermal Flow Motion Multiphysics Optimization Data Management & Automation Simulation Driven Design

11 User Scalable Simulation Capabilities For all User Levels Expert Analyst Works with Non-NX geometry Modern, role-based interface Designer Embedded in NX CAD Simulation wizards Design Engineer Embedded in NX CAD Part / assembly validation Statics / modal / thermal Superior geometry editing Powerful FE modeling tools Linear, dynamics, non-linear, thermal, flow, motion, optimization, multiphysics Part validation Stress & vibration Motion analysis Clearance & interference NX Nastran + Multiple solver environments Guided process NX Nastran solver NX Nastran solver Problem Complexity

Global NX CAE Examples Aerojet ATK (Thiokol) Arianespace Avio Canadian Space BAE.

Source: GE, PLM World European Space environment for CAE: DLR to (German use synchronous Aerospace) EADS Astrium Agency Honeywell

features and solutions IHI Space Development ISRO Satellite Centre Exploration Agency Research Inst.

Communications model, a CFD Control NX best mesh Space Globally MDA managed Space Missions MHI model Spaceor a thermal (fewest elements)

manipulation NASA - Jet Propulsion Lab NASA - Johnson NASA Kennedy NASA - Langley Nathan Christensen Northrop Grumman Steven Mueller Sr

12 Global NX CAE Examples Aerojet ATK (Thiokol) Arianespace Avio Canadian Space BAE...our Systems analysts are very Ball Aerospace NX most reliable mesher Boeing Space NX is a Agency world-class excited about being able Source: GE, PLM World European Space environment for CAE: DLR to (German use synchronous Aerospace) EADS Astrium Agency Honeywell technology to de-feature NX fastest mesher Full support of solver Japan Aerospace Korea Aerospace models and get the Source: GE, PLM World features and solutions IHI Space Development ISRO Satellite Centre Exploration Agency Research Inst. geometry down to what Batch capability for they need to build a finite LM Missiles & Fire Lockheed Martin parametric FEA models L-3 element Communications model, a CFD Control NX best mesh Space Globally MDA managed Space Missions MHI model Spaceor a thermal (fewest elements) NASA Ames NASA Glenn Powerful NASA geometry - Goddard Source: GE, PLM World model. manipulation NASA - Jet Propulsion Lab NASA - Johnson NASA Kennedy NASA - Langley Nathan Christensen Northrop Grumman Steven Mueller Sr Manager, Engineering Team lead for Gas Turbines NASA - Marshall (TRW) Oerlikon Space Orbital Sciences Tools & Analysis ATK Pratt & Whitney (Rocketdyne) Raytheon RUAG Aerospace Saab Bofors Dynamics Space Exploration United Space Alliance SpaceDev Volvo Aero Thales Alenia Space Siemens Energy United Launch Alliance

13 Elements of a Modern Simulation Environment Integrated Modeling and Solutions Multi-Discipline Simulation and Optimization System Level Modeling and Simulation Simulation Data and Process Management

14 NX CAE Integrated Modeling and Solutions Leveraging geometry for CAE analysis Fast, easy-to-use geometry tools Automatic clean up of CAD models Quick creation of fluid domain Associativity to design geometry Rapid updates when designs change

15 The Traditional CAE Process Part Design Find & Import Data Repair & Edit Geometry Mesh Loads & BCs Analysis Modeling Solve Evaluate

16 NX CAE vs. Traditional CAE Traditional CAE Process Faster initial iteration Rapid update for later iterations

17 Simulation Modeling Demo

ATA Engineering Case Study Business challenge: Increase productivity and efficiency Adapt to changes in specifications or requirements Keys to Success: Exploit NX integrated design and analysis

18 ATA Engineering Case Study Business challenge: Increase productivity and efficiency Adapt to changes in specifications or requirements Keys to Success: Exploit NX integrated design and analysis modeling approaches, including ST Results: 100 times faster than the manual process 3 times faster for meshing of the updated model Real-world structures have complex design definitions and challenging analysis requirements and both are constantly changing. NX helps you cope with changes very efficiently and productively. Allison Hutchings Engineer ATA Engineering, Inc.

19 Elements of a Modern Simulation Environment Integrated Modeling and Solutions Multi-Discipline Simulation and Optimization System Level Modeling and Simulation Simulation Data and Process Management

Aerospace Typical Requirements & Analyses Design

Stiffness Natural frequencies Useful life Temperatures

Types Stress Stiffness Modal Frequency response

20 Aerospace Typical Requirements & Analyses Design Requirements Deformation, clearance Stress Strength Stiffness Natural frequencies Useful life Temperatures Pressures Weight Thermal Random Vibration Tests Analysis Types Stress Stiffness Modal Frequency response Transient response Durability Thermal Fluid flow Optimization Test correlation

21 NX CAE Multi-Discipline Simulation and Optimization Streamlined workflows for combined physics solutions Broad range of solutions Single environment Coupled solutions for structural, thermal, flow, and motion Scalable performance on HPC

22 NX CAE Multi-Discipline CAE in One Environment Structural Thermal Flow Linear Nonlinear Dynamics Rotor Dynamics Durability Composites Conduction Convection Conjugate Heat Transfer Radiation Compressible Incompressible 1-D Fluid Networks Non-Newtonian CFD Modeling Motion Rigid Body Contacts Flexible Bodies Co-simulation & Control Systems Packaging Studies Optimization Geometry FE Parameter Multiphysics Thermal Stress Thermal Fluid Fluid Structure Interaction Motion Structural Acoustic Structural

content Weight reduction Easier manufacturing of complex

23 Structural Analysis Composite Materials Composite materials increasingly important in Aerospace Airliner composites content Weight reduction Easier manufacturing of complex shapes Parts consolidation No corrosion Freedom to design the material

Structural Analysis Challenges to Analyzing Composites

Access to composite design data Need faster and more

analysis models Optimization of product performance

24 Structural Analysis Challenges to Analyzing Composites Need to validate the as-manufactured design Challenges Access to composite design data Need faster and more frequent iteration cycles Data accuracy of composites analysis models Optimization of product performance Lack of analysis driving design Closing the loop with manufacturing

25 Structural Analysis An Integrated Solution for Composites Siemens PLM Acquired Vistagy in 2011 Fibersim now part of Siemens product family

26 Structural Analysis Composites Demo

27 Thermal Analysis Demo

28 Motion Analysis with Flexible Bodies Demo

ATK Case Study Business challenge: Redesign Arming Switch for

loads using analysis in lieu of full scale system testing Keys to

without full system testing High fidelity can be achieved with

29 ATK Case Study Business challenge: Redesign Arming Switch for improved reliability and ease of fabrication Validate system thermal loads using analysis in lieu of full scale system testing Keys to Success: NX Thermal Results: System Thermal Simulation successful without full system testing High fidelity can be achieved with detailed modeling/analysis High confidence in redesigned switch gained thru simulation

NASA Jet Propulsion Laboratory (JPL) Case Study Business challenge:

the mission NX was able to evaluate the thermal control system s

manufacturing Multi-discipline simulation with NX CAE Results:

30 NASA Jet Propulsion Laboratory (JPL) Case Study Business challenge: Tighter schedules Large daily temperature swings during the life of the mission NX was able to evaluate the thermal control system s performance under conditions that JPL could not simulate with physical testing. Keys to Success: Single software platform (NX) from design through manufacturing Multi-discipline simulation with NX CAE Results: Faster design-analysis redesign iterations More confidence in the hardware modeling, the design implementation, and mission simulations

31 Elements of a Modern Simulation Environment Integrated Modeling and Solutions Multi-Discipline Simulation and Optimization System Level Modeling and Simulation Simulation Data and Process Management

32 NX CAE System Level Modeling and Simulation Distributed CAE Assembly Model Analogous to CAD assembly Individual FE component models Assembly model instances FE components x 4 Supports very large models

33 Assembly FEM Demo

Case Study NASA - Kennedy 2010 Challenges: Building

by groups or layers NX CAE Benefit: Assembly FEM allows

Stabilizer, Damper, and Vehicle Support Posts Color by

properties Drag and Drop Change on the fly Run what-if

34 Case Study NASA - Kennedy 2010 Challenges: Building assemblies Property management Toggling entities on and off by groups or layers NX CAE Benefit: Assembly FEM allows separate development of component models Used for Stabilizer, Damper, and Vehicle Support Posts Color by physical property Collectors make it fast to assign properties Drag and Drop Change on the fly Run what-if scenarios quickly Color by metadata (properties, etc.) Stabilizer component connecting with tower

Correlate analysis with analysis Ensure accuracy of reduced DOF models

35 NX CAE Test-Model Correlation Quantitatively and qualitatively compare simulation with physical test Correlate analysis with physical test Correlate analysis with analysis Ensure accuracy of reduced DOF models Pre-test planning to optimize sensor locations Optimize analysis model to better reflect reality

36 Elements of a Modern Simulation Environment Integrated Modeling and Solutions Multi-Discipline Simulation and Optimization System Level Modeling and Simulation Simulation Data and Process Management

37 Simulation Data and Process Management Intelligent integration between design & simulation processes Out of the box integration with Teamcenter Synchronize models with design Knowledge capture and process automation

Case Study Honeywell 2012 Challenges: Form of analysis data has changed over the last 20 years Management of this data has not kept pace Key to Success: Introduced PLM to Analysis World at Honeywell

38 Case Study Honeywell 2012 Challenges: Form of analysis data has changed over the last 20 years Management of this data has not kept pace Key to Success: Introduced PLM to Analysis World at Honeywell Rolled out Teamcenter Simulation Process Management data model The Problem Benefit: (Difficult to quantify all the savings) Centralized - Know where to find analysis data Global - Sharing data is more efficient. Enables collaboration and reuse Secure - Sensitive data remains sensitive, ITAR controlled Relational -Traceable, Locate all data related to a part. The Need: Central, Global, Secure, Relational Data Management System

Simulation Data and Process Management Automate simulation processes for analysts and designers Automation tools that can drive complex analysis

39 Simulation Data and Process Management Automate simulation processes for analysts and designers Automation tools that can drive complex analysis Common architecture allowing plug-ins Managed environment to distribute process automation to enterprise Guide designers through basic simulation tasks

Case Study GE Aircraft Engines 2012 Challenges: Modifying mesh of legacy models without geometry Key to Success: Developed utility in NX Open to

40 Case Study GE Aircraft Engines 2012 Challenges: Modifying mesh of legacy models without geometry Key to Success: Developed utility in NX Open to morph node locations Benefit: Automates a routine process to save time Dead mesh imported Region of nodes selected Displacement specified Mesh morphed

41 Elements of a Modern Simulation Environment Integrated Modeling and Solutions Multi-Discipline Simulation and Optimization System Level Modeling and Simulation Simulation Data and Process Management

Anton Huber, CEO Siemens Industry Automation We are

42 Why Siemens? Major Investments in CAE for Product Development The integration of product development, simulation and validation is now at the top of our agenda. Anton Huber, CEO Siemens Industry Automation We are investing heavily in CAE for multi-disciplinary analysis throughout the product definition cycle. Chuck Grindstaff, CEO

43 Siemens acquires LMS International Providing a closed-loop, systems-driven product development solution Based on system simulation and test Enabling mission-critical applications and best practices Embracing open strategies Supported by world-class engineering services Providing unprecedented value to customers

LMS A Siemens Business Simulation software, hardware and test solutions

systems to predict performance in physical domains 3D Simulation finite element

Test physical prototype testing and analysis solutions for durability, noise

44 LMS A Siemens Business Simulation software, hardware and test solutions Mechatronic system simulation modeling and analysis of multi-domain intelligent systems to predict performance in physical domains 3D Simulation finite element and multi-body modeling software to simulate and optimize mechanical systems Test physical prototype testing and analysis solutions for durability, noise and vibration engineering Services problem solving, process optimization and co-development

EU co-funded R&T project led by Airbus 59 organizations including Siemens PLM Objectives: 10% reduction

45 Collaborative and Robust Engineering using Simulation Capability Enabling Next Design Optimisation What is it? EU co-funded R&T project led by Airbus 59 organizations including Siemens PLM Objectives: 10% reduction of development lifecycle duration and cost 50% reduction in rework 20% reduction in the cost of physical tests Learn More: Webinar available at:

46 A Modern Simulation Environment for Aerospace Development Smarter decisions, better products

Siemens PLM Software. Simcenter 3D. Realizing innovation with 3D simulation. siemens.com/plm/simcenter3d

Siemens PLM Software. Simcenter 3D. Realizing innovation with 3D simulation. siemens.com/plm/simcenter3d Siemens PLM Software Simcenter 3D Realizing innovation with 3D simulation siemens.com/plm/simcenter3d Evolving product engineering To meet complex challenges, product engineering teams need a unified,