LMS Virtual.Lab Durability

Transcription

1 LMS Virtual.Lab Durability

2 LMS Virtual.Lab Durability Designing for optimal durability performance 2 LMS Virtual.Lab Durability

3 LMS Virtual.Lab Durability 3

4 LMS Virtual.Lab Durability Designing for optimal durability performance Undoubtedly the most challenging task for durability engineers is designing fail-safe components and systems in the most efficient manner. System parts with insufficient fatigue strength may cause permanent structural damage and potentially lifethreatening situations. Mistakes can cause product recalls which negatively influence the overall brand image. In addition to this, short design cycles, more design variants and increased usage of new lightweight materials increase the complexity of the durability engineering process. Transforming durability challenges into advantages Shorter development cycles and increased quality requirements have stretched traditional test-based durability processes to the limit. Evaluating and reliably optimizing durability performance on a virtual prototype is the only valid alternative. Just a few years ago, predicting component-level fatigue life took weeks while a system-level analysis could translate into months - if possible at all. Exploring multiple options to optimize design durability was simply not feasible and the only real option was to use expensive hardware treatments late in the development cycle. Thanks to years of customer and research institute experience, LMS Virtual.Lab Durability tightly integrates various virtual prototyping aspects including finite element (FE), modal analysis, multi-body simulation (MBS) and fatigue-life prediction. Users can quickly explore and optimize the structural strength and fatigue life on both component and system assembly levels in time or frequency domains. LMS Virtual.Lab Durability executes fast and accurate durability predictions. Dedicated post-processing capabilities provide engineers with immediate feedback regarding all critical durability areas, critical loads and critical events. Validate more design variants for fatigue life within evershorter development cycles Confidently simulate durability performance of large-and complex systems Optimize durability performance with lightweight and eco-friendly materials Better understand and improve fatigue testing 4 LMS Virtual.Lab Durability

5 LMS Virtual.Lab Durability Solutions for: Automotive and Ground Transportation LMS Virtual.Lab Durability accurately traces the fatigue performance of each vital chassis component. LMS Virtual.Lab Durability efficiently predicts fatigue-life on body frames, panels, cross-members and door systems as well as on sunroofs, latches and locking systems. LMS Virtual.Lab Durability also guarantees a high degree of accuracy for specific seam weld and spot weld analyses. Advanced numerical durability predictions can be applied to specific engine and powertrain parts. Engine brackets, gear box chain heels and exhaust lines are typical examples of components that can be effectively optimized with LMS Virtual.Lab Durability. Aerospace LMS Virtual.Lab Durability predicts mechanical system fatigue life for landing gear, control mechanisms, slat tracks and other critical assemblies. Local stress concentrations are identified based on all possible combinations of local load conditions to address durability problems long before prototypes are built. A wide range of methods can localize weak spots and assess fatigue life. Industrial machinery In industrial applications, economic efficiency and safety depend on critical parts typically subjected to large dynamic multi-axial load cases. Any metal component subjected to dynamic loading cycles can be efficiently optimized. LMS Virtual.Lab Durability is capable of accurately determining rotor base fatigue life in large wind turbines or crane parts integrated in industrial trucks. Virtual Shaker Table Shaker tables are a key testing facility. Already in the design phase, efficient simulation of sine sweeps, harmonic excitations and random loads helps optimize durability behavior. Specifically, LMS Virtual.Lab Vibration Fatigue is the tool to set up any virtual shaker table experiment from simple excitations to complex multi-axial scenarios. LMS Virtual.Lab Durability 5

6 An integrated process approach to durability engineering The LMS fatigue solvers have been maturing for almost two decades to guarantee fast and accurate results. Technology breakthroughs in intelligent filter algorithms, analysis for welded structures, application of time dependent stress gradients are just some examples of recent technological innovations. This is accompanied by usability breakthroughs, like the only real seamless integration of multi-body simulation and fatigue, state-of-the-art automation tools, and optimal post-processing tools to analyze the source of fatigue problems. Efficient seam and spot weld assessments Vehicle body and suspension systems can include thousands of welds. For spot welds, LMS Virtual.Lab Durability supports the Rupp/LBF approach, CDH and a special JSAE model as well as a stress-based approach using detailed modeling. LMS Virtual.Lab Durability automates seam-weld durability assessments, eliminating the tedious task of adapting the FE mesh according to seam-weld meshing guidelines. Users simply define the manufacturing details and LMS Virtual.Lab Durability identifies local stress concentrations based on all the possible combinations of (local) load conditions. Sheet connections are automatically detected and classified according to element or predefined groups while connection types are automatically classified according to butt welds, overlap joints and T-joints. Outstanding accuracy through in-depth investigation Assessing load effects can be challenging, particularly with multiple independent inputs that generate forces with local multi-axial stress states, LMS Virtual.Lab achieves outstanding accuracy by treating these cases based on the critical plane approach, which accounts for anisotropy caused by microscopic small cracks. Fatigue cracks below the surface can be analyzed as well. Fatigue-life solver fit for rigid and flexible bodies While components such as knuckles are never excited close to their natural frequencies, other parts such as suspension sub-frames, truck chassis, or exhaust systems are. To accurately and efficiently tackle any situation, LMS Virtual.Lab Durability supports different approaches for predicting stresses, based on quasi-static, inertial relief and modal superposition techniques. Top analysis speed with smart data reduction When creating real-life industrial size models, LMS Virtual.Lab Durability intelligently and automatically reduces the amount of data via node elimination reverse path (RP) filtering and load-based filtering. There is no need to guess where the critical locations might be - all locations are found automatically. Analyzing a complex car body model with hundreds of spot and seam welds and over 350,000 elements takes just a few hours. 6 LMS Virtual.Lab Durability

7 From component-level to system-level durability prediction Full-assembly design issues are too often discovered late in the development process. To solve this, durability engineers need to optimize subsystems or systems as a whole. This is where LMS Virtual.Lab Durability steps in. It tightly integrates multibody simulations with fl exiblebody analyses and fatigue-life predictions. The durability performance of any particular system part can be effectively and accurately traced. LMS Virtual.Lab s proven solver technology and real-life modeling capabilities guarantee top-class prediction accuracy. Accurate system load simulation Long before the actual vehicle prototype is created, LMS Virtual.Lab Durability can be used to generate system loads, starting from virtual driver sessions or road tests from a previously released vehicle. The LMS Digital Test Track approach predicts spindle loads via realistically simulated driver sessions. A virtual vehicle is equipped with virtual tires and drives over a digitized test track. For tracks and public roads that are too complex or expensive to digitize, LMS Virtual.Lab Durability offers a valid alternative. The LMS Hybrid Road approach incorporates test-based system loads from a predecessor vehicle to generate loads for the new vehicle design. Automated durability analysis LMS Virtual.Lab Durability provides all the automation functionalities to defi ne a complete durability analysis case from scratch. Users will benefi t from the powerful LMS Virtual.Lab toolset to defi ne templates and to effi ciently automate the preparation of loads and post processing cases. Furthermore, the automation functionality provides extensive fl exibility to interact with external optimization tools. LMS Virtual.Lab Durability CAD Meshing Mesh based Pre-processing Standard Loads Stress Simulation Fatigue Simulation Durability Performance Re-use CAD and CAE models from industry-standard tools. Transfer loads from multi-body simulation to durability analysis. Set-up and solve fatigue problems. Automation tools solve hundreds of cases and prepare the postprocessing. LMS Virtual.Lab Durability 7

8 LMS Virtual.Lab Component Fatigue VL-DUR.24.2 LMS Virtual.Lab Component Fatigue is a complete solution to accurately assess the fatigue performance of individual components in one single, integrated simulation environment. By combining component loads derived from prototype measurements or multibody simulations, FE-based stress results and cyclic fatigue material parameters, LMS Virtual.Lab Component Fatigue allows engineers to predict fatigue hotspots and corresponding fatigue life, and optimize the component design for fatigue performance. The straightforward interface offers a clear built-in workflow and set-up templates to guide users through the process. With seamless access to FE meshes and stresses, automatic Nastran and Ansys driving, and direct component load importing, users can quickly prepare fatigue analyses all within the same environment. LMS Virtual.Lab Component Fatigue offers all the fatigue-life analysis capabilities of the popular LMS FALANCS solver, including assessment of lowcycle fatigue, high-cycle fatigue and infinite life, stress gradient correction, below-surface fatigue as well as seam and spot weld analysis. Starting from a component designed in CATIA V5... With dedicated post-processing functionalities, engineers can quickly identify and solve fatigue life problems, and experiment with multiple design options. Parametric analyses let users identify innovative design solutions before physical prototyping....users interactively define the load case to be applied to the component. Features Process solution that tightly integrates FE, test and fatigue life prediction Seamless access to structural FE meshes and stresses from all leading FEA tools Direct component-load importing from prototype measurements or multibody simulation based on LMS and 3rd party time-data formats Industry standard fatigue-life solver with proven accuracy and speed Dedicated durability visualization and post-processing tools Analysis templates that capture simulation workflow Benefits Reduce fatigue analysis time Quick and accurate fatigue life predictions based on realistic loading conditions Immediate feedback on critical durability areas Understand the cause of fatigue problems Explore multiple design options and optimize the design for fatigue performance LMS Virtual.Lab Durability runs the fatigue analysis and determines the critical regions. Based on the analysis results, users can change their design and evaluate the impact on the fatigue resistance. 8 LMS Virtual.Lab Durability

9 LMS Virtual.Lab System-Level Fatigue LMS Virtual.Lab System-Level Fatigue offers a complete solution for optimizing subsystems or assemblies, and analyzing their strength and fatigue. It allows engineers to calculate component loads from prescribed system motion through multibody simulation, using the embedded LMS Virtual.Lab Motion solver. These component loads are combined with structural stresses. Finally, material fatigue parameters are applied to predict the component fatigue hotspots and corresponding fatigue life. Its easy-to-use interface with dedicated templates and customized wizards facilitates multibody model set-up. Scalable modeling makes it possible to refi ne models at any time and work with rigid or fl exible component representations. The previously lengthy and error-prone job of integrating a fl exible body now only takes a few mouse clicks. All the user needs to do is pick up the component FE mesh and drag it into the system model. All body connections are automatically established based on detected attachment nodes and degrees of freedom. LMS Virtual.Lab System-Level Fatigue cascades road profi les down to load responses on the component level. The multibody model is put on a virtual test rig and appropriate boundary conditions for the road profi le are automatically set. For each individual system part, predicted information on dynamic load cases, modal participation factors, excitation locations and local axes confi gurations are automatically transferred to the fatigue-life solver. The post-processing functions provide fast and critical insights into the load transfer path for the fatigue life of any component. This allows engineers to quickly investigate hotspots and rerun analyses for numerous system-level design variants. VL-DUR.25.2 Features Easy creation of multibody models for system load prediction and cascading of system loads to component loading Automatic transfer of component loads for detailed component durability analysis Optimize durability performance by tuning system characteristics for optimal load input Parallel optimization of motion, loading and fatigue Flexible body modeling and robust multibody solver guarantee accurate component load prediction Benefits Analyze durability performance earlier in the design process before flexibility is lost Safe and efficient process avoids manual load transfer Quickly explore fatigue life of multiple system-level designs Accurately predict component loads Optimize system-level fatigue performance by optimizing load-transfer paths Optimize the ride and handling behavior of the suspension; easily apply the real road profiles. Replace the knuckle by a flexible representation with one mouse click. The stress recovery is automatically transferred to the durability analysis. The fatigue results can also be post-processed in the complete system. LMS Virtual.Lab Durability 9

10 LMS Virtual.Lab Vibration Fatigue VL-DUR.23.2 Traditionally, fatigue damage is associated with time-dependent loading from local stress or strain histories. In many situations, a description in the frequency domain is more practical. For example, take the case of a randomly excited shaker table or an active wind turbine, where loading time signals are not easily determined, but described using stationary processes or, engine accessories which are excited by the engine and the loads are defi ned in small frequency bands. Another example would be simulating a complete sine sweep on a virtual shaker table usually handled in the time domain but, for effi ciency reasons, the simulation is best completed in the frequency domain using a harmonic vibration approach. LMS has solid experience in frequency-based solvers and both component-level and system-level load transfers. With its vibration fatigue solver, LMS combines its leadingedge knowledge with durability assessment methods using frequency-based solvers. Users can easily benefi t from the simple and consistent set-up and highly effi cient analysis methods, including random and deterministic loads in the frequency domain. The solver combines well-known methodology with technology breakthroughs like real multi-axial load and local stress behavior as well as seam and spot weld capabilities for highly accurate results. Post-processing features are adaptable to particular applications to quickly and effi ciently identify critical regions and provide answers to the durability issue. Features Uni & Multi-axial load input (PSDs/ cross-psds input for load correlation) Deterministic sine and random loads High performance (including storage requirements) for large models & multiple load conditions Multi-axial local stress states Durability-centered post-processing Benefits Reduce time by highly optimized calculation efficiency Reduce risk by understanding multiple load conditions Gain insight to critical design issues Analyze any frequency-based load Optimal design for fatigue early in the design phase For a bracket subjected to a sine sweep, a modal analysis is performed. The amplitudes of the sine sweep are defined. The user selectes the type and the length of the sine sweep......within minutes the results may by assessed. 10 LMS Virtual.Lab Durability

11 LMS Virtual.Lab Durability - Options VL-DUR.13.3 VL-DUR.12.3 VL-DMP.04.3 Road Durability Profile Parallel Interface Processing (Stackable 4-node) The With Road parallel Profile processing Interface capabilities, provides a LMS convenient fatigue way solvers to make can handle a complex large 3D problems road profile or efficiently. surface. Already The new in feature the standard generates configuration, geometry for larger the analysis road surface calculations from 3 different are split in file sources. two processes Spline to curves, take advantage spline surfaces, of modern and dual the CDTire core processors. ROAD 2000 Adding format. the The durability road surface parallel processing feature is aimed option at increases connecting the the calculation analytical power road surface and drastically used by decreases the solver with the calculation visualized times geometry. by another 4 processing nodes. This option is stackable, which means that that one can add 8 nodes using simply two licenses. The durability parallel processing option is compatible with the vibration fatigue solver (VL-DUR.23.2) and the FALANCS solver for component and system-level fatigue (VL-DUR.24.2 and VL.DUR.25.2). Spot Weld Modeling This package contains functionality for finding and modifying or creating new spot weld connections in the mesh. It is able to extract spot weld definitions from CAD structures and existing meshes directly. New spot welds may be defined interactively or automatically. The module supports various spot weld representations from simple bars and hexahedra to Nastran CWELD and fine spot weld models for enhanced durability simulations. Spot weld modeling covers fatigue life analysis of spot welds including traditional force-based approaches (Rupp, LBF, and JSAE) as well as local stressbased approaches. A unique and intelligent algorithm combines the ease-of-use and performance of the first approach with the enhanced accuracy of the latter, delivering an ideal balance of performance and accuracy. Seam Weld Modeling Seam-welded components typically have a limited lifespan. Simulating the fatigue behavior of welded structures is key to the design process. Structure loads can be represented as load-time histories or in frequency domain. The module lets users examine multiple loads. This unique seam weld module automatically detects connections between different sheets and classifi es the connection into butt and edge welds, overlap joints and T joints with different angles. Using the information from the fi nite element model the appropriate sheet thickness is assigned. The designer only has to check specifi c manufacturing and welding details. VL-DUR.14.3 Thermal Fatigue Environmental temperature and especially changes in the temperature have a significant influence on fatigue. On one hand, engineers need to include these effects in the fatigue analysis. On the other hand, material data accounting for these effects are expensive to achieve. This module offers a multi-level approach to achieve a good compromise between accuracy and efficiency. From simple temperature dependent SN-curves to temperature dependent stress-strain behavior and to creep and oxidation, the user can choose the method matching his problems. VL-OPT.22.2 Optimization LMS Virtual.Lab Optimization provides a set of powerful capabilities for single and multiattribute optimization. Through Design of Experiments (DOE) and Response Surface Modeling (RSM) techniques, engineers gain a rapid insight in all the possible design options that meet their requirements. Using advanced optimization routines including manufacturing for Six Sigma, LMS Virtual.Lab automatically selects the optimal design, taking into account real-world variability and meeting the strictest robustness, reliability and quality criteria. LMS Virtual.Lab Durability 11

12 LMS is an engineering innovation partner for companies in the automotive, aerospace and other advanced manufacturing industries. With approximately 30 years of experience, LMS helps customers get better products to market faster and turn superior process efficiency into key competitive advantages. With a unique combination of 1D and 3D simulation software, testing systems and engineering services, LMS tunes into mission critical engineering attributes, ranging from system dynamics, structural integrity and sound quality to durability, safety and power consumption. With multi-domain solutions for thermal, fluid dynamics, electrical and mechanical system behavior, LMS can address the complex engineering challenges associated with intelligent system design. LMS INTERNATIONAL Researchpark Z1, Interleuvenlaan 68 B-3001 Leuven [Belgium] T F info@lmsintl.com Thanks to our technology and dedicated people, LMS has become the partner of choice of more than 5,000 leading manufacturing companies worldwide. LMS is certified to ISO9001:2000 quality standards and operates through a network of subsidiaries and representatives in key locations around the world. For more information on LMS, visit Worldwide For the address of your local representative, please visit