Simcenter FE Model Correlation, Testing & FE Model Updating

Transcription

1 Simcenter FE Model Correlation, Testing & FE Model Updating Filip Deblauwe PhD, Test Technical Manager CoE EMEA Realize innovation.

2 Simcenter FE Model Correlation, Testing & FE Model Updating - Industries Aerospace & Defense Automotive & Transportation Industrial Machinery & Heavy Equipment Electronics & Semiconductors Marine Energy & Utilities Consumer Products & Retail Medical Devices & Pharmaceuticals Page 2

3 Simcenter FE Model Correlation, Testing & FE Model Updating - Importance Demand for increasingly complex products Growth of competition in global markets Demand for Product Quality at lower costs Trends in the market Integrated Correlation Solution Demand for Global R&D and Manufacturing Re-use proven Product and Component Data Need for Efficient products Leverage Simulation Tools with Test Data Frequent product and process innovations Remotely Prescribe Tests and Share Data Correlate simulation of advanced materials Leverage Continual Improvement Loops Page 3

4 Delivering Simcenter Portfolio for Predictive Engineering Analytics Unparalleled portfolio of solutions Multi-disciplinary and multi-physics Based on market leading solvers and industry specific applications and analytics capabilities Spanning full range of simulation solutions (1D, 3D), including test solutions Combining with controls to enable system level mechatronics simulation Enabling verification and validation in all stages of a product lifecycle, from concept to physical testing and utilization Note: For simplicity, additional 3D simulation products including LMS Virtual.Lab, LMS Samtech are not represented in the image Page 4

5 Simcenter Model Correlation, Testing & FE Model Updating Accurate multi-discipline simulation/testing with connections between 1D, simulation, test, and data management Best-in-class geometry editing and associative CAE modeling Engineering Desktop Unified, scalable, open and extensible environment Capture knowledge and automate processes to extend to team Page 5

6 Simcenter FE Model Correlation, Testing & FE Model Updating Offering Bring Simulation and Test data together to add value Pre-Test Structural Testing Correlation Sensitivity Updating Quantitatively and qualitatively compare simulation with physical test Page 7

7 Why is an integrated correlation solution important? FE Analysis [Modal/ FRF] Correlation & Updating NVH Acoustic Motion Flexible body Composite Durability Propagate Accuracy & Quality Page 8

8 Enabling closed loop system driven product development 3D Simulation Simcenter 3D Nastran Dynamics Pre test Planning Test Correlation Update Optimize Simcenter 3D & Test.Lab Engineering Services Page 11

9 Sturctural Dynamics: Model based test preparation and Test based model verification Full process support for Structural Dynamic Test campaigns Virtual Modal Test Physical prototype available Modal Test campaign Engineering Insight - Correlation / Modal Updating Page 12

10 Simcenter FE Model Correlation & Updating - Process to meet the challenge How do you know the analysis model is accurate? How to prescribe a cost effective test? Analysis NXN Model Pre-Test Test / FE Model How to compare quantitatively and qualitatively? How update the model to align with reality? Correlation Sensitivity and Updating Page 13

11 Simcenter FE Model Correlation & FE Model Updating - Overview Pre-Test Planning Analysis- Analysis Correlation Test-Analysis Correlation Sensitivity (NX Sol 200) Updating Page 14

12 Simcenter Correlation Pretest Objective: Get as-much-as possible information from as-lessas possible measurements on ever-more complex systems Use modal information of your preliminary FE model to obtain a good set of: Measurement DOFs Excitation DOFs Analysis NXN Model Pre-Test Test / Analysis Model Correlation metrics (criteria): MAC for measurement points DPR (Driving Point Residues) for excitation points Correlation Sensitivity and Updating Page 15

13 Simcenter Correlation Pretest Process Sensor selection Pre-Test Planning Analysis NOK Analyze Quality OK Import in Test package Export to.unv or.uff Analysis NXN Model Test Model Page 16

14 Sturctural Dynamics: Model based test preparation and Test based model verification Full process support for Structural Dynamic Test campaigns Virtual Modal Test Physical prototype available Modal Test campaign Engineering Insight - Correlation / Modal Updating Page 17

15 LMS SCADAS hardware: Signal Conditioning And Data Acquisition Dynamic data acquisition for field and lab usage Scalable size and performance Systems for smart recording, mobile testing and lab testing From compact systems to high-channel count configurations High performance digitization and DSP Addressing full dynamic testing scope Designed for noise, vibration, wind tunnel, testing Supporting broad range of standard aviation sensors From generic data acquisition up to turnkey engineering application LMS SCADAS Lab Delivering operational efficiency and flexibility enabling methods and tools harmonization LMS SCADAS Mobile Data recording In-field troubleshooting Large scale testing From component to system level Page 18

16 T ra ns fer P at h Ana lys is P r oj ect - Se ct ion Path Specific TTargets ts 5/7 P aths: Point/Direction DriverEars:Left:S DriverEars:Right:S Seat:1:+Z Path Unit Method EngineMnts:1-BS:+X N M a tr ix EngineMnts:1-BS:+Y N M a tr ix EngineMnts:1-BS:+Z N M a tr ix EngineMnts:2-BS:+X N M a tr ix EngineMnts:2-BS:+Y N M a tr ix EngineMnts:2-BS:+Z N M a tr ix EngineMnts:3-BS:+X N M a tr ix EngineMnts:3-BS:+Y N M a tr ix EngineMnts:3-BS:+Z N M a tr ix Mnt:4-BS:+X N Direct Mnt:4-BS:+Y N Direct Mnt:4-BS:+Z N Direct Mnt:5-BS:+X N Direct Mnt:5-BS:+Y N Direct Mnt:5-BS:+Z N Direct Exhaust:S m3/s2 Indirect Or ders: Case Name Order 1 Order 2 Order 3 Order 4 Order 5 Range rpm rpm S av e Pa th Sp ec ifi da ta T P A M od el Con tr ibu tion TPA Loads TPA Results LMS Test.Lab Solutions The integrated platform for physical testing Vibration Qualif. Structural Dyn. GVT / Flutter General Purpose Acoustics Transfer Path Jet-Engine Connected TPA Model ASAM ODS LMS Test.Lab software Test Based Engineering Laboratory Mobile LMS SCADAS LMS Test.Xpress software Siemens STS has over 6,000 systems active worldwide Page 19

17 Excitation Techniques Impact Testing Shaker Testing Page 20

18 Structural Dynamics Testing The most suited method(s) for each type of test Impact (burst) Random Periodic Random Swept Sine Stepped Sine Normal Modes t Phase Separation or Frequency Response Function (FRF) based methods Phase Resonance / Mode Appropriation AP(F) [N²] AP(F) [N²] AP(F) [N²] AP(F) [N²] AP(F) [N²] f AP(F) [N²] w [Hz] w [Hz] w [Hz] w [Hz] w [Hz] w resonance w [Hz] Measure FRF Modal Parameter Estimator Experimental Modal Model [ w, x, y ] Measure / Identify Mode [ w, x, y ] ( (m/s2)/n) db FRF DRV :1:+X / FOR:1:+ FRF DRV :2:+X / FOR:2: Page 21

19 Structural Dynamics Testing Setting new industry standards for Modal Parameter identification Time Domain Polyreference (LSCE) PolyMax PolyMax Plus Automatic Parameter Selection Ease of use Reliability Page 22

20 Structural Dynamics Testing Extending the application Range Operational Deflection Shapes Operational Modal Analysis Order Based Modal Analysis Insight Application Page 23

21 LMS Test.Lab - Ground Vibration Testing Efficient & reliable A/C testing supporting the entire team World-class structural dynamics identification Industrial modal testing: fully automatic LMS Test.Lab PolyMAX Full range of non-linearity assessment capabilities Expert opinion embedded + services also available Supporting the process From aircraft instrumentation to validated engineering insight Tight integration between test and analysis Connected to the engineering backbone GVT test and analysis team Maximum efficiency at minimal risk supporting test and simulation teams De-risking Virtual GVT Efficient first-shot automatic modal In-depth dynamics insight Validation and online correlation Post-test model updating Page 24

22 Sturctural Dynamics: Model based test preparation and Test based model verification Full process support for Structural Dynamic Test campaigns Virtual Modal Test Physical prototype available Modal Test campaign Engineering Insight - Correlation / Modal Updating Page 25

23 Simcenter Correlation Process Objective: Create comparable sets of data Get a qualitative and quantitative understanding of dynamic correlation : Mode shapes Eigen frequencies Analysis NXN Model Pre-Test Test / Analysis Model Correlation metrics (criteria): MAC Modal Assurance Criteria COMAC Coordinate MAC MSF Modal Scale Factor X-Ortho Cross-orthogonality Correlation Sensitivity and Updating Page 26

24 Simcenter 3D Correlation Workflows Test-Analysis Correlation 1. Import test model and results. Supported Data types: UNV 2. Align test geometry with analysis geometry 3. Manage sensors 4. Create mode pairs (Automatic) Analysis-Analysis Correlation 1. Create or insert a reference solution. Supported result types: NX Nastran, Abaqus, ANSYS, MSC and Samcef 2. Create the Correlation Sim 3. Create mode pairs (Automatic) 4. Post-process Analysis NXN Model Pre-Test Correlation Sensitivity and Updating Test / Analysis Model Page 27

25 Simcenter 3D Geometric Correlation Reviewing test results Test solution import through UNV or UFF files Legacy and current datasets Geometry Mode shapes Test frequency response functions, Animate the test mode shapes Easily overlay the coarser test geometry and sensor locations to the analysis model. Scaling tools Translate and rotate for alignment Use point mapping for automatic computation transformation parameters: fast and easy Page 29

26 Simcenter 3D Correlation Metrics Modal Assurance Criteria MAC Coordinate MAC COMAC Modal Scale Factor MSF Cross- Orthogonality X-Ortho Page 30

27 Simcenter 3D FE Model Correlation Offering Recap FE Analysis Data Access and Viewing Pretest Planning Test solution Import Modal Test Results Reviewing Toolkit Geometry Mapping Modal assurance criteria (MAC) Coordinate Modal Assurance Criteria (COMAC) Cross- Orthogonality Mode Pairing Visual Comparison Synchronization Tools Page 31

28 Simcenter 3D Updating Overview Update FE Models to Match Real-Life Test Data Fully integrated with Simcenter 3D Suite Analysis NXN Model Pre-Test Test / FE Model Add-on to Simcenter FE Model Correlation Process Confirm the Modelling Assumptions Correlation Sensitivity and Updating Page 32

29 Simcenter 3D FE Model Updating Objective: Retrieve which of the uncertain parameters in your model influence your correlation targets the most Set up and carry out the updating process to improve correlation Correlation targets: Mass to test mass Mode Frequencies to test eigen frequencies, difference to 0 Mode Shapes MAC values to 1 Analysis NXN Model Pre-Test Correlation Test / FE Model Design variables: Material characteristics (E, mass density) Element properties (shells, springs, ) CAD parameters (automatic re-meshing) Sensitivity and Updating Page 33

30 Early Component Model verification Component Sub-assembly Major Assembly Integrated Aircraft Lab-Testing Operational Testing Numerical Modelling Airbus A320 Slattrack Page 36

31 Sub-assembly dynamics testing Component Sub-assembly Major Assembly Integrated Aircraft Lab-Testing Operational Testing Numerical Modelling Rolls-Royce Trent 500Engine Nacelle Page 37

32 Larger Sub-assembly dynamics testing Lab-Testing Component Sub-assembly Major Assembly Integrated Aircraft Operational Testing Numerical Modelling Goodrich A380 Main & Body LG Page 38

33 Full Aircraft Ground Vibration Test Component Sub-assembly Major Assembly Integrated Aircraft Lab-Testing Operational Testing Numerical Modelling References see next Slides Page 39

34 Full Aircraft Flight Flutter Test Component Sub-assembly Major Assembly Integrated Aircraft Lab-Testing 8.00 Real / Time forl [DA] Time forr [DA] s Operational Testing Numerical Modelling Airbus A340 Polymax Validation on Airbus Flutter Data (m/s2) Real Time w inr:61:+z Time w inr:62:+z 0.00 s FRF w inl:61:+z / Volt:1:+X FRF w inl:61:+z / Volt:1:+X (1) ((m/s2)/n) db Phase Hz 5.00 Page 40

35 The voice of our customers We are reducing our warranty costs annually. has been very beneficial to us throughout our establishment of NVH best practices. We believe that significant cost savings and productivity gains can be accomplished with careful and strategic CAE tool standardization. Nathan Christensen Senior Manager - Engineering Tools and Analysis ATK Aerospace Group Glen Steyer Executive Director of Product Engineering AAM With technology, we are able to offer a wide range of solutions that meet and exceed [our customers ] initial expectations in a very short period of time. Edgar Benavente - Project Engineer Frisa In the space of three hours, four different designs were created and evaluated, and by that afternoon we were designing the part that was going into production, Andre Van der Watt, Chief Technology Officer, VW Group South Africa Motor Division Page 41

36 Space Industry Using NX and LMS software to avoid failure Reducing Risk with CAE Component Design Assembly Design Dynamic Analysis Correlation & Updating Virtual Test Analysis Certification Courtesy of CSA DFL Correlation, Updating & Virtual testing Standardize on NX CAE and NX Nastran for NVH simulation Develop a strong reliance on simulation and correlation of analysis results with physical testing with LMS Test.Lab and NX CAE Faster development with reduced risk Page 42

37 Aero Industry Using NX and LMS software for Ground Vibration Testing Getting off the ground with CAE Airbus-ONERA-DLR, GVT of the A380 FE Analysis (GVT) Test Prototype Design Analysis Pre-test Testing Correlation Updating End to End capabilities with Simcenter Suite Leverage simulation and correlation of analysis results with physical testing with LMS Test.Lab and Simcenter 3D Build reliable dynamic models using test to calibrate and increase accuracy of CAE models Get through certifications faster saving time and money Page 43

38 American Axle & Manufacturing Using NX and LMS software to reduce warranty costs Shrinking CAE process time Noise, vibration and harshness FE simulation Speed CAE process time with NX CAE Reduced warranty costs Enabled confident prediction of real-world performance Reduced over-design by performing simulation prior to building a prototype Standardize on NX CAE and NX Nastran for driveline NVH simulation Develop a strong reliance on simulation and correlation of analysis results with physical testing with LMS Test.Lab and NX CAE We are reducing our warranty costs annually. has been very beneficial to us throughout our establishment of NVH best practices. Glen Steyer, Executive Director Product Engineering Page 44

39 The voice of our customers Page 45

40 Simcenter 3D FE Model Correlation & FE Model Updating Summary Bring Simulation and Test data together Correlate analysis with physical test Full Suite of Correlation Tools Pre-Test, Correlation Sensitivity and Updating Unique Offering Both Simulation (Simcenter 3D) and Test (test.lab) Solver support Close integration with NX Nastran and Response Sim Optimize analysis model to better reflect reality Fully CAE associative Natively integrated with Simcenter 3D Page 46

41 Thank You