ENTERPRISE-WIDE SOLUTIONS: PRODUCT DESIGN, ANALYSIS,

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1 ENTERPRISE-WIDE SOLUTIONS: PRODUCT DESIGN, ANALYSIS, AND MANAGEMENT THROUGH ENGINEERING TEAMWORK

2 Collaborative Product Development Enterprise-Wide Solutions: Product Design, Analysis, and Management Through Engineering Teamwork A new class of enterprise-wide engineering analysis software allows design engineers to perform finite-element analysis (FEA) more routinely throughout product development, and also streamlines the process in which dedicated analysts handle advanced studies. In this way, analysis can be seamlessly integrated into a continuous design process, rather than interjected as a point solution for isolated problems. Using these tools, an engineer developing parts on a computer-aided design (CAD) system can easily check the design at any time to gain insight into product behavior and perform what-if? simulations to explore options and arrive at a superior design early. Moreover, Web-enabled reporting functions allow engineers to quickly transfer project information throughout the organization. And links to dedicated analysts facilitate more efficient detailed analysis when needed. With these analysis and communications capabilities, enterprise-wide engineering tools enable product development teams to work together efficiently. Engineers, analysts, and product development management can collaborate on product designs; reducing design cycle time, improving product performance, and documenting the entire design engineering process from concept to final design. In the conceptual stages, an engineer develops ideas and runs a conceptual shape optimization or first-pass analysis to evaluate alternative ideas and determine part size and shape. This is accomplished relatively easily and changes are readily made because of the associative link between CAD and analysis. In the next stages of more detailed design, an engineer can firm up dimensions and further refine the configuration, validating decisions with more detailed structural, thermal, and modal analysis. Engineers can use reporting features to send project results to colleagues, or post the information on an Intranet Website for review by other engineers working on the project. Analysts also can access these reports to add their own input based on experience with past projects and knowledge of the company s products, as well as sign-off on the preliminary analysis results. At an appropriate point in the design process, an engineer may need advanced analysis performed on the part to simulate multiphysics effects including coupled stress and thermal studies; contact analysis with other parts; nonlinear, computational fluid dynamics; or electromagnetic behavior. To send the model to the analyst, the engineer uses a predefined computer-aided engineering (CAE) template to automatically preprocess the FEA model. The process is a vast improvement over having the analyst start from scratch in the traditional manner. If a problem exists, the engineer, analyst, engineering colleagues, manufacturing personnel, managers, and other parties can go over the design and iron out problems. If convenient, face-to-face meetings can be held. But with dispersed

3 global organizations, fast communication takes place via phone calls, , and the Internet. Enterprise-wide engineering analysis does not replace a company s current design process, but rather facilitates and accelerates it with appropriate analysis and communication tools. Overview of Traditional FEA The latest version of the DesignSpace Shape Wizard predicts the optimal shape of a part based on its loads and supports. Color-coded contours indicate the optimal shape in contrast with the shape as analyzed. Figure 1 Traditionally, FEA is one of the most widely used methods for studying structures to determine stress, deformation, and other engineering parameters in mechanical parts under load. FEA can be thought of as an accurate approximation technique for analyzing complex structures which, handled as a whole, would represent a mathematical problem much too complicated to set up and solve. Instead, FEA uses a threestep approximation technique to tackle manageable pieces of the problem, and then combine the results into an overall solution. In the first step, called preprocessing, a mathematical model is constructed by dividing the structure into elements connected at nodes to form a mesh. Next, the solver performs the actual analysis on a computer to determine the behavior of the structure. In the last step, called postprocessing, the computer converts the analysis results from raw numbers into graphical form for display. FEA has come a long way since the early days of the technology in the 1960s and 1970s, when analysts had to enter node and element locations by hand, and wade through stacks of computer printouts to interpret the results. Today, FEA is considerably more efficient thanks to automation and graphical tools in both pre- and postprocessing. Also, FEA solvers now can handle a wider range of problems with continually enhanced features and functions. Moreover, increasing computing power allows relatively inexpensive personal computers (PC) and workstations to run problems in seconds or minutes which formerly took hours or days on older mainframe systems. Even with all of the advancements in user interfaces, graphics, computing power, and automated features, FEA users have to be skilled analysts. And it can take a significant amount of time to complete advanced analyses. To produce meaningful results, full-blown analysis software requires users to know how to apply proper mesh densities, element types, load types, and boundary conditions. Many users also must know how to go about translating some CAD geometry into a proper format for preprocessing. Correctly interpreting stress plots and other output information requires expertise, education, and experience. Throwing Designs Over the Wall As a result of traditional views, today FEA is performed in most engineering organizations the same as it has been for decades: by dedicated analysts with the knowledge and experience to properly apply the technology. Typically, engineers develop part configurations independently and then throw their designs over the wall to analysts, who assign a priority to the project and then perform the analyses when they can. Engineers may provide CAD models from which analysts can build the FEA models. But, in many cases, part geometry is conveyed on 2D drawings that must be interpreted and translated by analysts. It may take days or even weeks to obtain the results. In most organizations, this exchange is so inefficient that FEA typically is applied only in the final phases of product development. Often, the technology is not used to solve problems until parts fail during prototype testing. Results are given to engineers, who then reconfigure the parts, and send the new design back through the testing and analysis cycle. Such design-test-redesign cycles add considerable time and expense to product development. In the automotive industry, for example, handmade physical mock-ups of vehicles take months to build and cost $300,000 to $500,000. Additional expenses are incurred for the actual testing procedures in labs and test tracks, which automotive manufacturers spend millions of dollars on annually. Significant engineering effort is expended throughout this process in changing designs, modifying drawings, and seeking appropriate approvals for configurations. Also, designs often prove to be far less than optimal, with quick-fix changes inserted hurriedly at the last minute. In many cases, the rush to meet production deadlines may force engineers to grossly overdesign parts so they do not fail; resulting in added size, weight, and materials. Solving isolated problems late in development also may detract from the design of the product and contribute to problems with assembly operations.

4 The New Engineering Paradigm DesignSpace Report automatically generates engineering reports. DesignSpace products also provide the ability to publish live reports using Microsoft s Internet Information Server to be viewed as engineering homepages on a corporate network. Clearly, if analysis can be brought forward in design, the benefits will be significant, including shortened time to market, improved product designs, and reduced product development costs. The need for such capabilities has led to the development of a new class of software intended to make FEA more accessible to engineers. These new tools comprise much more than an easyto-use version of traditional FEA packages. Customizable templates allow designers to automatically preprocess analysis runs based on their existing design data. Wizards guide users step-by-step through common engineering problems. Webbased reports document results in easily used and shared formats. Robust geometry readers work effortlessly with a variety of CAD and geometry formats. Such software tools serve as an enabling technology for enterprise-wide engineering analysis, giving engineers the capability to use FEA routinely throughout product development and collaborate more effectively with analysts. Thus, analysis is seamlessly integrated into the design process rather than interjected as a point solution for isolated problems. This enterprise solution increases speed, quality, and communication throughout the product development process; thus moving analysis forward in the design process, where changes are more easily made. Studies have shown that 85 percent of the total time and cost of product development are committed in the early stages of product development, when only five percent of project time and cost have been expended. This is because, in the early concept stages, fundamental decisions are made regarding basic geometry, materials, system configuration, and manufacturing processes. Further along in the cycle, changes become harder to make. Essentially, there is a ten-fold increase in the time and cost to correct problems with each step of the product development cycle: conceptual, detailed design, drafting, prototype testing, and production. So a relatively minor change made in conceptual design for a few dollars could end up costing hundreds of thousands of dollars if not made until production begins, or even millions if flawed products are shipped. Using enterprise-wide engineering, analysts and engineers can collaborate during product design, documenting and publishing their work automatically. In this way, engineers can more efficiently exchange information with colleagues, professionals in other disciplines, customers, suppliers, and managers: all members of a collaborative team that can be neighbors in adjoining office cubicles or dispersed around the world. Engineering analysis models and reports are critical elements in documenting design activities, accountability, and decisions made regarding the product. Records become part of the aggregated databases an increasing number of companies are assembling in product data management (PDM) systems to control product-related data (including design geometry, engineering drawings, project plans, analysis models and reports, and correspondence, as well as work processes). By documenting design activities thoroughly in a standard and concise format, an enterprise-wide engineering analysis system facilities the use of PDM in an engineering organization, and enables manufacturers to more efficiently implement PDM technology. An enterprise-wide solution integrates the engineers design software with the advanced capabilities of design analysis software for companies to optimize their product designs and internal processes. In a typical scenario, the engineer developing parts on a CAD system can easily check the design at any time. Such ready access to information gives users greater insight into product behavior and promotes creativity through what-if? simulations that try out different ideas. By evaluating these alternative approaches, an engineer can explore options early to arrive at a superior design. Engineering Enterprise Tools Figure 2 As a leading supplier of FEA software, ANSYS Inc. developed the DesignSpace Enterprise product line as the first of this emerging and evolving class of software. Serving as a collaborative engineering vehicle, DesignSpace products provide enterprise-wide engineering analysis through a set of functions new to the engineering market. DesignSpace products can be run to conveniently evaluate the design while CAD solid models are being built. Users are prompted for information such as material type and operating conditions. With no further user intervention, the package then calculates and presents the results as intuitive graphics.

5 Automated design-checking functions give engineers guidance, direction, and insight into product performance. This gives engineers access to fundamental engineering performance data as they design, helping them make informed decisions about designs and run through various what-if? scenarios to optimize components. Routines operating in the background within DesignSpace products are based on proven FEA technology from ANSYS, Inc. With carefully applied technologies for a defined range of problems, DesignSpace products allow engineers to test their design s performance under actual operating conditions, without sending the designs to analysis specialists. At the heart of the DesignSpace technology is a powerful set of analysis, simulation, and database software running transparent to the user. Problem setup, specific commands, and input/output requirements have been automated so that engineers can take advantage of advanced technology without having to learn detailed operations and commands for many different programs. Templates, defaults, and preferences have already been established for well-defined sets of problems. As a result, users can more readily evaluate and refine their designs throughout product development, instead of waiting to perform analysis late in the design cycle. The software also allows engineers to work more collaboratively with dedicated analyst groups and testing facilities in verifying the integrity of the design later in the cycle. Extensive communication functions are provided by a Web-enabled report generator, called DesignSpace Report, that lets users send information about the design s performance to others. Through a single user interface, DesignSpace products associatively read geometry directly from solid model Figure 3 The DesignSpace Explorer shows how equivalent stress varies across a part. CAD programs including Pro/ENGINEER, Unigraphics, SolidWorks, and Autodesk Mechanical Desktop. They also support geometry based on Parasolid and ACIS geometry kernels. Associativity allows design engineers to freely modify parts without the need to redefine units, materials, or loads and supports; saving time and improving productivity. Providing a common look and feel, DesignSpace products integrate directly through the host CAD software s API and, unlike traditional geometry translators, maintain associativity to the original CAD part. A design engineer simply opens his/her DesignSpace tool and attaches a CAD part. Subsequent changes to the part are automatically adopted by clicking Refresh. Associativity virtually eliminates the need to redo engineering work in the software. Engineers check their designs through a simple process that prompts them for appropriate information about dimensional units, materials, loads, and supports. The software has built-in libraries of real-world conditions such as bolt loads and pin supports that automatically preprocess these problems properly. Wizards lead the user in answering fundamental questions in the areas of topological shape optimization, linear static stress, deflection, and natural frequencies such as: What should it look like? ; Will it break? ; How will it deform? ; and How will it vibrate?. DesignSpace software tools provide answers in the form of red or green flags indicating if predefined performance boundaries have been exceeded. Graphic capabilities provide users with dynamic viewing, slicing, and advanced animation capabilities including dynamic rotation of parts while simultaneously viewing animated deformation and color-coded result contours. Topological optimization technology in the DesignSpace Shape Wizard provides users with insight into the optimal geometry of a part based on its loading. This feature allows designers to carve a part from a solid lump of material, or to strategically remove material from an existing part. This tool can reduce fabrication costs and part weight tremendously, while improving performance and maintaining structural integrity. DesignSpace Expert also lets analysts create reusable templates that automatically generate ANSYS input files, relieving analysts of recreating part models. Automatic report generation provides a fully-formatted engineering document in the HTML format, including JPEG figures illustrating results. The report automatically captures material properties, environmental conditions, calculated results, and expected accuracy. All current design scenarios are described with the touch of a button, without any additional setup, and are automatically updated during the use of DesignSpace products. Organizations on an Intranet have the option to use one computer with DesignSpace or DesignSpace Expert as a Web server for authorized users to view reports as Websites. Using such a network, design engineers can easily communicate with analysts, clients, suppliers, colleagues, and man-

6 agers. Web-enabled companies can publish reports on the Internet to share information in real-time around the world. Reports generated with DesignSpace tools also may become part of the company s PDM information base which is useful for record keeping, archiving, and documenting the decision-making process used in developing the product. Continuous Versus One-Shot Analysis Enterprise-wide engineering analysis aims to integrate analysis seamlessly into the product development process, not merely making FEA easier to use. Traditionally FEA has been used in one-shot analysis near the end of product development, but now the new enterprise-wide paradigm makes analysis an integral part of the design process so it can be done routinely at any point in the cycle. Moreover, built-in communication and collaboration tools provide a framework for groups to better work in teams to develop new products. Such product development processes could be described as continuous (ongoing analysis is used throughout product development) and collaborative (everyone works together as a team in his/her areas of expertise and responsibility). This approach allows for flexibility not only in changing and refining product designs along the way, but also in modifying the product design process itself when necessary. In this way, the process allows for continuous refinement and optimization of designs, and it is readily adaptable to changes including customer-required changes, cost-reduction ideas, late shipments, and equipment breakdowns. Communication and collaboration in such an environment enables engineers to exchange information and ideas freely with manufacturing personnel to quickly resolve design-for-assembly issues. This eliminates, We can not make that! and, If only you had responses from production in organizations in which designs are thrown over the wall to manufacturing at the end of product development. Similar communication can take place with marketing, shipping, purchasing, and other groups including customers and suppliers. Customers can be brought into the product development process early to provide valuable input on service requirements so engineers can gain a better understanding of the OEM s expectations, problems, and concerns. Similarly, valuable product development information can be exchanged with component suppliers to improve their designs. The Changing Role of Engineers and Analysts An enterprise-wide engineering analysis system may lead to changes in the way engineers and analysts work together in an organization. The Advanced Controls feature found in DesignSpace Expert helps engineering companies capture best practice methods for solving their company-specific DesignSpace Expert features the Advanced Controls Module for performing advanced finite element analysis. ANSYS users can create templates that automatically preprocess analysis files. DesignSpace users simply select a template to generate a complete input file for the analyst to run in ANSYS software. Figure 4 analysis problems. Analysts most familiar with how to handle specific problems create reusable templates for their design engineers to produce input files. Through these templates, the analysts knowledge and expertise are captured. With engineers performing their own analysis on components throughout the product development process, analysts are free to concentrate on complex problems and their solutions, which make better use of their respective tools and specialization. The analyst is relieved of repetitive preprocessing tasks, and can now focus on results interpretation and analysis-mentoring for the design engineers. Moreover, enterprise-wide analysis gives analysts a vehicle for bringing their wealth of expertise and background to new product development processes. Rather than relinquishing power because of these new software tools, the new role of analysts in product development increases their responsibility and influence during the whole cycle. Conversely, engineers are given more convenient access to analysis tools that they can use routinely to study part designs, pinpoint problems early enough to easily correct them, and gain a greater understanding of part behavior and product performance. The intention of enterprise-wide engineering analysis is not to detract from the roles of engineers, analysts, and engineering managers, but rather to give them greater input throughout product development. Nor is it to make analysts out of engineers, but rather to enable them to quickly check their designs. The key is providing appropriate tools so that engineers, analysts, and managers can collaborate on projects and more effectively apply their expertise at the right times and in the right areas throughout product development.

7 ANSYS, Inc. Southpointe 275 Technology Drive Canonsburg, PA T F Toll Free USA and Canada: WE.R.FEA.1 Toll Free Mexico: Regional Offices: North America Ien.zera@ansys.com T F International jim.tung@ansys.com T F Europe brian.butcher@ansys.com T F ANSYS and DesignSpace are registered in the U.S. Patent and Trademark Office. All other trademarks and registered trademarks are the property of their respective owners SAS IP, Inc. All Rights Reserved. Printed in U.S.A. MWP-WP6-6/98