NASA STEP for Aerospace Workshop Jet Propulsion Lab Pasadena CA January 25 -27, 2000 Automating Product Data-Driven Analysis Using Multifidelity Multidirectional Constrained Objects Russell S. Peak Senior Researcher & Assistant Director Engineering Information Systems Lab eislab. gatech. edu CALS Technology Center Georgia Institute of Technology
Outline u Analysis Integration Objectives & Challenges u Technique Highlights and Applications u Constrained Objects (COBs) Overview u Usage for Analysis Integration u Summary © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 2
Analysis Integration Objectives for Simulation-based Design Analysis Module Catalogs • Highly automated • Reusable, modular, extensible • Product-specific • Leveraging generic solvers Design Product Model Selected Analysis Module (CBAM) MCAD ECAD CAE Ansys Automated Idealization/ Defeaturization Conditions Environments, Mfg. CAD/CAM, Measurements, etc. Abaqus Iterative Improvements Analysis Results Improved Design / Process © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu CBAM= context-based analysis model 3
Analysis Integration Challenges: Diverse Disciplines Electromagnetic Thermomechanical Electrical Fatigue De N Vibration © 1999 GIT Thermal Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 4
Analysis Integration Challenges: Heterogeneous Transformations u Homogeneous Transformation Design Model A Design Model B STEP AP 210 Mentor Graphics u Cadence Heterogeneous Transformation Design Model A STEP AP 210 ? ? Mentor Graphics © 1999 GIT Analysis Model A STEP AP 209 Georgia Tech Engineering Information Systems Lab eislab. gatech. edu Ansys 5
Multi-Fidelity Reusable Idealizations Analysis Models Solder Joint Deformation Multiple Uses Design Model 2 -D bounding box PWA Cooling Multi-Fidelity Idealizations Solder Joint Deformation Multiple Uses 3 -D bounding box © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu PWA Cooling 6
Multi-Fidelity Idealizations Design Model (MCAD) Analysis Models (MCAE) 1 D Beam/Stick Model flap support assembly inboard beam p 17, 20 3 D Continuum/Brick Model p 19. 1 © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 7
Design Geometry - Analysis Geometry Mismatch Detailed Design Model Missing: Explicit idealization relations G 1 : b = cavity 3. inner_width + rib 8. thickness/2. . . + rib 9. thickness/2 Analysis Model (with Idealized Features) G Idealizations Channel Fitting Analysis “It is no secret that CAD models are driving more of today’s product development processes. . . With the growing number of design tools on the market, however, the interoperability gap with downstream applications, such as finite element analysis, is a very real problem. As a result, CAD models are being recreated at unprecedented levels. ” Ansys/ITI press Release, July 6 1999 http: //www. ansys. com/webdocs/Visit. Ansys/Corp. Info/PR/pr-060799. html © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 8
Missing Today: Explicit Design-Analysis Associativity CAD Model bulkhead assembly attach point detailed design geometry No explicit fine-grained CAD-CAE associativity CAE Model channel fitting analysis material properties idealized analysis geometry analysis results © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 9
Multi-Directional Relations “The Big Switch” u Sizing/synthesis during early design stages – Input: Desired results - Ex. fatigue life, margin of safety – Output: Idealized design parameters – Outputs then used as targets to guide detailed design u Analysis/req. checking during later design stages – – © 1999 GIT Input: Detailed design parameters Intermediate results: Idealized design parameters Output: Analysis results - Ex. fatigue life, margin of safety Outputs then compared with requirements Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 10
X-Analysis Integration Techniques Multi-Representation Architecture (MRA) Explicit Design-Analysis Associativity Analysis Module Creation Methodology © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 11
Xai. Tools TM X-Analysis Integration Toolkit Multi-Representation Architecture (MRA) Implementation CAD/E Framework Architecture Analysis Modules & Building Blocks Constraint Schematics Implementations Product-Specific Applications u u Aerospace structural analysis PWA-B thermomechanical analysis & design Xai. Tools PWA-BTM u Electronic package thermal analysis Xai. Tools Chip. Package. TM © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 12
Example Projects u Team Integrated Electronic Response (TIGER) – Sponsor: Defense Advanced Research Prog. Admin. (DARPA) (SCRA subcontract) – Domain: PWA/B thermomechanical analysis u Product Data-Driven Analysis in a Missile Supply Chain (Pro. AM) – Sponsor: U. S. Do. D JECPO National ECRC Program (CTC subcontract) – Stakeholder: U. S. Army Missile Command (AMCOM) – Domain: PWA/B thermomechanical analysis u Design-Analysis Associativity Technology for PSI (PSI-DANTE) – Sponsor: Boeing – Domain: Structural analysis u Design-Analysis Integration Research for Electronic Packaging – Sponsor: Shinko Electric – Domain: Chip package thermal resistance analysis © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 13
Flexible High Diversity Design-Analysis Integration Aerospace Examples: “Bike Frame” / Flap Support Inboard Beam Design Tools Modular, Reusable Template Libraries MCAD Tools CATIA Analysis Modules (CBAMs) of Diverse Feature: Mode, & Fidelity Xai. Tools 1. 5 D Image API (CATGEO) Analyzable Product Model Xai. Tools Lug: Axial/Oblique; Ultimate/Shear Assembly: Ultimate/ Fail. Safe/Fatigue* FASTDB-like In-House Codes Fitting: Bending/Shear 3 D Fasteners DB General Mathematica 1. 5 D Materials DB MATDB-like Analysis Tools FEA Elfini* * = Item not yet available in toolkit (all others have working examples) © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 14
Pro. AM Design-Analysis Integration Electronic Packaging Examples: PWA/B Design Tools Modular, Reusable Template Libraries ECAD Tools Mentor Graphics, Accel* STEP AP 210‡ Gen. CAM**, PDIF* PWB Layup Tool Xai. Tools PWA-B Analyzable Product Model Xai. Tools PWA-B Analysis Modules (CBAMs) of Diverse Mode & Fidelity Solder Joint 1 D, Deformation* 2 D, 3 D Xai. Tools Analysis Tools PWA-B General Mathematica FEA Ansys PWB Warpage 1 D, 2 D Laminates DB PTH Deformation & Fatigue** Materials DB ‡ AP 210 DIS WD 1. 7 © 1999 GIT * = Item not yet available in toolkit (all others have working examples) 1 D, 2 D ** = Item available via U-Engineer. com Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 15
Design Automation Post-Lamination Thickness Calculation Before: Typical Manual Worksheet After: Tool-Aided Design (as much as 1 hour engr. time) © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 16
Iterative Design & Analysis using Xai. Tools PWA-B PWB Layup Design Tool 1 D Thermal Bending Model Quick Formula-based Check Layup Re-design Analyzable Product Model PWB Warpage Modules 2 D Plane Strain Model 1 Oz. Cu 3 x 1080 Tetra GF 2 Oz. Cu 1 Oz. Cu Tetra GF 1 Oz. Cu 2 x 2116 3 x 1080 © 1999 GIT Detailed FEA Check 1 Oz. Cu Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 17
Flexible High Diversity Design-Analysis Integration Electronic Packaging Examples: Chip Packages/Mounting (work-in-progress for Shinko Electric) Design Tools Modular, Reusable Template Libraries Analysis Modules (CBAMs) of Diverse Mode & Fidelity Prelim/APM Design Tool Xai. Tools Chip. Package Analyzable Product Model PWB Laminates DB Materials DB* Xai. Tools Thermal Resistance 3 D Analysis Tools Xai. Tools General Math Chip. Package Mathematica FEA Ansys Thermal Stress EBGA, PBGA, QFP Basic 3 D** ** = Demonstration module © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 18
APM Design Tool Preliminary Design of Packages © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 19
COB-based Analysis Tools Typical Input Objects Customized Analysis Module Tool with idealized package cross-section Generic COB Browser with design and analysis objects (attributes and relations) © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 20
COB-based Analysis Tools Typical Highly Automated Results Analysis Module Tool with Results Summaries Auto-Created FEA Inputs & Mesh Model FEA Temperature Distribution Thermal Resistance vs. Air Flow Velocity © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 21
Using Internet-based Analysis Solvers User Engineering Service Bureau Client PC Solver Servers Internet Finite Element Analysis (FEA) Solver Ansys Thick Client CORBA Xai. Tools Current: U-Engineer. com Pilot Demo Future: Company Internal or U-Engineer. com Math Solver Mathematica © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 22
Outline u Objectives & Challenges u Technique Highlights and Applications u Constrained Objects (COBs) Overview u Usage for Analysis Integration u Summary © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 23
COB Structure: Graphical Forms Spring Primitive Figure Constraint Schematic Relations Basic Constraint Schematic Notation Template Structure (Schema ) Subsystem View (for reuse by other COBs) © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 24
COB Structure: Lexical Form Spring Primitive Constraint Schematic Lexical COB Schema Template © 1999 GIT COB spring SUBTYPE_OF abb; undeformed_length, L<sub>0</sub> : REAL; spring_constant, k : REAL; start, x<sub>1</sub> : REAL; end, x<sub>2</sub> : REAL; length, L : REAL; total_elongation, Δ L : REAL; force, F : REAL; RELATIONS r 1 : "<length> == <end> - <start>"; r 2 : "<total_elongation> == <length> - <undeformed_length>"; r 3 : "<force> == <spring_constant> * <total_elongation>"; END_COB; Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 25
Example COB Instance Spring Primitive Constraint Schematic Instance Views Lexical COB Instances input: INSTANCE_OF spring; undeformed_length : 20. 0; spring_constant : 5. 0; start : ? ; end : ? ; length : ? ; total_elongation : ? ; force : 10. 0; END_INSTANCE; Basic Constraint Schematic Notation Instances result (reconciled): INSTANCE_OF spring; undeformed_length : 20. 0; spring_constant : 5. 0; start : ? ; end : ? ; length : 22. 0; total_elongation : 2. 0; force : 10. 0; END_INSTANCE; © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 26
Multi-Directional I/O (non-causal) Spring Primitive Constraint Schematic Instance View Design check Lexical COB Instance (state 5) input: INSTANCE_OF spring; undeformed_length : 20. 0; spring_constant : ? ; start : 10. 0; end : ? ; length : 22. 0; total_elongation : ? ; force : 40. 0; END_INSTANCE; Design synthesis result: INSTANCE_OF spring; undeformed_length : 20. 0; spring_constant : 20. 0; start : 10. 0; end : 32. 0; length : 22. 0; total_elongation : 2. 0; force : 40. 0; END_INSTANCE; © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 27
COBs as Building Blocks Two Spring System Constraint Schematic Lexical COB Schema Template COB spring_system SUBTYPE_OF analysis_system; spring 1 : spring; spring 2 : spring; deformation 1, u<sub>1</sub> : REAL; deformation 2, u<sub>2</sub> : REAL; load, P : REAL; RELATIONS bc 1 : "<spring 1. start> == 0. 0"; bc 2 : "<spring 1. end> == <spring 2. start>"; bc 3 : "<spring 1. force> == <spring 2. force>"; bc 4 : "<spring 2. force> == <load>"; bc 5 : "<deformation 1> == <spring 1. total_elongation>"; bc 6 : "<deformation 2> == <spring 2. total_elongation> + <deformation 1>"; END_COB; © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 28
Analysis System Instance Two Spring System Constraint Schematic Instance View © 1999 GIT Lexical COB Instance input: INSTANCE_OF spring_system; spring 1. undeformed_length spring 1. spring_constant : spring 2. undeformed_length spring 2. spring_constant : load : 10. 0; END_INSTANCE; : 8. 0; 5. 5; : 8. 0; 6. 0; result: INSTANCE_OF spring_system; spring 1. undeformed_length : 8. 0; spring 1. spring_constant : 5. 5; spring 1. start : 0. 0; spring 1. end 0 : 9. 81818182; spring 1. force : 10. 0; spring 1. total_elongation : 1. 818181818; spring 1. length : 9. 81818182; spring 2. undeformed_length : 8. 0; spring 2. spring_constant : 6. 0; spring 2. start : 9. 81818182; spring 2. force : 10. 0; spring 2. total_elongation : 1. 66666666; spring 2. length : 9. 66666667; spring 2. end 0 : 19. 48484848; load : 10. 0; deformation 1 : 1. 818181818; deformation 2 : 3. 484848484; END_INSTANCE; Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 29
Spring Examples Implemented in Xai. Tools X-Analysis Integration Toolkit © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 30
COB Modeling Views HTML © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 31
Flexible High Diversity Design-Analysis Integration Tutorial Examples: Flap Link (Mechanical/Structural Analysis) Design Tools Modular, Reusable Template Libraries MCAD Tools CATIA Analysis Modules (CBAMs) of Diverse Mode & Fidelity Xai. Tools Analysis Tools General Mathematica Analyzable Product Model Extension 1 D, 2 D, 3 D* FEA Ansys Xai. Tools Torsion 1 D Materials DB * = Item not yet available in toolkit (all others have working examples) © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 32
Tutorial Example: Flap Link Analysis Problems/CBAMs (1 a) Analysis Problem for 1 D Extension Analysis Flap Link SCN Design/Idealization Links (2) Torsion Analysis (1) Extension Analysis a. 1 D Extensional Rod b. 2 D Plane Stress FEA 1. Mode: Material Links Shaft Tension 2. BC Objects Flaps down : F = 10000 lbs 3. Part Feature (idealized) Leff = A= 5. 0 in 1. 13 in 2 E= 1020 HR Steel 30 e 6 allowable = 18000 psi 4. Analysis Calculations 5. Objective 1. 03 Pullable Views* BC Object Links (other analyses)* Solution Tool Links * Boundary condition objects & pullable views are WIP* © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 33
Flap Linkage Extensional Model: Lexical COB Structure COB link_extensional_model SUBTYPE_OF link_analysis_model; DESCRIPTION "Represents 1 D formula-based extensional model. "; ANALYSIS_CONTEXT PART_FEATURE link : flap_link BOUNDARY_CONDITION_OBJECTS associated_condition : condition; MODE "tension"; OBJECTIVES stress_model : margin_of_safety_model; ANALYSIS_SUBSYSTEMS */ deformation_model : extensional_rod_isothermal; RELATIONS al 1 : "<deformation_model. undeformed_length> == <link. effective_length>"; al 2 : "<deformation_model. area> == <link. shaft. critical_cross_section. basic. area>"; al 3 : "<deformation_model. material_model. youngs_modulus> == <link. material. stress_strain_model. linear_elastic. youngs_modulus>"; al 4 : "<deformation_model. material_model. name> == <link. material. name>"; al 5 : "<deformation_model. force> == <associated_condition. reaction>"; al 6 : "<stress_model. allowable> == <link. material. yield_stress>"; al 7 : "<stress_model. determined> == <deformation_model. material_model. stress>"; END_COB; © 1999 GIT Desired categorization of attributes is shown above (as manually inserted) to support pullable views. Categorization capabilities is a planned Xai. Tools extension. Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 34
FEA-based Analysis Subsystem Used in Linkage Plane Stress Model (2 D Analysis Problem) Higher fidelity version vs. Linkage Extensional Model © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 35
Flap Linkage Torsional Model Diverse Mode (Behavior) vs. Linkage Extensional Model © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 36
Today’s Typical Analysis Catalogs paper-oriented, no associativity Calculation Steps Categories of Idealized Fittings Channel Fitting End Pad Bending Analysis Channel Fitting © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu Angle Fitting Bathtub Fitting 37
Transformation into Object-Oriented Hierarchy of ABBs ABB * = Working Examples Specialized Analysis Body Fitting Casing Body Fitting Washer Body Specialized Analysis System Fitting Bolt Body* bolt washer casing Fitting System ABB load Channel Fitting Casing Body* Open Wall Fitting Casing Body Bathtub Fitting Casing Body K 1 = f (r , R, r 0, e) 1 © 1999 GIT Fitting Wall ABB K 2 = f (te , tw ) Angle Fitting Casing Body Fitting End Pad Bending ABB a +b Open Wall Fitting End Pad Bending ABB tw = min(t wa, twb) R = K 3 = f (r 1, b, h) Fitting End Pad ABB e = R- fbe = p f +d 2 C 1 = K 1 K 2 Georgia Tech Engineering Information Systems Lab eislab. gatech. edu P C 1 P 2 hte Fitting End Pad Shear ABB* fse = P 2 pr 0 te Channel Fitting End Pad Bending ABB* C 1 = K 3 ( 2 e - tb ) 38
Channel Fitting System ABBs End Pad Bending Analysis End Pad Shear Analysis © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 39
Reusable Fitting Analysis Module (CBAM) with explicit design associativity © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 40
Fitting Analysis Module in Xai. Tools Integration Focal Point Detailed CAD data from CATIA Library data for materials & fasteners Idealized analysis features in APM Fitting & Mo. S ABBs Explicit multi-directional associativity between detailed CAD data & idealized analysis features © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 41
Constrained Object Language (COBs) u Capabilities & features: – – u Various forms: computable lexical form, graphical form, etc. Sub/supertypes, basic aggregates, multi-fidelity objects Multi-directionality (I/O change) Wrapping external programs as white box relations Analysis module/template applications: – – Product model idealizations Explicit associativity relations with design models & other analyses White box reuse of existing tools (e. g. , FEA, in-house codes) Reusable, adaptable analysis building blocks – Synthesis (sizing) and verification (analysis) © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 42
Constrained Object Language (cont. ) u Overall characteristics – – u Declarative knowledge representation Combining object & constraint graph techniques COBs = (STEP EXPRESS subset) + (constraint concepts & views) Advantages over traditional analysis representations: » Greater solution control » Richer semantics (e. g. , equations wrapped in engineering context) » Capture of reusable knowledge Further needs … – Higher order constraints – Hybrid declarative/procedural approaches – Etc. © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 43
Summary u u u © 1999 GIT Emphasis on X-analysis integration (XAI) for design reuse (DAI, SBD) Multi-Representation Architecture (MRA) – Addressing fundamental XAI/DAI issues: » Multi-fidelity, multi-directional, fine-grained associativity, etc. – General methodology --> Flexibility & broad application Research advances & applications – Product data-driven analysis (STEP AP 210, Gen. CAM, etc. ) – Internet-based engineering service bureau (ESB) techniques – Object techniques for next-generation aerospace analysis systems – ~10: 1 analysis time reduction in pilot tests (chip packages) Tools and development services – Analysis integration toolkit: Xai. Tools Framework and applications – Pilot commercial ESB: U-Engineer. com – Company-tailored engineering information system solutions Motivated by industry & government collaboration Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 44
Selected Tools and Services offered via Georgia Tech Research Corp. http: //eislab. gatech. edu/ u Xai. Tools Framework ™ – General-purpose analysis integration toolkit u Product-Specific Toolkits – Xai. Tools PWA-B – Xai. Tools Chip. Package ™ u U-Engineer. com ™ ™ – Internet-based engineering service bureau (ESB) – Self-serve analysis modules « Full-serve consulting u Research, Development, and Consulting – – Analysis integration & optimization Product-specific analysis module catalogs Internet-based ESB development Engineering information technology » PDM, STEP, Gen. CAM, XML, UML, Java, CORBA, Internet, … – CAD/CAE/CAM, FEA, thermal & mechanical analysis © 1999 GIT Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 45
For Further Information. . . u u u © 1999 GIT EIS Lab web site: http: //eislab. gatech. edu/ – Publications, project overviews, tools, etc. – See Publications, DAI/XAI, Suggested Starting Points Xai. Tools home page: http: //eislab. gatech. edu/tools/Xai. Tools/ Pilot commercial ESB: http: //www. u-engineer. com/ – Internet-based self-serve analysis – Analysis module catalog for electronic packaging – Highly automated front-ends to general FEA & math tools Georgia Tech Engineering Information Systems Lab eislab. gatech. edu 46
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