Seminar NIST Gaithersburg, Maryland October 9, 2001 Techniques and Tools for Product-Specific Analysis Templates Towards Enhanced CAD-CAE Interoperability for Simulation-Based Design and Related Topics Russell S. Peak Senior Researcher Manufacturing Research Center Georgia Tech
© 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 2
Nomenclature © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 3
Analysis Module Catalog: Chip Package Simulation thermal, hydro(moisture), fluid dynamics(molding), mechanical and electrical behaviors u Pak. Si-TM and Pak. Si-E tools http: //www. icepak. com/prod/paksi/ as of 10/2001 u Chip package-specific behaviors: thermal resistance, popcorning, die cracking, delaminating, warpage & coplanarity, solder joint fatigue, molding, parasitic parameters extraction, and signal integrity © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 4
Analysis Module Catalog: Excavator/Loader Structural and Vibration & Noise Analysis u u Infinik (Korea)http: //www. infinik. com/solution/software. htm as of 10/2001 Optimal Mount Design of Cabin – Objective: Mininize vibration and reaction force at cabin mounting points – Analysis Type: Modal, forced vibration, substructure technique u Structures using ANSYS – Analysis Objects: Boom, arm, upper frame, lower frame – Analysis Type: Static, model, fatigue, life analysis u © 1993 -2001 GTRC Noise & Vibration Engineering Information Systems Lab eislab. gatech. edu 5
Analysis Module Toolkit & Catalogs: Diverse Application Libraries in EASY 5 From http: //www. boeing. com/assocproducts/easy 5/products/prod_libraries. htm as of 9/2001 © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 6
Analysis Module Catalog: Tire-roadway interaction on full-vehicle performance From http: //www. adams. com/product_line/tire. pdf as of 6/20/2001 Diverse Analysis Modules Diverse Design Data Fidelities Different Behaviors Various Environment / Boundary Condition Fidelities © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 7
Analysis Template Methodology & X-Analysis Integration Objectives (X=Design, Mfg. , etc. ) u u Goal: Improve engineering processes via analysis templates with enhanced CAx-CAE interoperability Challenges: – Idealizations – Diversity: Information, Behaviors, Disciplines, Fidelity, Feature Levels, CAD/CAE Methods & Tools, … – Multi-Directional Associativity: Design Analysis, Analysis Initial Focus: Capture analysis template knowledge in modular form for regular design usage One Approach: Multi-Representation Architecture (MRA) using Constrained Objects (COBs) © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 8
Multi-Fidelity Idealizations Design Model (MCAD) Analysis Models (MCAE) Behavior = Deformation 1 D Beam/Stick Model flap support assembly inboard beam 3 D Continuum/Brick Model © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 9
An Introduction to X-Analysis Integration (XAI) Short Course Outline - Highlights Part 1: Constrained Objects (COBs) Primer – Nomenclature Part 2: Multi-Representation Architecture (MRA) Primer – Analysis Integration Challenges – Overview of COB-based XAI – Ubiquitization Methodology Part 3: Example Applications » Airframe Structural Analysis (Boeing) » Circuit Board Thermomechanical Analysis (Do. D: Pro. AM; JPL/NASA) » Chip Package Thermal Analysis (Shinko) – Summary Part 4: Advanced Topics & Current Research © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 10
COB Structure: Graphical Forms Spring Primitive a. Shape Schematic-S c. Constraint Schematic-S b. Relations-S Basic Constraint Schematic-S Notation d. Subsystem-S (for reuse by other COBs) © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 11
COB Structure: Lexical Form Spring Primitive Constraint Schematic-S Lexical COB Structure (COS) 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; © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 12
Example COB Instance Spring Primitive Constraint Schematic-I example 1, state 1. 1 Lexical COB Instance (COI) state 1. 0 (unsolved): INSTANCE_OF spring; undeformed_length : 20. 0; spring_constant : 5. 0; total_elongation : ? ; force : 10. 0; END_INSTANCE; state 1. 1 (solved): Basic Constraint Schematic-I Notation © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 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; 13
Traditional Mathematical Representation Two Spring System Figure Free Body Diagrams Variables and Relations Kinematic Relations Boundary Conditions Constitutive Relations © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 14
Constraint Graph-S Two Spring System P bc 3 bc 1 F 2 k 1 r 13 x 11 r 23 L 2 x 22 L 1 r 11 k 2 spring 1 L 1 bc 4 L 2 r 21 r 12 r 22 x 12 x 21 L 10 L 20 bc 6 bc 5 u 1 u 2 bc 2 © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 15
COB Representation Extended Constraint Graph-S: Two Spring System Constraint Graph-S Extended Constraint Graph-S partial (BC relations not included) © 1993 -2001 GTRC • Groups objects & relations into parent objects • Object-oriented vs. flattened Engineering Information Systems Lab eislab. gatech. edu 16
COB Representation Constraint Schematic-S: Two Spring System Constraint Graph-S Constraint Schematic-S • Encapsulated form (hides details) © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 17
COB Constraint Schematic-S Two Spring System Analysis Primitives with Encapsulated Relations © 1993 -2001 GTRC System-Level Relations (Boundary Conditions) Engineering Information Systems Lab eislab. gatech. edu 18
COBs as Building Blocks Two Spring System Constraint Schematic-S Lexical COB Structure (COS) 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; © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 19
Analysis System Instance Two Spring System Constraint Schematic-I example 2, state 1. 1 Lexical COB Instance (COI) state 1. 0 (unsolved): INSTANCE_OF spring_system; spring 1. undeformed_length spring 1. spring_constant : spring 2. undeformed_length spring 2. spring_constant : load : 10. 0; deformation 2 : ? ; END_INSTANCE; : 8. 0; 5. 5; : 8. 0; 6. 0; state 1. 1 (solved): INSTANCE_OF spring_system; spring 1. undeformed_length : 8. 0; spring 1. spring_constant : 5. 5; spring 1. start : 0. 0; spring 1. end : 9. 818; spring 1. force : 10. 0; spring 1. total_elongation : 1. 818; spring 1. length : 9. 818; spring 2. undeformed_length : 8. 0; spring 2. spring_constant : 6. 0; spring 2. start : 9. 818; spring 2. force : 10. 0; spring 2. total_elongation : 1. 667; spring 2. length : 9. 667; spring 2. end : 19. 48; load : 10. 0; deformation 1 : 1. 818; deformation 2 : 3. 485; END_INSTANCE; © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 20
Spring Examples Implemented in Xai. Tools X-Analysis Integration Toolkit spring: state 1. 1 (solved) spring system: similar to state 1. 1 (solved): spring: state 5. 1 (solved) © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 21
Using Internet/Intranet-based Analysis Solvers Thick Client Architecture Users Engineering Service Bureau Client PCs Host Machines Internet/Intranet © 1993 -2001 GTRC CORBA Daemon Iona orbixdj CORBA Servers Xai. Tools. Ansys Xai. Tools. Math. Xai. Tools. Ansys Xai. Tools Server Solver FEA Solvers Ansys Math Solvers EIS Lab - Regular internal use U-Engineer. com - Demo usage: - US - Japan Nov. ’ 00 -Present: Electronics Co. - Began production usage (dept. Intranet) Future: . . . Xai. Tools CORBA IIOP Internet Thick Client June’ 99 -Present: Mathematica Engineering Information Systems Lab eislab. gatech. edu Company Intranet and/or U-Engineer. com (commercial) - Other solvers 22
COB Modeling Languages & Views Structure Level (Template) Instance Level © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 23
COB Object Model View (EXPRESS-G) Spring Schema Real undeformed Real _length force total Real load spring_2 _elongation Real spring length deformation 1 spring_1 spring _system Real © 1993 -2001 GTRC deformation 2 end 0 start spring _constant Engineering Information Systems Lab eislab. gatech. edu 24
Constrained Objects (COBs) Representation Characteristics & Advantages u Overall characteristics – Declarative knowledge representation (non-causal) – Combining object & constraint graph techniques – COBs = (STEP EXPRESS subset) + (constraint graph concepts & views) u Advantages over traditional analysis representations – Greater solution control – Richer semantics (e. g. , equations wrapped in engineering context) – Unified views of diverse capabilities (tool-independent) – Capture of reusable knowledge – Enhanced development of complex analysis models u Example Toolkit: Xai. Tools v 0. 5 © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 25
An Introduction to X-Analysis Integration (XAI) Short Course Outline Part 1: Constrained Objects (COBs) Primer – Nomenclature Part 2: Multi-Representation Architecture (MRA) Primer – Analysis Integration Challenges – Overview of COB-based XAI – Ubiquitization Methodology Part 3: Example Applications » Airframe Structural Analysis (Boeing) » Circuit Board Thermomechanical Analysis (Do. D: Pro. AM; JPL/NASA) » Chip Package Thermal Analysis (Shinko) – Summary Part 4: Advanced Topics & Current Research © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 26
X-Analysis Integration Techniques for CAD-CAE Interoperability http: //eislab. gatech. edu/tools/Xai. Tools/ a. Multi-Representation Architecture (MRA) b. Explicit Design-Analysis Associativity c. Analysis Module Creation Methodology © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 27
Multi-Representation Architecture for Design-Analysis Integration © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 28
Analysis Building Blocks (ABBs) Object representation of product-independent analytical engineering concepts Analysis Primitives Analysis Systems - Primitive building blocks Material Models e Linear. Elastic Continua De e Bilinear Plastic N Low Cycle Fatigue Discrete Elements Plate Interconnections body 2 body 1 q(x) Distributed Load Rigid Support x Beam Cantilever Beam System No-Slip Analysis Variables q(x) Temperature, T General - User-defined systems Stress, Damper Distributed Load © 1993 -2001 GTRC - Predefined templates y Plane Strain Body Rigid Support Spring Specialized Beam Geometry Mass - Containers of ABB "assemblies" Strain, e Engineering Information Systems Lab eislab. gatech. edu 29
COB-based Libraries of Analysis Building Blocks (ABBs) Continuum ABBs Extensional Rod Material Model ABB 1 D Linear Elastic Model modular re-usage © 1993 -2001 GTRC Torsional Rod Engineering Information Systems Lab eislab. gatech. edu 30
Multi-Representation Architecture for Design-Analysis Integration © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 31
Analyzable Product Models (APMs) Provide advanced access to design data needed by diverse analyses. Design Applications Solid Modeler Combine information Add reusable multifidelity idealizations Analysis Applications FEA-Based Analysis . . . Materials Database Fasteners Database © 1993 -2001 GTRC Analyzable Product Model (APM) Support multidirectionality Engineering Information Systems Lab eislab. gatech. edu Formula. Based Analysis 32
Flap Link Geometric Model (with idealizations) © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 28 b 33
Flap Linkage Example Manufacturable Product Model (MPM) = Design Description Extended Constraint Graph Product Attribute Ri COB Structure (COS) Product Relation © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 34
Flap Linkage Example Analyzable Product Model (APM) = MPM Subset + Idealizations flap_link Extended Constraint Graph effective_length w sleeve_1 t r x w sleeve_2 R 1 t R 1 r Product Attribute cross_section Product Relation wf R 4 t 1 f Idealized Attribute Ri R 6 R 5 t 2 f critical_section Idealization Relation critical_detailed wf tw rib_1 t rib_2 t 2 f R 2 critical_simple wf tw R 3 E linear_elastic hw n name stress_strain_model R 8 area h material R 7 t 1 f b t R 11 hw b h © 1993 -2001 GTRC Partial COB Structure (COS) R 3 tw shaft Ri R 2 x effective_length, Leff == inter_axis_length (sleeve 1. hole. cross_section. radius + sleeve 2. hole. cross_section. radius) tf cte R 9 R 10 area Engineering Information Systems Lab eislab. gatech. edu R 12 35
Flap Link APM Implementation in CATIA v 5 Design-Idealization Relation Design Model Idealized Model © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 36
Multi-Representation Architecture for Design-Analysis Integration © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 37
COB-based Constraint Schematic for Multi-Fidelity CAD-CAE Interoperability Flap Link Benchmark Example © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 38
Tutorial Example: Flap Link Analysis Template (CBAM) Flap Link Analysis Documentation (2) Torsion Analysis (1 a) Analysis Template: Flap Link Extensional Model CBAM (1) Extension Analysis a. 1 D Extensional Rod 1. Behavior: Shaft Tension CAD-CAE Associativity (idealization usage) 2. Conditions: Flaps down : F = 10000 lbs APM 3. Part Features: (idealized) Leff = 5. 0 in 1020 HR Steel A = 1. 125 in 2 E= 30 e 6 allowable = 18000 Geometry Material Models ABB psi SMM psi 4. Analysis Calculations: ABB 5. Conclusion: 1. 025 b. 2 D Plane Stress FEA. . . Solution Tool Boundary Condition Objects (links to other analyses)* Interaction Pullable Views* * Boundary condition objects & pullable views are WIP concepts* © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 39
Flap Linkage Extensional Model (CBAM) Example COB Instance Flap Link Analysis Documentation (2) Torsion Analysis Constraint Schematic Instance (1) Extension Analysis a. 1 D Extensional Rod 1. Behavior: Shaft Tension 2. Conditions: Flaps down : F = 10000 lbs 3. Part Features: (idealized) Leff = 5. 0 in 1020 HR Steel A = 1. 125 in 2 E= 30 e 6 allowable = 18000 psi 4. Analysis Calculations: 5. Conclusion: 1. 025 b. 2 D Plane Stress FEA. . . © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 40
Flap Link Extensional Model (CBAM) Example COB Instance in Xai. Tools example 1, state 1 Library data for materials Detailed CAD data from CATIA Idealized analysis features in APM Modular generic analysis templates (ABBs) F CAD ocus P oint -CA of E In tegr atio n Explicit multi-directional associativity between design & analysis © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 41
COB-based Constraint Schematic for Multi-Fidelity CAD-CAE Interoperability Flap Link Benchmark Example © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 42
Flap Linkage Plane Stress Model (with FEA-based ABB system) Higher fidelity version vs. Linkage Extensional Model ABB SMM © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu SMM Template 43
Flap Linkage Torsional Model Diverse Mode (Behavior) vs. Linkage Extensional Model © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 44
An Introduction to X-Analysis Integration (XAI) Short Course Outline Part 1: Constrained Objects (COBs) Primer – Nomenclature Part 2: Multi-Representation Architecture (MRA) Primer – Analysis Integration Challenges – Overview of COB-based XAI – Ubiquitization Methodology Part 3: Example Applications » Airframe Structural Analysis (Boeing) » Circuit Board Thermomechanical Analysis (Do. D: Pro. AM; JPL/NASA) » Chip Package Thermal Analysis (Shinko) – Summary Part 4: Advanced Topics & Current Research © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 45
Airframe Structural Analysis GIT Work in Boeing PSI Project Current Situation: Limited Analysis Integration Design Objects flap support assembly inboard beam (a. k. a. “bike frame”) Manually-Maintained Associativity Analysis Documentation bulkhead assembly attach point diagonal brace attach point Error-Prone, Labor-Intensive, Little Knowledge Capture © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 46
Flexible High Diversity Design-Analysis Integration Phase 1 Airframe 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) © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 47
Today’s Fitting Catalog Documentation from DM 6 -81766 Design Manual Calculation Steps Categories of Idealized Fittings Channel Fitting End Pad Bending Analysis Channel Fitting © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu Angle Fitting Bathtub Fitting 48
Object-Oriented Hierarchy of Fitting 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 1, R, r 0, e) © 1993 -2001 GTRC Fitting Wall ABB K 2 = f (te , tw) Angle Fitting Casing Body tw = min(twa, twb) R = a + b K 3 = f (r 1, b, h) Fitting End Pad ABB Fitting End Pad Bending ABB Open Wall Fitting End Pad Bending ABB p e = R- f +d 2 C 1 = K 1 K 2 Engineering Information Systems Lab eislab. gatech. edu fbe = 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 ) 49
Channel Fitting System ABBs End Pad Bending Analysis End Pad Shear Analysis © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 50
Bike Frame Bulkhead Fitting Analysis COB-based Analysis Template (CBAM) - Constraint Schematic © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 51
Bike Frame Bulkhead Fitting Analysis COB-based Analysis Template (CBAM) - in Xai. Tools F CAD ocus P oi -CA E In nt of tegr Detailed CAD data atio n from CATIA Library data for materials & fasteners Idealized analysis features in APM Modular generic analysis templates (ABBs) Explicit multi-directional associativity between detailed CAD data & idealized analysis features © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 52
An Introduction to X-Analysis Integration (XAI) Short Course Outline Part 1: Constrained Objects (COBs) Primer – Nomenclature Part 2: Multi-Representation Architecture (MRA) Primer – Analysis Integration Challenges – Overview of COB-based XAI Part 3: Example Applications » Airframe Structural Analysis (Boeing) » Circuit Board Thermomechanical Analysis (Do. D: Pro. AM; JPL/NASA) » Chip Package Thermal Analysis (Shinko) – Summary Part 4: Advanced Topics & Current Research © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 53
Pro. AM Focus Highly Automated Internet-based Analysis Modules World Wide End User AMCOM Feedback, Products Pro. AM Focus Life Cycle Needs Response to RFP, Prime 1 Technical Feedback, Products RFP with Product Data (STEP, IPC, …) © 1993 -2001 GTRC Friona PWB Fabricator SME 2 Atlanta Physical Simulation U-Engineer. com Missile Mfg. Rockhill PWB Fabricator SME 1 Internet-based Engineering Service Bureau … Engineering Information Systems Lab eislab. gatech. edu Idealized Product Data Self-Serve Results Tempe PWB Fabricator SME n 54
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 Stackup 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 1 D, Deformation 2 D & Fatigue** Materials DB ‡ AP 210 DIS WD 1. 7 © 1993 -2001 GTRC * = Item not yet available in toolkit (all others have working examples) ** = Item available via U-Engineer. com Engineering Information Systems Lab eislab. gatech. edu 55
R • • • STEP AP 210 Models Requirements Models • Design • Constraints • Interface • Allocation Functional Models Functional Unit Interface Declaration Network Listing Simulation Models Signals Component / Part Models • Analysis Support • Package • Material Product • Properties • “White Box”/ “Black Box” • Pin Mapping Assembly Models • User View • Design View • Component Placement • Material product • Complex Assemblies with Multiple Interconnect GD & T Model • Datum Reference Frame • Tolerances • • • Configuration Mgmt Identification Authority Effectivity Control Net Change • • • Interconnect Models User View Design View Bare Board Design Layout templates Layers planar non-planar conductive non-conductive
Pro. AM Technical Team Missile supply chain SME • PWB design & fabrication expertise • Tool usage & feedback Circuit Express Missile system end-users • Supply chain context • Technical oversight AMCOM S 3 Missile supply chain SME • PWB fabrication expertise • Tool usage & feedback © 1993 -2001 GTRC Georgia Tech Atlanta ECRC Electronic commerce resource center • Mgt. , ESB, computing support Engineering Information Systems Lab eislab. gatech. edu Research & development lab • Program management • Technical concepts • Tool implementation 57
Iterative Design & Analysis PWB Stackup Design & Warpage Analysis PWB Stackup Design Tool 1 D Thermal Bending Model (TIGER extensions) 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 © 1993 -2001 GTRC Detailed FEA Check 1 Oz. Cu Engineering Information Systems Lab eislab. gatech. edu 58
PWB Warpage Modules a. k. a. CBAMs: COB-based analysis templates PWB Thermal Bending Model (1 D formula-based CBAM) APM PWB Plane Strain Model (2 D FEA-based CBAM) © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 59
Example SME Usage u Original design: – – u Six layer board Unsymmetrical layup Severe warpage Analysis predicted thermal distortion Alternate design: – Modeled construction variables – Analysis predicted improved distortion u © 1993 -2001 GTRC New capability aided design improvement Engineering Information Systems Lab eislab. gatech. edu 60
U-Engineer. com Self-Serve Engineering Service Bureau Analysis Documentation Ready-to-Use Analysis Modules Lower cost, better quality, fewer delays in supply chain © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 61
Phase 1 Accomplishments u u Conceptual architecture and roadmaps Repository/PDM methodology in Metaphase PWB stackup design tool extensions Next-generation Xai. Tools PWA-B – Web-based mockup illustrating target extended capabilities u u AP 210/STEP-based tool methodology Analysis module methodology & general-purpose tools – Xai. Tools Frame. Work v 0. 5 © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 62
Stackup Detailed Design: Build-Up Type © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 63
Stackup Design: Updated Requirements Status © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 64
An Introduction to X-Analysis Integration (XAI) Short Course Outline Part 1: Constrained Objects (COBs) Primer – Nomenclature Part 2: Multi-Representation Architecture (MRA) Primer – Analysis Integration Challenges – Overview of COB-based XAI Part 3: Example Applications » Airframe Structural Analysis (Boeing) » Circuit Board Thermomechanical Analysis (Do. D, JPL/NASA) » Chip Package Thermal Analysis (Shinko) – Summary Part 4: Advanced Topics & Current Research © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 65
Chip Package Products Shinko Quad Flat Packs (QFPs) Plastic Ball Grid Array (PBGA) Packages © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 66
Flexible High Diversity Design-Analysis Integration Electronic Packaging Examples: Chip Packages/Mounting Shinko Electric Project: Phase 1 (completed 9/00) Design Tools Modular, Reusable Template Libraries Analysis Modules (CBAMs) of Diverse Behavior & Fidelity Prelim/APM Design Tool Xai. Tools Chip. Package Analyzable Product Model PWB DB Materials DB* 3 D Xai. Tools Thermal Stress EBGA, PBGA, QFP ** = Demonstration module © 1993 -2001 GTRC Thermal Resistance Analysis Tools Xai. Tools General Math Chip. Package Mathematica FEA Ansys Basic 3 D** Basic Documentation Automation Engineering Information Systems Lab eislab. gatech. edu Authoring MS Excel 67
Traditional VTMB FEA Model Creation Manually Intensive: 6 -12 hours FEA Model Planning Sketches - EBGA 600 Chip Package © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu VTMB = variable topology multi-body 68
APM Design Tool Preliminary Design of Packages - PBGA Screens © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu APM = analyzable product model 69
Example Chip Package Idealizations (PBGA) Idealization for solder-joint/thermal ball Idealization for thermal via Courtesy of Shinko - see [Koo, 2000] © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 70
COB-based Analysis Template Typical Input Objects for EBGA Thermal Resistance Module COB = constrained object Customized Analysis Module Tool with idealized package cross-section Generic COB Browser with design and analysis objects (attributes and relations) © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 71
COB-based Analysis Template Typical Highly Automated Results Analysis Module Tool COB = constrained object Auto-Created FEA Inputs (for Mesh Model) FEA Temperature Distribution Thermal Resistance vs. Air Flow Velocity © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 72
![VTMB = variable topology multi-body technique [Koo, 2000] Pilot & Initial Production Usage Results](https://present5.com/presentation/9516bc5bf432d17d6a37e4460ffd2e7e/image-73.jpg "VTMB = variable topology multi-body technique [Koo, 2000] Pilot & Initial Production Usage Results")
VTMB = variable topology multi-body technique [Koo, 2000] Pilot & Initial Production Usage Results Product Model-Driven Analysis u u Reduced FEA modeling time > 10: 1 (days/hours minutes) References [1] Shinko 5/00 (in Koo, 2000) Reduced simulation cycle > 75% [2] Shinko evaluation 10/12/00 Enables greater analysis intensity Better designs Leverages XAI / CAD-CAE interoperability techniques – Objects, Internet/web services, ubiquitization methodology, … © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 73
Cost of Associativity Gaps Categories of Gap Costs u Associativity time & labor – Manual maintenance – Little re-use – Lost knowledge u u Inconsistencies Limited analysis usage – Few iterations/part – Limited part coverage u “Wrong” values – Too conservative: Extra costs, inefficiencies – Too loose: Re-work, failures, law suits © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 74
Summary u u Provides methodology for bridging associativity gap Multi-representation architecture (MRA) & constrained objects (COBs): – Address fundamental issues » Explicit CAD-CAE associativity: multi-fidelity, multi-directional, fine-grained – Enable analysis template methodology Flexibility & broad application u Increase quality, reduce costs, decrease time (ex. 75%): » Capture engineering knowledge in a reusable form » Reduce information inconsistencies » Increase analysis intensity & effectiveness © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 75
Towards Greater CAD-CAE Interoperability Target Analogy with Electronics Systems u u Today: Next Steps: - Monolithic software applications; Few interchangeable “parts” - Identify other formal patterns and use cases (natural subsystems / levels of “packaging”) - Define standard architectures and interfaces among subsystems Middleware Generic Geometric Modeling Tools, Math Tools, FEA Tools, Requirements & Function Tools, … Product-Specific Simulation-Based Design Tools APMs CBAMs Extended MRA ABBs SMMs © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu Linkages to Other Life Cycle Models 76
Summary of Tools and Services offered via Georgia Tech Research Corp. http: //eislab. gatech. edu/ u Xai. Tools Frame. Work ™ – 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 automated analysis modules Full-serve consulting u Research, Development, and Consulting – – Analysis integration & optimization – Short courses Product-specific analysis module catalogs Internet/Intranet-based ESB development Knowledge-based engineering & information technology » PDM, STEP, Gen. CAM, XML, UML, Java, CORBA, Internet, … – CAD/CAE/CAM, parametric FEA, thermal & mechanical analysis © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 77
For Further Information. . . u EIS Lab web site: http: //eislab. gatech. edu/ – Publications, project overviews, tools, etc. – See: X-Analysis Integration (XAI) Central http: //eislab. gatech. edu/research/XAI_Central. doc u u 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 © 1993 -2001 GTRC Engineering Information Systems Lab eislab. gatech. edu 78
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