TEA Pipe. A tool to simulate the behaviour of brake pipes within CATIA V5 P. Morelle, Samtech Deutschland GmbH. P Morelle

Transcription

1 TEA Pipe A tool to simulate the behaviour of brake pipes within CATIA V5 P. Morelle, Samtech Deutschland GmbH Autosim seminar 4 5 May. 2006, Page 1

2 Samtech group, who are we? Autosim seminar 4 5 May. 2006, Page 2

3 SAMTECH Presentation Key Activities Computer Aided Engineering Integrated and associative modelling environment SAMCEF Field and CATIA V5 Calculation of linear and non-linear structures with metallic or composite materials Thermal and thermo-mechanical analyses Random vibration and fatigue Fracture mechanics and damage tolerance Dynamics of rigid or flexible mechanical systems (rotors, wind turbines, machine-tools, transmissions, deployable structures ) Impact and explosion simulation Multi-physics analyses (vibroacoustic, piezoelectricity ) Parametrical analysis, statistical analysis, model updating and multidisciplinary optimisation Autosim seminar 4 5 May. 2006, Page 3

4 Integrated SW Offer in Automotive Industry Autosim seminar 4 5 May. 2006, Page 4

5 Integration Autosim seminar 4 5 May. 2006, Page 5

6 General L C L-L C INTEGRATED in CATIA V5 x L Analyses- Strategy Simple Simulation with predef. parameters Automatic Simulation (Optimisation) Autosim seminar 4 5 May. 2006, Page 6

7 Materials Autosim seminar 4 5 May. 2006, Page 7

8 General What is needed to perform a simulation with TEA-PIPE: - midpoint of pipe connectors - Direction vector of connectors (line) - Manufacturer database with pipe dimensions - Material database - eventually kinematicfile (name.txt) -> open TEA-PIPE menue via icon Autosim seminar 4 5 May. 2006, Page 8

9 Confidence Autosim seminar 4 5 May. 2006, Page 9

10 3. Meassurement RED = simulated pipe; BLUE = Measured point cloud Autosim seminar 4 5 May. 2006, Page 10

11 What makes TEA Pipe? Autosim seminar 4 5 May. 2006, Page 11

12 1. Simple Analyses Kinematik-Definition (Link mit CATIA DMU Kinematics) CATIA-Kinematics can be taken into account All for the simulation of pipes necessary movements of points and faces can be used from CATIA-kinematics. Connectors, supports, surfaces, starr verbunden zu "Moving Points" (intern) positioniert in Bezug auf diese Punkte Autosim seminar 4 5 May. 2006, Page 12

13 1. Simple Analyses Manually definition of the pipe with connectors and length, diameter, thickness and material or values from database Autosim seminar 4 5 May. 2006, Page 13

14 1. Simple Analyses Input data for pipes with stiffners and spirales Autosim seminar 4 5 May. 2006, Page 14

15 1. Simple Analyses Input data for intermediate support It s possible to define up to 3 intermediate supports, Autosim seminar 4 5 May. 2006, Page 15

16 1. Simple Analyses Intermediate support can be used as rigid (clamped) or free eye, the input datas are: point of location, direction vector and distance to contact face, length of the contact face and connection to the kinematics of the intermediate support. CLAMPED NOT CLAMPED Autosim seminar 4 5 May. 2006, Page 16

17 1. Simple Analyses : deformed positions Autosim seminar 4 5 May. 2006, Page 17

18 1. Simple Analyses Collision with surrounding parts can checked Autosim seminar 4 5 May. 2006, Page 18

19 2. Simple Analyses - Postprocessing Postprocessing with classical CATIA-functions Deformed geometry Curvature Autosim seminar 4 5 May. 2006, Page 19

20 2. Postprocessing Result Collisions distance to preselected surface (colour mode) Autosim seminar 4 5 May. 2006, Page 20

21 2. Postprocessing Result Collisions distance to preselected surface (value mode) Autosim seminar 4 5 May. 2006, Page 21

22 3: Pipe Optimization Compute and Retrieve the Optimization Results Autosim seminar 4 5 May. 2006, Page 22

23 What is hidden behind the transparent tool? Autosim seminar 4 5 May. 2006, Page 23

24 Transparent non linear finite element analysis TEA Pipe automatically defines the analysis problem : Meshing (mesh density is predefined) Element type (beams here) Boundary conditions - ex : clamped, non clamped support The user picks a material and a type in the DB CLAMPED NOT CLAMPED Then TEA Pipe starts trying to simulate the mounting of the pipe. Severall scenarii are tested (ex : first I position connector one, then I move connector 2 to the end point, then I turn connector 2 to the right direction). Unstable scenarii are eliminated a stable mounting history defined The following positions from the kinematics are then computed (TEA Pipe moves from one position to the next one) We could do better if the user really defines a movie rather than photos. We could even compute with inertia so to check the pipes in a scenario the car is moving in a fast curve for example. Autosim seminar 4 5 May. 2006, Page 24

25 Transparent gradient based optimisation TEA Pipe automatically defines the optimisation problem : Economy of material (find the shortest pipe satisfying the constraints) Safest design (find the pipe staying as far as possible of dangerous parts) The user defines the design variables (connectors position and/or orientation, pipe length TEA Pipe transparently compute sensitivities TEA Pipe transparently solve the optimisation problem (iterative process) The optimal pipe is proposed to the user as a new object Autosim seminar 4 5 May. 2006, Page 25

26 Thanks for your attention! Autosim seminar 4 5 May. 2006, Page 26

27 2. Postprocessing Vorgehensweise zur Darstellung der Ergebnisse mittels der sogenannten Porcupine-Analyses: ins Product zurückwechseln mittels Doppelklick Insert Analyses / Porcupine Analyses Autosim seminar 4 5 May. 2006, Page 27

28 2. Postprocessing Curvature oder Radius einstellen dann Pipe-Object selektieren mit der Maus über die Fläche zeigt immer den aktuellen Wert an Mausposition an. Autosim seminar 4 5 May. 2006, Page 28

29 2. Postprocessing Darstellung der Schlauchkrümmung (Porcupine-Analyse) Autosim seminar 4 5 May. 2006, Page 29

30 2. Postprocessing Darstellung des Krümmungs-Radiuses (Porcupine-Analyse) Autosim seminar 4 5 May. 2006, Page 30

31 Strategy L C L-L C x L Analyses- Strategy Simple Simulation with predef. parameters Automatic Simulation (Optimisation) Autosim seminar 4 5 May. 2006, Page 31

32 3. Automatic Simulation (Optimisation) Within that simulation, opened with a double click on TEA-Pipe Optimisation Set.1 in the data tree a pipe-optimisation can be done automatically. All parameters from a simple analyses can be used and the programm will find automatically for example the minimum length of a brake pipe with respect to surrounding collision surfaces of other parts. Or the connector-pointpositions and the tangents can be optimised. Autosim seminar 4 5 May. 2006, Page 32

33 3. Automatic Simulation (Optimisation) Input mask for defining parameters and the possible objectives (Length, Torsion, Curvature, collision distance). Autosim seminar 4 5 May. 2006, Page 33

34 3. Automatic Simulation (Optimisation) The first step is to launch an optimisation with the corresponding button. Afterwards pressing the button Solution will show all iterations and reached optimums reached with your chosen restraints, then a last calculation is performed with your chosen results! These will be automatically transfered into the TEA- Pipe mask! 1 2 Autosim seminar 4 5 May. 2006, Page 34

35 3. Automatic Simulation (Optimisation) Parametric study = Several Simple calculations, but automatically performed! Autosim seminar 4 5 May. 2006, Page 35

36 3. Automatic Simulation (Optimisation) ohne Kin. o. Zw.h. ohne Kin. m.zw.fix ohne Kin. m.zw.aug mit Kin. o. Zw.h. mit Kin. m. Zw. fix mit Kin. m.zw.aug o. Opt. o. Koll. o. Opt. m. Koll. ( ) o. Opt. m. Stützschlauch????? m. Opt. m. Koll.??? mit Opt. mit Koll. mit Stütz.??????? Autosim seminar 4 5 May. 2006, Page 36

37 3. Automatic Simulation (Optimisation) Optimierte Simulation mit 12 Positionskinematik (Connector 1-Winkel und Schlauchlänge als Parameter) Autosim seminar 4 5 May. 2006, Page 37

38 General Settings within Tools/Options The following settings can be made within the CATIA-Tools / options menue: Memory and Working directory for temporary files (/tmp). Furthermore the Database for Pipe manufacturer and Materials should be selected. The databases can be edited by administrators (List, Edit), also the minimum pipe radius and the max. torsion. Autosim seminar 4 5 May. 2006, Page 38

39 1. Simple Analyses Aktivate Kinematic-Loadcases within TEA-PIPE: With the button FILE OPEN (Kinematic Description) in the main windows of TEA-PIPE, all the previous stored kinematic-positions can be reloaded. Then the basic- or mounting position has to be selected in Mount Reference Case, this will be the stressless starting position for the simulation. Optional Autosim seminar 4 5 May. 2006, Page 39

40 1. Simple Analyses Procedure: 1. Using Measure-Tools (icon a. Origin point of connector or support (e.g. Connector-Point) b. one FIRST axes (e.g. Connector-axes, pipe direction) c. one SECOND axes (e.g. Connector-line perpendicular to first axes) These meassure values appear in the datatree under Applications/Measure. 2. Renaming the objects in the following way: a. Origin point: <anyname>_o b. FIRST axes: <anyname>_x c. SECOND axes: <anyname>_y Attention: the convention anyname_x and _Y must be used, regardless how the axes are located. The datatree should look like this: Autosim seminar 4 5 May. 2006, Page 40

41 1. Simple Analyses 3. Choice of sensors for recording First of all the simulation window must be opened with the icon and the sensors have to be activated (Activate Sensors check box) In this window you can see the predefined meassure points (Gx, Gy, Gz) and -directions (Dirx, Diry, Dirz). They can be activated by simply clicking on them. Autosim seminar 4 5 May. 2006, Page 41

42 1. Simple Analyses 4. Using Kinematic-Positions Activate in the simulation windows the parameter On request and Number of steps 1. Then move to the prefered position (e.g. FEDERN L 96 = suspension out, this is the so called Mounting position!!!) and all the other positions, also the so called K0-straight-position (which is the CATIA original position, where the car is standing on the wheels witout steering). In the History-window the recorded positions will be listed. 5. Saving in a TEXT-File: With the Button FILE all the listed positions can be stored in a MS-EXCEL- or TEXT-file. TEA-PIPE will use these informations from a TEXT-File (name.txt). Autosim seminar 4 5 May. 2006, Page 42

43 1. Simple Analyses 6. Aktivate Kinematic-Loadcases within TEA-PIPE: With the button FILE OPEN (Kinematic Description) in the main windows of TEA-PIPE, all the previous stored kinematic-positions can be reloaded. Then the basic- or mounting position has to be selected in Mount Reference Case, this will be the stressless starting position for the simulation. Autosim seminar 4 5 May. 2006, Page 43

44 1. Simple Analyses Running a simulation and possible results 1 3 DEFORMED MESH DISTANCES/SURFACES CURVATURE FORCES MOMENTS THICK SURFACE 2 Choose TEA Pipe Solution Set Autosim seminar 4 5 May. 2006, Page 44

45 2. Postprocessing Zuerst mit Deformed Mesh Ergebnisse laden (Link-Manager: Show/Hide) D E FO R M E D M E S H D IS T A N C E S /S U R F A C E S C U R V A T U R E FO R C E S M O M E N T S TH IC K S U R F AC E Dann mittels Thick Surface und Selektion des TEA-Pipe- Parts die Volumenschläuche darin erzeugen. 1 2 Autosim seminar 4 5 May. 2006, Page 45

46 2. Postprocessing Automatische Generierung aller berechneten Schlauchpositionen in aus SMARAGD-kommenden Parts, welche vom Konstrukteur bereits festgelegt wurde. (Namenskonvention wird aktuell noch geändert!) Autosim seminar 4 5 May. 2006, Page 46

47 2. Postprocessing The Distances/Surfaces icon displays coloured bullets on the pipe showing the distance from the pipe centre line to the selected surfaces The Curvature icon access the curvature tensor: o component 1 = torsion (angle / length unit) o component 2 = curvature in local orientation 1 o component 3 = curvature in local orientation 2 Note that global curvature or the curvature radii can be drawn using standard CATIA features The Forces icon access the force vector (N,T 1,T 2 ) (normal force, shear forces for orientations 1 and 2) The Moment icon access the moment vector (M T,M B1,M B2 ) (torsion moment, bending moments for orientations 1 and 2) Autosim seminar 4 5 May. 2006, Page 47