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Simulation-driven design: Motives, Means, and Opportunities
KTH, Superseded Departments, Machine Design.
1999 (English)Doctoral thesis, comprehensive summary (Other scientific)
Abstract [en]

Efficiency and innovative problem solving are contradictory requirements for productdevelopment (PD), and both requirements must be satisfied in companies that strive to remainor to become competitive. Efficiency is strongly related to ”doing things right”, whereasinnovative problem solving and creativity is focused on ”doing the right things”.Engineering design, which is a sub-process within PD, can be viewed as problem solving or adecision-making process. New technologies in computer science and new software tools openthe way to new approaches for the solution of mechanical problems. Product datamanagement (PDM) technology and tools can enable concurrent engineering (CE) bymanaging the formal product data, the relations between the individual data objects, and theirrelation to the PD process. Many engineering activities deal with the relation betweenbehavior and shape. Modern CAD systems are highly productive tools for conceptembodiment and detailing. The finite element (FE) method is a general tool used to study thephysical behavior of objects with arbitrary shapes. Since a modern CAD technology enablesdesign modification and change, it can support the innovative dimension of engineering aswell as the verification of physical properties and behavior. Concepts and detailed solutionshave traditionally been evaluated and verified with physical testing. Numerical modeling andsimulation is in many cases a far more time efficient method than testing to verify theproperties of an artifact. Numerical modeling can also support the innovative dimension ofproblem solving by enabling parameter studies and observations of real and syntheticbehavior. Simulation-driven design is defined as a design process where decisions related tothe behavior and performance of the artifact are significantly supported by computer-basedproduct modeling and simulation.A framework for product modeling, that is based on a modern CAD system with fullyintegrated FE modeling and simulation functionality provides the engineer with tools capableof supporting a number of engineering steps in all life-cycle phases of a product. Such aconceptual framework, that is based on a moderately coupled approach to integratecommercial PDM, CAD, and FE software, is presented. An object model and a supportingmodular modeling methodology are also presented. Two industrial cases are used to illustratethe possibilities and some of the opportunities given by simulation-driven design with thepresented methodology and framework.

Place, publisher, year, edition, pages
Stockholm: KTH , 1999. , vi, 42 p.
Series
Trita-MMK, ISSN 1400-1179 ; 1999:26
Keyword [en]
CAD, CAE, FE method, Metamodel, Object model, PDM, Physical behavior, System
Identifiers
URN: urn:nbn:se:kth:diva-2875ISBN: 99-3055738-5 OAI: oai:DiVA.org:kth-2875DiVA: diva2:8603
Public defence
1999-12-01, 00:00
Note
QC 20100810Available from: 2000-01-01 Created: 2000-01-01 Last updated: 2010-08-11Bibliographically approved
List of papers
1. A Survey of PDM Implementation Projects In Selected Swedish Industries
Open this publication in new window or tab >>A Survey of PDM Implementation Projects In Selected Swedish Industries
1996 (English)In: ASME Design Engineering Technical Conference, August 18-22 1996, Irvine, California, 1996Conference paper, Published paper (Other academic)
Abstract [en]

Technology and engineering might be characterized as becoming more knowledge-intensive. A huge amount of data is used and produced in most product development projects. Increasing competition requires shorter reaction time to customer demands and a higher level of innovation. Concurrent Engineering (CE) is a strategic response to competition. It has proved to be a powerful approach to integrating engineering activities in product development. However, integration and parallel activities, that  is the essence of CE, add complexity to the process. Consequently, information management is recognized as a major component in many CE models. Product Data Management (PDM) systems are a class of computer based systems that address the need to manage product related information that is mainly formal and computer interpretable. PDM systems are sometimes referred to as CE enablers. Results from a recent survey of PDM implementation projects in six Swedish industrial companies, with products ranging from telecommunications systems to trucks and medical equipment, indicate the importance of also utilizing the Concurrent Engineering (CE) approach in the process of implementing an enterprise-wide PDM solution.

Identifiers
urn:nbn:se:kth:diva-19446 (URN)
Note
QC 20100810Available from: 2010-08-10 Created: 2010-08-10 Last updated: 2010-08-11Bibliographically approved
2. Requirements on a FEA Assisted Engineering Process
Open this publication in new window or tab >>Requirements on a FEA Assisted Engineering Process
1997 (English)In: NAFEMSWorld Congress 1997, April 9-11, Stuttgart, Germany, 1997Conference paper, Published paper (Other academic)
Abstract [en]

There is a strong international trend towards collaborative engineering and reduction of organizational barriers in product development (PD). The organizational changes combined with the new and evolving CAD/CAE technology strongly enable finite element analysis (FEA) to efficiently assist the engineering process. Collaborative engineering benefit from a rich and flexible modeling environment that allows conceptual finite element (FE) models of product behavior to be created, detailed and expanded throughout the products life-cycle. Requirements on a product modeling methodology with associative models of physical behavior, i.e. a meta-model approach, is presented. The methodology that is based on commercial state-of-the-art CAD/CAE software is exemplified with two case studies

Identifiers
urn:nbn:se:kth:diva-19448 (URN)
Note
QC 20100810Available from: 2010-08-10 Created: 2010-08-10 Last updated: 2010-08-11Bibliographically approved
3. Behavior modeling in mechanical engineering: A modular approach
Open this publication in new window or tab >>Behavior modeling in mechanical engineering: A modular approach
1998 (English)In: Engineering with Computers, ISSN 0177-0667, E-ISSN 1435-5663, Vol. 14, no 3, 185-196 p.Article in journal (Refereed) Published
Abstract [en]

Many engineering activities are confronted with the relation between shape and behavior. Modern 'state-of-the-art' CAD systems can support a dynamic design process with flexible and umambiguous geometric modeling of artifacts. The Finite Element (FE) method is a general method to model and simulate physical behavior CAD and FE integration enables numerical prediction of the physical behavior of artifacts. To deal with the complexity of modern products and the dynamic character of the design process, the integration must be addressed from both a systems and a process point of view. The models must thus be flexible, scalable, and reusable. A modularized modeling approach based on four stages is proposed, and exemplified with behavior modeling of a turn-key grinding machine.

Keyword
CAD, feature, finite element modeling, order-based design, physical behavior
Identifiers
urn:nbn:se:kth:diva-19443 (URN)000076499500001 ()
Note
QC 20100810Available from: 2010-08-10 Created: 2010-08-10 Last updated: 2017-12-12Bibliographically approved
4. Attachment of Mating Faces: an Interrelational Feature Approach
Open this publication in new window or tab >>Attachment of Mating Faces: an Interrelational Feature Approach
1998 (English)In: 8th Int. ANSYS Conference, August 17-19 1998, Pittsburgh, PA, USA, 1998Conference paper, Published paper (Other academic)
Abstract [en]

Many engineering systems are characterized by a physical behavior that to a large extent is determined by complex interactions between subsystems. FE modeling and simulation of the physical behavior of complex systems is enabled by methods and technologies that allow subsystems to be modeled independently of other subsystems, and where systems models can be aggregated from a set of submodels, that that may be defined at various levels of abstraction, i.e. detailed, coarse, and condensed superelements. A method to attach pairs of nodally incompatible submodels is presented in this paper. A major benefit of the approach is that FE submodels and superelements are treated with the same formalism. The essence of the approach starts by first establishing a master-slave relation between sets of nodes on mating faces, followed by a Delaunay triangulation of the selected master node set, and finally a step where each slave nodal degree of freedom (DOF) is mapped to the DOFs of the three most appropriate master nodes. The method is robust and it has been developed as a support tool for FE modeling and simulation of multiphysics behavior of complex systems. It has been implemented in the general purpose FE software ANSYS as a macro library.

Identifiers
urn:nbn:se:kth:diva-19451 (URN)
Note
QC 20100810Available from: 2010-08-10 Created: 2010-08-10 Last updated: 2010-08-11Bibliographically approved
5. Application of a constitutive model for micro-slip in finite element analysis
Open this publication in new window or tab >>Application of a constitutive model for micro-slip in finite element analysis
1999 (English)In: Computer Methods in Applied Mechanics and Engineering, ISSN 0045-7825, E-ISSN 1879-2138, Vol. 170, no 1-2, 65-77 p.Article in journal (Refereed) Published
Abstract [en]

Micro-slip is a phenomenon that occurs between contacting surfaces when a frictional load, less than that necessary to produce macro-slip, is applied to the contacting surfaces. Micro-slip is an elastoplastic physical behavior that is important for fretting fatigue, control engineering, the damping and stiffness of connections and joints. A micro-slip friction lau, suitable for finite element (FE) analysis of systems of interacting bodies where micro-slip effects are of importance has been implemented in a commercial FE software. Physical arguments for a micro-slip friction law are presented. The friction law is based on asperity deformation and is capable of simulating oscillating movements. An important feature of the frictional model is that it decouples the parameters that are related to shape, material and surface topography, respectively. Two examples are chosen to illustrate the applicability of the model. Significant differences in friction force distribution between an elastic Coulomb friction law and the micro-slip friction law are detected on local level as well as on global level.

Keyword
CLASSICAL FRICTION LAWS; CONTACT PROBLEMS; ALGORITHM; ELASTICITY
Identifiers
urn:nbn:se:kth:diva-19442 (URN)000079092700005 ()
Note
QC 20100810Available from: 2010-08-10 Created: 2010-08-10 Last updated: 2017-12-12Bibliographically approved
6. A Contact Model for Rough Surfaces
Open this publication in new window or tab >>A Contact Model for Rough Surfaces
1999 (English)In: NAFEMS World Congress, April 25-28 1999, Newport, Rhode Island,USA, 1999Conference paper, Published paper (Other academic)
Abstract [en]

Engineering surfaces can be characterized as more or less randomly rough. Contact between engineering surfaces is thus discontinuous and the real area of contact is a small fraction of the nominal contact area. The stiffness of a rough surface layer will thus have an influence on the contact state as well as on the behavior of the surrounding system. A contact model that takes the properties of engineering surfaces into account has been developed and implemented in a commercial FE software. Results obtained with the model have been compared and verified with results from an independent numerical method. Results have shown that the height distribution of the topography has a significant influence on the contact stiffness but that the curvature of the roughness is of minor importance. The contact model that was developed for determining the apparent contact area and the distribution of the mean contact pressure could thus be based on a limited set of height parameters that describe the surface topography. By operating on the calculated apparent pressure distribution with a transformation function that is based on both height and curvature parameters, the real contact area can be estimated in a post processing step.

 

Identifiers
urn:nbn:se:kth:diva-19452 (URN)
Note
QC 20100810Available from: 2010-08-10 Created: 2010-08-10 Last updated: 2010-08-11Bibliographically approved
7. A Methodology and a Framework for FE Modeling of Complex Systems
Open this publication in new window or tab >>A Methodology and a Framework for FE Modeling of Complex Systems
1999 (English)In: NAFEMS World Congress, Rhode Island, USA, April 25-28, 1999, 1999Conference paper, Published paper (Other academic)
Abstract [en]

Integration of CAD and CAE technology enables engineers to explore design alternatives andto ensure product quality before the first prototypes are manufactured. It also helps to clarifyproblems that are identified in the use phase for a product. Present commercial CAD and CAEsoftware supports an associativity on component model level. Engineers are usually hinderedin their efforts to simulate the physical behavior of complex systems of components. Thispaper describes a framework and a modeling methodology, with the scope to enable numericalmodeling, simulation and analysis of the physical behavior of complex systems. Theframework, which is based on commercial CAD, CAE and PDM software, includes ametamodel, which can be characterized as ISO STEP aware but not STEP compliant. Thepresented approach is exemplified with an industrial case.

Identifiers
urn:nbn:se:kth:diva-19453 (URN)
Note
QC 20100810Available from: 2010-08-10 Created: 2010-08-10 Last updated: 2010-08-11Bibliographically approved
8. Simulation of brake block induced corrugation on railway wheels
Open this publication in new window or tab >>Simulation of brake block induced corrugation on railway wheels
1998 (English)In: 8th Int. ANSYS Conference, August 17-19, 1998, Pittsburgh, PA, USA, 1998Conference paper, Published paper (Other academic)
Abstract [en]

Railway wheels that are equipped with cast-iron brake blocksgenerate significantly more rolling noise than wheels with othertypes of braking devices or block materials. The roughness of thetreads on cast-iron block-braked wheels has typically a peak at awavelength around 6 cm. The complex interaction between quasistaticand dynamic mechanical behavior and thermal, chemical.

Identifiers
urn:nbn:se:kth:diva-19454 (URN)
Note
QC 20100810Available from: 2010-08-10 Created: 2010-08-10 Last updated: 2010-08-11Bibliographically approved
9. Finite Element Modeling and Optimization of a Robot Boomer
Open this publication in new window or tab >>Finite Element Modeling and Optimization of a Robot Boomer
1999 (English)Report (Other academic)
Abstract [en]

In a complex system, there are several sources of physical uncertainty, as well as there are many unintended interactions between the sub-systems. To predict the physical behavior of such a system, there is a need to treat the uncertainties in the physical quantities as well as there is a strong need for scaleable and reusable models that are easy to adapt and to modify. The essence of the MOSAIC approach to behavior modeling of complex systems is to support behavior analysis and simulation in an iterative and thus complex engineering process, by using encapsulated sub-models of components and of their interfaces. Various modeling and simulation aspects of an Atlas Copco Robot Boomer are presented in this report. The rig, which is an Atlas Copco product that is used for tunneling applications, is a complex system with long and slender mechanical parts, hydraulic actuators, sensors and a control system. The system is highly stressed during normal operations, and there are increasing customer demands for performance, with precision and speed as crucial parameters. Due to the modular structure of the product, it is advantageous to configure also the numerical models of the physical behavior of the design system in a modular way. An existing Ansys based FE model of a boomer has been reorganized, modularized, and adapted to allow for a wide range of simulations and analyses of the physical behavior. Methods and techniques to configure and to connect FE submodels, and techniques to utilize optimization techniques available in the FE software Ansys are elaborated on. Movements of the boomer to a target position is accomplished by changing the state of the actuator elements. Positioning errors due to dead weight and preloading and the sensitivity to some selected feature properties are also studied. It is shown that the Ansys optimization routines can be used to find a specified target position by minimizing the positioning error for the boomer. Modal extraction is used as a tool to study the stability limits for the hydraulic cylinders. A component within the system is studied with an ESO based Ansys macro routine that has been developed as a general tool for topological optimization.

Place, publisher, year, edition, pages
Stockholm: KTH, 1999
Series
Trita-MMK, ISSN 1400-1179 ; 1999:21
Identifiers
urn:nbn:se:kth:diva-24045 (URN)
Note
QC 20100811Available from: 2010-08-11 Created: 2010-08-11 Last updated: 2010-08-11Bibliographically approved

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CiteExportLink to record
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Citation style
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  • ieee
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  • en-US
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  • nn-NO
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  • Other locale
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Output format
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