Automated Bolt Connection Generation for CAE Model Assembly

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  • 1. Automated Bolt Connection Generation forCAE Model AssemblyBerk Yavuz Özberk,GETRAG FORD Transmissions GmbH2013 European Altair Technology Conference, Turin, Italy
  • 2. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk2Agenda• Company Profile• Problem Definition• Why Automation of Bolt Creation?• Workflow• Demonstration of Create Bolt Script• Summary
  • 3. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk3GETRAG worldwide(12/2012)24 locations worldwide in Europe, North America and Asia14 individual companiesLargest independent supplier of passenger car transmissions worldwide13.000 employees worldwide
  • 4. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk4GETRAG in figuresSome of our CustomersTurnover (in mill. €):Volumes (in 000 items):
  • 5. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk5Problem DefinitionExampleTransmission: Powershift MPS6Parts: Clutch Case, Gear Box, RollRestrictor, Engine Mount, BearingPlates, DifferentialNumber of Bolts Required for StaticAnalysis: 45Time Required (without errorchecking): 45 x 5 = 225 minutesTime Required to make one modelrun: 450 minutes
  • 6. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk6Why Automation of Bolt Creation ? Save Time- Model Assembly time is significatly shorter. No need to create pre-tensionsurfaces, nodes, boundary conditions and contact surfaces manually Error Free- No assembling failures because of human error Reusability- - If you have the bolt coordinates of the initial design, you can use them forlater design stages or remeshing and assembling of a transmissioncomponent
  • 7. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk7WorkflowCreate Bolt GUIGenerates Hypermeshcommand file(cmf) for theselected bolt typeHypermesh User Button„Load Bolt“Loads the generatedcommand file and setsSTEP DefinitionsHypermesh User Button„Create Bolt“ Creates the bolt with Pretension surface,Tied Contact at Thread andSurface to Surface Contact at Bolt HeadCAE ModelBolts have already been createdfor this Transmission Part ?no yesDo it for all boltsHypermesh User Button„Bolts from Coordinates“Creates all bolts using thecoordinates from previousbolt generation
  • 8. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk8Create Bolt Script GUIPre-Tension ForceAfter Selecting the Bolt Type, thevalues are generated from BoltDatabase TransmissionOrientation
  • 9. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk9Example Clutch Case and Gearbox
  • 10. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk10Demonstration of Bolt Creation
  • 11. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk11Bolt Contact DefinitionThe corresponding Pre-Tension definition andContact Surfaces are automatically createdHead ContactPre-TensionThread Contact(tied)
  • 12. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk12Create Bolt Automatically using PreviousCoordinates
  • 13. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk13Input Data for Creating Bolts Automatically1st to 6th Columns are used for the node coordinates at the bolt head7th Column – Component Names8th Column – Coordinate of Node at the thread surface Hypermesh built-in functions are used to find the correspondingnodes and elements.(getclosestnode, *createmark elems 1 "by node“)
  • 14. © GETRAG FORD Transmissions, March 27th, 2013 M.Sc. Berk Yavuz Özberk14Summary Create Bolt Script saves time in modelling and assembling. One cansave up to 8 hours for single application and design stage.GETRAG has currently ongoing 10 New Transmission Projects withmany different applications and design stages. Reduce potential modeling errors Built-in Hypermesh functions make development easier (like rotation,transformation, getclosestnode ...) Power of command.cmf- Every task in Hypermesh is written into this file- Do changes in GUI and get the corresponding TCL code- Use this TCL Code for script development
  • 15. Thank you for your attention !15ManualShiftPowerShiftHybridDrive ExtendedDrive