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PLM Connection: MAYA - Breaking CAD CAE Barriers
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PLM Connection: MAYA - Breaking CAD CAE Barriers

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Remi Duquette of MAYA HTT presented at PLM Connection Europe on breaking the CAD CAE barriers in NX. See www.siemens.com/plm/blog for related blog post and more from this event.

Remi Duquette of MAYA HTT presented at PLM Connection Europe on breaking the CAD CAE barriers in NX. See www.siemens.com/plm/blog for related blog post and more from this event.

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PLM Connection: MAYA - Breaking CAD CAE Barriers PLM Connection: MAYA - Breaking CAD CAE Barriers Presentation Transcript

  • Breaking the Barriers between NX CAD and NX CAE
    Case Study Example: Intake Manifold
    Mass Flow Rate Simulation with NX Flow
    By Remi Duquette
    www.mayahtt.com
  • Engineering Services focused on CAE
    • Thermal and structural analysis
    • Custom software development
    • Software implementation and support
    • Engineering process improvement
    • CAE process automation
    Broad Expertise in
    • Thermal, heat transfer
    • CFD/flow analysis
    • Electronics packaging
    • Structural design, analysis
    • Structural dynamics
    • Coupled loads analysis
    • Laminates, composites
    • Test support and FE Model Correlation
    Experts with all Siemens PLM CAE products…
    • Teamcenter for Simulation
    • NX Nastran, NX Nastran Adv. Non-linear
    • NX Thermal
    • NX Flow
    • TMG, ESC
    • NX Response Analysis (Shock, Random,…)
    • NX FE Model Correlation
    • NX Durability (Fatigue analysis)
    • NX Motion
    • Velocity
    • FEMAP
    • NX PCB Exchange (Mechatronics)
    • NX PCB Exchange for Zuken (Mechatronics)
    www.mayahtt.com
  • What “were” the barriers
    Stopping you?
    • Lack of time
    • Lack of CAE expertise
    • Heterogeneous software environment (ie the CAE person is using a different software than NX)
    • Average number of CAE-tools to learn and the different types of mechanical analysis to perform is too much
    • Technology for automatic FE model generation for parts and assemblies was not mature
    • Any engineering process change is difficult: a cultural change involving 2 groups collaborating to improve the product requires too much work
  • What does NX CAD/CAE offer
    to remove those barriers?
    • Automated CAE Process allow 2-wks cycle to ½-day turn-around
    • Your CAE colleague will set it up for you (collaboration is key)
    • NX CAD & NX CAE associativity is built-in (a single software environment for design/simulation is key to your success)
    • The NX CAD & NX CAE environment is the same so there is no new tools to learn & your CAE colleague can setup the process
    • NX CAE is a recognized leader in automated meshing for robustness & quality of resulting FEM (including auto-cleanup)
    • Change is going to be difficult…this is human nature, our brains are somewhat hard-wired to resist change. In this case the huge return vs the time invested to change cannot be ignored.
    • Lack of time
    • Lack of CAE expertise
    • Heterogeneous software environment (ie the CAE person is using a different software than NX)
    • Average number of CAE-tools to learn and the different types of mechanical analysis to perform is too much
    • Technology for automatic FE model generation for parts and assemblies was not mature
    • Any engineering process change is difficult: a cultural change involving 2 groups collaborating to improve the product requires too much work
  • Parasolid, JT, CGM, IGES, STEP, DXF, VRML, Catia V4/V5/V6, I-deas, Pro/E,, …
    AutoDesk, Catia, I-deas JT, NX, Pro/E, Solidworks, SolidEdge, …
    Multi-Geometry
    Multi-CAE Results
    Multi- CAE Solvers
    Multi-CAD
    ABAQUS, ANSYS, LS Dyna, MSC Nastran, NX Nastran, I-deas UNV, TMG, NX Flow, NX Thermal, CGNS …
    NX: Working in an
    Open Environment
    CATIA
    NX
    Pro/E
    Inventor
    SolidWorks
  • Case Study: Automotive Intake Manifold
    CFD Analysis… NX Flow with Process Automation
    Same Process, Different Manifold Designs… Over and over again…
  • Integrated Multi-Disciplinary Analysis Manifold Mass Flow Rate Calculations:
    The“old”Process with non-integratedCAE tools…
    PartDesign
    What is the mass flow rate?
    Evaluate
    Export & repair design geometry
    Balance the airflow, (mass flow rate) in an engine manifold
    Create CAE Topology
    Mesh
    Look for information
    Loads
    BCs
    Solve
    Create geometry
    Answer did not arrive in time… Arghh!@#$^$#
    NX
    ICEM CFD
    Gambit
    Ensight
    Fluent
    10 Days Effort
  • Integrated Multi-Disciplinary Analysis Manifold Mass Flow Rate Calculations:
    “New” Process Automation with NX Flow
    Balance the airflow, (mass flow rate) in an engine manifold
    ~ 4 hours
    Evaluate
    Mesh
    Look for information
    Create geometry
    Loads
    BCs
    Solve
    NX Delivers a 10 to 15 times Improvement
    PartDesign
    NX
    NX Advanced FEM + NX Flow
    NX Open Application built in under one day using journal files
  • Integrated Multi-Disciplinary Analysis
    { SHOW & TELL… Twice! }
    This is a live demonstration of same process applied to two very different manifold designs
    Same Process, Different Manifold Designs… Over and over again…
  • Typical CFD Workflow for Mass Flow Rate Analysis
    Intake Manifold CFD : Analysis is done to predict the mass of airflow going through the intake manifold when a fixed pressure is applied at one of the intakes. The analysis is repeated for all the intake branches on the manifold.
    Goal: Mass flow rate must be uniform between each manifold, and maximal.
    Intake Manifold Design
    Geometry idealization
    - Create Fluid Domain from Manifold Body
    - Add “block of air” at each manifold entry points
    Design changes
    Meshing, Problem Setup, Solve
    3 CFD solver runs are used in the solution process to ensure CFD convergence 100% of the time while achieving maximum accuracy:
    Run#1: Incompressible 1st order advection scheme
    Run#2: Compressible 1st order advection scheme
    Run#3: Compressible 2nd order advection
  • Manifold Mass Flow Rate CFD Typical Analysis Workflow…
    • STEP-1 : Start and setup CFD analysis files leveraging pre-existing NX templates
    • STEP-2 : Fluid Volume Creation – leveraging Synchronous Technology
    • STEP-3 : Addition of a plenum chamber upstream of the manifold entry point: This is done to replicate the physical laboratory test setup conditions
    • STEP-4: Meshing
    • STEP-5: Simulation Setup using Best Practices from CFD experts
    • An NX automatic report object is also defined at the exit to extract the mass flow rate for each simulations
  • NX Open : A Common Framework
    • Uniform object model across all language, including KF
    • Includes popular language bindings
    • Journal record for all programming languages, playback for VB.NET, C#
    • Journaling coverage
    • Full automation coverage requires UF wrappers
  • Manifold Mass Flow Rate CFD Typical Analysis Workflow…
  • How to Create the “Manifold CFD Analysis” Process?1- Easy Creation of Custom BlockStyler Dialogs
  • How to Create the “Manifold CFD Analysis” Process?2- Easy Creation of VB.Net code using Journaling
  • How to Create the “Manifold CFD Analysis” Process?3- Copy BlockStyler auto-generated code into VB code from Journaling
  • How to Create the “Manifold CFD Analysis” Process?4- Create Custom User Menu (and Role) for your Process Steps
  • NX Flow Solver Parameter Set-up
    CFD Best Practice in the context of an NX Flow Process Automation
    • Experts do not usually require to go through a stepped approach to convergence with NX Flow. However, in order to automate a CFD process, the procedure proved reliable and accurate 100% of the time and was chosen as the baseline for the solver setup.
    • Three solutions are set up to be solved for each inlet in sequence :
    • Run#1: Incompressible flow, 1st order advection, default time step
    • Run#2: Compressible flow option turned on, 1st order advection, with restart from Run#1 results. For this case, the time step is lowered.
    • Run#3: High speed compressible flow option turned on, 2nd order advection SOU on momentum, with automatic limiters. Restart is done from Run#2 results. The time step is brought back to the default value.
    • The k-e 2-equations turbulence model is used for all scenarios, considering that all the walls are smooth with friction.
    • All these advanced solvers parameters are set by CFD experts within the NX Open framework such that designers need not to be concerned about the solver parameter setup. The CFD experts in your company know about those solver parameters and can set those up easily and have them part of the NX Open automated NX Flow process.
  • NX Flow : Reliable Results
    • For the geometry tested, a 2.2% maximum differenceon expected results was attained which is well within the test results accuracy bounds. The CFD mass flow rate automated process leveraging NX Flow was validated and approved by the CFD expert team. The advanced design team is now using this workflow on all production manifold parts within their vehicle design process.
    • No work was done on changing the default mesh size and solver residual targets, which could help increase accuracy even more.
  • Questions?
    Remi Duquette
    remi.duquette.ext@siemens.com
    remi.duquette@mayahtt.com
    Thank You!
  • October 2009