First MIT Conference on Computational Fluid and Structural Mechanics Cambridge, Massachusetts USA June 12-15, 2001 Enhancing Engineering Design and Analysis Interoperability Part 2: A High Diversity Example Russell Peak and Miyako Wilson Georgia Tech Engineering Information Systems Lab eislab.gatech.edu Copyright © 1993-2001 by Georgia Tech Research Corporation, Atlanta, Georgia 30332-0415 USA. All Rights Reserved. Developed by eislab.gatech.edu. Permission to use for non-commercial purposes is hereby granted provided this notice is included.

An Introduction to X-Analysis Integration (XAI) Short Course Outline (Highlights in proceedings) Part 1: Constrained Objects (COBs) Primer Part 2: Multi-Representation Architecture (MRA) Primer Analysis Integration Challenges Overview of COB-based XAI Ubiquitization Methodology Example Applications Airframe Structural Analysis Circuit Board Thermomechanical Analysis Chip Package Thermal Analysis Summary Part 3: Advanced Topics & Current Research Progress towards Multi-Functional Optimization Flap Link: A High Diversity Example

Seamless communication between people, their models, and their tools. Interoperability Seamless communication between people, their models, and their tools. Requires techniques beyond traditional engineering Information models Abstract data types Object-oriented languages (UML, STEP Express, …) Knowledge representation Constraint graphs, rules, … Web/Internet computing Middleware, agents, mobility, … Emerging field: engineering information methods Analogous to CAD and FEA methods

X-Analysis Integration (X=Design, Mfg., etc.) Goal: Improve engineering processes by enhancing interoperability between analysis models and other life cycle models (X) Challenges: Heterogeneous Transformations & Idealizations Diversity: Information, Behaviors, Disciplines, Fidelity, Feature Levels, CAD/CAE Methods & Tools, … Multi-Directional Associativity: DesignAnalysis, Analysis  Analysis One Approach: Multi-Representation Architecture (MRA) using Constrained Objects (COBs) Initial Focus: Capturing & automating analysis knowledge for regular design usage

X-Analysis Integration Techniques a. Multi-Representation Architecture (MRA) b. Explicit Design-Analysis Associativity c. Analysis Module Creation Methodology

“XAI Panorama” Flexible High Diversity Design-Analysis Integration Benchmark/Tutorial Example: Flap Link (Structural Analysis)

Multi-Representation Architecture for Design-Analysis Integration

Analysis Building Blocks (ABBs) Object representation of product-independent analytical engineering concepts Analysis Primitives Analysis Systems - Primitive building blocks - Containers of ABB "assemblies" Material Models Continua Specialized - Predefined templates s e s e De N Beam x y q(x) Beam Distributed Load Rigid Support Linear- Bilinear Low Cycle Elastic Plastic Fatigue Plane Strain Body Plate Geometry Interconnections Cantilever Beam System Rigid body 1 body 2 Support No-Slip Discrete Elements Analysis Variables General - User-defined systems q(x) Temperature, T Stress, s Mass Spring Damper Distributed Load Strain, e

COB-based Libraries of Analysis Building Blocks (ABBs) Continuum ABBs Extensional Rod Material Model ABB 1D Linear Elastic Model modular re-usage Torsional Rod

Extensional Rod Constraint Graph 1D Linear Elastic Model (COB re-usage)

Multi-Representation Architecture for Design-Analysis Integration

Analyzable Product Models (APMs) Provide advanced access to design data needed by diverse analyses. Design Applications Analysis Applications Add reusable multifidelity idealizations Combine information Solid Modeler FEA-Based Analysis ... Materials Database Formula- Based Analysis Fasteners Database Analyzable Product Model (APM) Support multidirectionality

Flap Link Geometric Model (with idealizations) 28b

Extended Constraint Graph Flap Linkage Example Manufacturable Product Model (MPM) = Design Description Extended Constraint Graph Product Attribute Ri Product Relation COB Structure (COS)

Flap Linkage Example Analyzable Product Model (APM) = MPM Subset + Idealizations Extended Constraint Graph flap_link critical_section critical_simple t2f wf tw hw t1f area effective_length critical_detailed stress_strain_model linear_elastic E n cte tf sleeve_1 b h t sleeve_2 shaft rib_1 material rib_2 w r x name t2f wf tw t1f cross_section R 8 9 10 6 R7 12 11 1 2 3 4 5 R 3 2 1 effective_length, Leff == inter_axis_length - (sleeve1.hole.cross_section.radius + sleeve2.hole.cross_section.radius) Product Attribute Idealized Attribute Ri Idealization Relation Product Relation Partial COB Structure (COS)

Concurrent Multi-Fidelity Cross-Section Representations MULTI_LEVEL_COB cross_section; design : filleted_tapered_I_section; tapered : tapered_I_section; basic : basic_I_section; RELATIONS PRODUCT_IDEALIZATION_RELATIONS pir8 : "<basic.total_height> == <design.total_height>"; pir9 : "<basic.flange_width> == <design.flange_width>"; pir10 : "<basic.flange_thickness> == <design.flange_base_thickness>"; pir11 : "<basic.web_thickness> == <design.web_thickness>"; pir12 : "<tapered.total_height> == <design.total_height>"; pir13 : "<tapered.flange_width> == <design.flange_width>"; pir14 : "<tapered.flange_base_thickness> == <design.flange_base_thickness>"; pir15 : "<tapered.flange_taper_thickness> == <design.flange_taper_thickness>"; pir16 : "<tapered.flange_taper_angle> == <design.flange_taper_angle>"; pir17 : "<tapered.web_thickness> == <design.web_thickness>"; END_MULTI_LEVEL_COB; Detailed Design Cross-Section Idealized Cross-Sections Associativity Relations between Cross-Section Fidelities

Flap Link APM Implementation in CATIA v5 Design-Idealization Relation Design Model Idealized Model

Multi-Representation Architecture for Design-Analysis Integration

COB-based Constraint Schematic for Multi-Fidelity CAD-CAE Interoperability Flap Link Benchmark Example

Tutorial Example: Flap Link Analysis Template (CBAM) Flap Link Analysis Documentation (1a) Analysis Template: Flap Link Extensional Model APM ABB CBAM SMM (2) Torsion Analysis (1) Extension Analysis a. 1D Extensional Rod * Boundary condition objects & pullable views are WIP concepts* Solution Tool Interaction Boundary Condition Objects (links to other analyses)* CAD-CAE Associativity (idealization usage) Material Models Pullable Views* Geometry 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 in2 E= 30e6 psi allowable = 18000 psi 4. Analysis Calculations: 5. Conclusion: 1.025 b. 2D Plane Stress FEA ...

Test Case Flap Linkage: Analysis Template Reuse of APM Linkage Extensional Model (CBAM) material effective length, L eff deformation model linear elastic model o Extensional Rod (isothermal) F D s A e E x 2 1 youngs modulus, cross section area, al1 al3 al2 linkage mode: shaft tension condition reaction allowable stress t s1 Sleeve 1 s2 d Sleeve 2 Shaft q stress mos model Margin of Safety (> case) allowable actual MS Flap link (APM) reusable idealizations

Test Case Flap Linkage: Analysis Template Reuse of ABBs Linkage Extensional Model (CBAM) material effective length, L eff deformation model linear elastic model o Extensional Rod (isothermal) F D s A e E x 2 1 youngs modulus, cross section area, al1 al3 al2 linkage mode: shaft tension condition reaction allowable stress t s1 Sleeve 1 s2 d Sleeve 2 Shaft q stress mos model Margin of Safety (> case) allowable actual MS Extensional Rod (generic ABB) This slide show where “Extensional Rod ABB” is reused in the CBAM modular reusage

Flap Linkage Extensional Model: Lexical COB Structure COB link_extensional_model SUBTYPE_OF link_analysis_model; DESCRIPTION Represents 1D formula-based extensional model.; ANALYSIS_CONTEXT PART_FEATURE link : flap_link BOUNDARY_CONDITION_OBJECTS associated_condition : condition; MODE tension; OBJECTIVES stress_mos_model : margin_of_safety_model; ANALYSIS_SUBSYSTEMS deformation_model : extensional_rod_isothermal; RELATIONS PART_FEATURE_ASSOCIATIVITIES al1 : "<deformation_model.undeformed_length> == <link.effective_length>"; al2 : "<deformation_model.area> == <link.shaft.critical_cross_section.basic.area>"; al3 : "<deformation_model.material_model.youngs_modulus> == <link.material.stress_strain_model.linear_elastic.youngs_modulus>"; al4 : "<deformation_model.material_model.name> == <link.material.name>"; BOUNDARY_CONDITION_ASSOCIATIVITIES al5 : "<deformation_model.force> == <associated_condition.reaction>"; OBJECTIVE_ASSOCIATIVITIES al6 : "<stress_mos_model.allowable> == <link.material.yield_stress>"; al7 : "<stress_mos_model.determined> == <deformation_model.material_model.stress>"; END_COB; Desired categorization of attributes is shown above (as manually inserted) to support pullable views. Categorization capabilities is a planned XaiTools extension.

Flap Linkage Extensional Model Example COB Instance Flap Link Analysis Documentation Constraint Schematic Instance (2) Torsion Analysis (1) Extension Analysis a. 1D 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 in2 E= 30e6 psi allowable = 18000 psi 4. Analysis Calculations: 5. Conclusion: 1.025 b. 2D Plane Stress FEA ...

Flap Link Extensional Model COB-based Analysis Template (CBAM) - in XaiTools Focus Point of CAD-CAE Integration Library data for materials Detailed CAD data from CATIA Idealized analysis features in APM Modular generic analysis templates (ABBs) Explicit multi-directional associativity between design & analysis

Flap Linkage Instance with Multi-Directional I/O States material effective length, L eff deformation model linear elastic model o Extensional Rod (isothermal) F D s A e E x 2 1 youngs modulus, shaft critical_cross _section al1 al3 al2 linkage mode: shaft tension condition reaction allowable stress stress mos model Margin of Safety (> case) allowable actual MS description area, basic example 1, state 1 steel 10000 lbs flaps mid position 1.125 in 18000 psi 30e6 psi 1.025 5.0 in 8888 1.43e-3 in Flap Link #3 Design Verification - Input: design details - Output: i) idealized design parameters ii) physical response criteria material effective length, L eff deformation model linear elastic model o Extensional Rod (isothermal) F D s A e E x 2 1 youngs modulus, shaft critical_cross _section al1 al3 al2 linkage mode: shaft tension condition reaction allowable stress stress mos model Margin of Safety (> case) allowable actual MS description area, basic X 3.00e-3 in 1.125 in 5.0 in Flap Link #3 0.0 steel 10000 lbs flaps mid position 18000psi example 1, state 3 30e6 psi 18000 psi 0.555 in2 Design Synthesis - Input: desired physical response criteria - Output: i) idealized design parameters (e.g., for sizing), or ii) detailed design

COB-based Constraint Schematic for Multi-Fidelity CAD-CAE Interoperability Flap Link Benchmark Example

FEA-based Analysis Subsystem Used in Linkage Plane Stress Model (2D Analysis Problem) Higher fidelity version vs. Linkage Extensional Model ABBSMM SMM Template

SMM with Parameterized FEA Model Flap Link Plane Stress Model Preprocessor Model Figure ANSYS Prep7 Template @EX1@ = Parameters populated by context ABB /prep7 ! element type et,1,plane42 ! material properties mp,ex,1,@EX@ ! elastic modulus mp,nuxy,1,@NIUX@ ! Poissons ratio ! geometric parameters L = @L@ ! length ts1 = @TS1@ ! thickness of sleeve1 rs1 = @RS1@ ! radius of sleeve1 (rs1<rs2) tf = @TF@ ! thickness of shaft flange ... ! key points k,1,0,0 k,2,0,rs1+ts1 k,3,-(rs1+ts1)*sin(phi),(rs1+ts1)*cos(phi) ! lines LARC,3,2,1,rs1+ts1, LARC,7,3,1,rs1+ts1, ! areas FLST,2,4,4 AL,P51X

COB-based Constraint Schematic for Multi-Fidelity CAD-CAE Interoperability Flap Link Benchmark Example

Flap Linkage Torsional Model Diverse Mode (Behavior) vs. Linkage Extensional Model

An Introduction to X-Analysis Integration (XAI) Short Course Outline (Highlights in proceedings) Part 1: Constrained Objects (COBs) Primer Part 2: Multi-Representation Architecture (MRA) Primer Analysis Integration Challenges Overview of COB-based XAI Ubiquitization Methodology Example Applications Airframe Structural Analysis Circuit Board Thermomechanical Analysis Chip Package Thermal Analysis Summary Part 3: Advanced Topics & Current Research Progress towards Multi-Functional Optimization Flap Link: A High Diversity Example

Flexible High Diversity Design-Analysis Integration Phase 1 Airframe Examples: “Bike Frame” / Flap Support Inboard Beam Design Tools Modular, Reusable Template Libraries Analysis Modules (CBAMs) of Diverse Feature:Mode, & Fidelity MCAD Tools CATIA XaiTools Analysis Tools 1.5D General Math Mathematica In-House Codes Lug: Axial/Oblique; Ultimate/Shear Image API (CATGEO) Analyzable Product Model XaiTools 1.5D Fitting: Bending/Shear Materials DB FEA Elfini* MATDB-like 3D Assembly: Ultimate/ FailSafe/Fatigue* Fasteners DB FASTDB-like * = Item not yet available in toolkit (all others have working examples)

Bike Frame Bulkhead Fitting Analysis COB-based Analysis Template (CBAM) - Constraint Schematic

Lug Template Applied to Bike Frame Focus Point of CAD-CAE Integration *WIP items Solution Tool Interaction Boundary Condition Objects (links to other analyses)* CAD-CAE Associativity (idealization usage) Material Models Pullable Views* Geometry APM ABB CBAM SMM

ProAM Design-Analysis Integration Electronic Packaging Examples: PWA/B Design Tools Modular, Reusable Template Libraries Analysis Modules (CBAMs) of Diverse Mode & Fidelity ECAD Tools Mentor Graphics, Accel* Analysis Tools XaiTools PWA-B General Math Mathematica STEP AP210‡ GenCAM**, PDIF* Solder Joint Deformation* 1D, 2D, 3D FEA Ansys PWB Stackup Tool XaiTools PWA-B Analyzable Product Model PWB Warpage XaiTools PWA-B 1D, 2D Laminates DB Materials DB PTH Deformation & Fatigue** 1D, 2D ‡ AP210 DIS WD1.7 * = Item not yet available in toolkit (all others have working examples) ** = Item available via U-Engineer.com

PWB Warpage Modules a.k.a. CBAMs: COB-based analysis templates Pro AM PWB Thermal Bending Model (1D formula-based) PWB Plane Strain Model (2D formula-based)

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 Analysis Tools XaiTools ChipPackage XaiTools ChipPackage General Math Mathematica FEA Ansys Thermal Resistance Analyzable Product Model 3D PWB DB XaiTools Materials DB* Thermal Stress EBGA, PBGA, QFP Basic 3D** Basic Documentation Automation Authoring MS Excel ** = Demonstration module

An Introduction to X-Analysis Integration (XAI) Short Course Outline (Highlights in proceedings) Part 1: Constrained Objects (COBs) Primer Part 2: Multi-Representation Architecture (MRA) Primer Analysis Integration Challenges Overview of COB-based XAI Ubiquitization Methodology Example Applications Airframe Structural Analysis Circuit Board Thermomechanical Analysis Chip Package Thermal Analysis Summary Part 3: Advanced Topics & Current Research Progress towards Multi-Functional Optimization Flap Link: A High Diversity Example

COB-based Constraint Schematic for Multi-Fidelity CAD-CAE Interoperability Flap Link Benchmark Example

Diversity Demonstrated in Test Cases

Multi-Representation Architecture (MRA) Summary Provides formal analysis integration methodology Similar to “software design patterns” for CAD-CAE domain Identifies patterns between CAD and CAE (identifies major types of objects) Captures explicit associativity: design-to-many analyses Distinctive CAD-CAE associativity needs Multi-fidelity, multi-directional capabilities

COB-based Analysis Integration Business Benefits COB end user : Designer (uses instances & applications) Automation  Time savings & consistency More analysis  Improved designs COB creator : Analyst (creates models with COB definition language) Modularity & reusability  Faster, consistent modeling Semantic richness  Increased understanding Knowledge capture  Enhanced corporate memory COB application developer: Programmer (uses COB API to create COB-based custom tools) Modularity & reusability  Faster, consistent application development