Robust Design: The Future of Engineering Analysis in Design Gene Allen and Brett Malone

Future of Engineering Analysis COMPUTATION IS A COMMODITY GIVEN: IMPROVING COMPUTATIONAL CAPABILITIES BETTER COMMUNICATIONS CAPABILITIES HIGHER CUTOMER EXPECTATIONS HOW DO YOU DO BETTER ENGINEERING? IS PRODUCT UNDER-ENGINEERED? OVER-ENGINEERED?

Future of Engineering Analysis OBJECTIVE – DESIGN A ROBUST PRODUCT MINIMIZE THE IMPACT VARIABILITY IN DESIGN PARAMETERS HAS ON PRODUCT PERFORMANCE ATTRIBUTES: Reduced performance sensitivity to product and use variability Performance repeatability Designed-in product reliability, durability and operability Safety even under malfunctions

INTEGRATED CALCULATION OF Robust Design Variability Management Attacks Fundamental Causes of Failure INTEGRATED CALCULATION OF Predicted to occur Capability MANUFACTURING • RISK • RELIABILITY • ROBUSTNESS • LIFE Frequency Performance Parameter Assembly Models HARDWARE ASSEMBLY AND MATERIALS CHARACTERIZATION HARDWARE ENVIRONMENT CHARACTERIZATION Risk Measure Process Models LIFE CYCLE LOADS, TEMPS, ETC OPERATIONS QUALITY ASSURANCE MATERIALS Probability of detection (e.g., flaws) Loads . . . . . . . Alt Strain . ... . . . . . . . . . . . . . . . . . . .. . . . ... . ... . . Cycles Material Models Inspection Models Historical data and models Operating conditions

ROBUST DESIGN Future of Engineering Analysis PROVIDES ENGINEERS THE ABILITY TO: Anticipate and Prevent Design Problems Improve product and process Quality Reduce time to market and number of prototypes REPLACES TRIAL and ERROR WITH DESIGN DISCIPLINES Provides a structured method for engineering decision making.

Future of Engineering Analysis HOW DO YOU DO BETTER ENGINEERING TO GET A ROBUST DESIGN? FOLLOW METHODOLOGICAL ENGINEERING PROCESSES that provide: COHERENT DESIGN EXPLORATION QUICK RESULTS EASY TO USE

Future of Engineering Analysis PROCESS: CAPTURE A DESIGN ANALYSIS PROCESS RUN HUNDREDS OF INSTANCES OF THAT PROCESS FOLLOW COHERENT METHODS FOR EXPLORING DESIGN OPTIONS DO QUICKLY WITH COMPUTE CAPABILITIES AVAILABLE INTRANET NOW INTERNET TOMORROW

Future of Engineering Analysis DESIGN ANALYSIS PROCESS MODEL (MATH MODEL) A NETWORK OF ONE OR MORE INDEPENDENT SOFTWARE APPLICATIONS (FUNCTIONAL MODELS) REPRESENTS ONE INSTANCE OF THE DESIGN ANALYSIS PROCESS USED TO DETERMINE ONE POINT IN THE DESIGN SPACE. ONE OR MORE DESIGN EXPLORATIONS METHODS WILL BE USED TO RUN HUNDREDS OF INSTANCES OF THE DESIGN ANALYSIS MODEL BY METHODOLOGICALLY VARYING THE INPUT VARIABLES

Design Analysis Model (Math Model) Input Variables (X’s) Geometry Variables Heat Transfer Variables Mechanical Load Variables Material Property Variables Thermal Analyzer Geometry Engine Thermal Stress + Mechanical Stress Life (F.S.) Analyzer Mechanical Stress Analyzer Rapid Developed Links Response Variables (R’s) Mass Max.Temperature Max.Combined Stress F.S. Green boxes represent independent software applications called FUNCTIONAL MODELS 14

MSC.RD Design Analysis Model Service Pallet Connector Customizable Service Pallet; Click and Drop Services

ModelCenter Process Integration

Future of Engineering Analysis DESIGN EXPLORATION METHODS TYPICAL/EXTREME DETERMINISTIC ANALYSIS DESIGN SCANS SENSITIVITY ANALYSIS DETERMINISTIC OPTIMIZATION PROBABILISTIC (STOCHASTIC) SIMULATION TAGUCHI ANALYSIS

VIEW RESULTS TAGUCHI ANALYSIS RESULTS RESPONSE SURFACES Local Minimum Global Minimum

MSC.ROBUST DESIGN ENABLES RAPID DESIGN EXPLORATION BY LINKING Design Exploration with Methods Taguchi Monte Carlo Design Scans Sensitivity Analysis Optimization Single point Engineering Simulation with Distributed Computing Mechanical Design Manufacturing Stress Dynamics Risk Support Intranet Web

MSC.Robust Design Service Process Work with Users to establish design-analysis process input Integrate MSC.Software RD with the User’s IT infrastructure Ensure integration of functional models After services complete, User left with: Software and process that provides capability to conduct Robust Design for a family of products/parts with significant increase in use of installed software tools and hardware

ESTABLISH PROCESS PARTNERSHIP MSC HAS: WORLD CLASS MULTI-DISCIPLINE ENGINEERS WHO KNOW SOFTWARE AND ENGINEERING ANALYSES CUSTOMER HAS: WORLD CLASS EXPERTISE IN MAKING WHATEVER BOTH ARE NEEDED TO PROVIDE A ROBUST DESIGN CAPABILITY THAT CUSTOMER’S PEOPLE CAN USE TO IMPROVE THEIR PRODUCTS

MSC.Software - Phoenix Partnership Has BEST NT-based process capture tools: Easy to use Easy to install Easy to learn CATIA V5 Development Environment MSC.Software Has BEST process analysis capability: Selection of design exploration methods Parallel analysis through distributed computing Structural analysis applications Dassault Strategic Partnership