1. 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 © by Georgia Tech Research Corporation, Atlanta, Georgia USA. All Rights Reserved.
Developed by eislab.gatech.edu. Permission to use for non-commercial purposes is hereby granted provided this notice is included.

2. 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

3. 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

4. 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

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

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

7. Multi-Representation Architecture for Design-Analysis Integration

8. 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

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

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

11. Multi-Representation Architecture for Design-Analysis Integration

12. 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

13. Flap Link Geometric Model (with idealizations)
28b

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

15. 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)

16. 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

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

18. Multi-Representation Architecture for Design-Analysis Integration

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

20. 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
...

21. 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

22. 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

23. 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.

24. 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
...

25. 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

26. 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

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

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

29. SMM with Parameterized FEA Model Flap Link Plane Stress Model
Preprocessor Model Figure
ANSYS Prep7 Template
= Parameters populated by context ABB
/prep7
! element type
et,1,plane42
! material properties
! elastic modulus
! Poissons ratio
! geometric parameters
L = ! length
ts1 = ! thickness of sleeve1
rs1 = ! radius of sleeve1 (rs1<rs2)
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

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

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

32. 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

33. 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)

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

35. 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

36. 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 WD * = Item not yet available in toolkit (all others have working examples) ** = Item available via U-Engineer.com

37. 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)

38. 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

39. 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

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

41. Diversity Demonstrated in Test Cases

42. 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

43. 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