Techniques and Tools for Product-Specific Analysis Templates Towards Enhanced CAD-CAE Interoperability for Simulation-Based Design and Related Topics Russell.

Techniques and Tools for Product-Specific Analysis Templates Towards Enhanced CAD-CAE Interoperability for Simulation-Based Design and Related Topics Russell S. Peak Senior Researcher Manufacturing Research Center Georgia Tech Seminar NIST  Gaithersburg, Maryland October 9, 2001

4 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analysis Module Catalog: Chip Package Simulation thermal, hydro(moisture), fluid dynamics(molding), mechanical and electrical behaviors u PakSi-TM and PakSi-E tools http://www.icepak.com/prod/paksi/ as of 10/2001 u Chip package-specific behaviors: thermal resistance, popcorning, die cracking, delaminating, warpage & coplanarity, solder joint fatigue, molding, parasitic parameters extraction, and signal integrity

5 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analysis Module Catalog: Excavator/Loader Structural and Vibration & Noise Analysis u Infinik (Korea)http://www.infinik.com/solution/software.htm as of 10/2001 u Optimal Mount Design of Cabin –Objective: Mininize vibration and reaction force at cabin mounting points –Analysis Type: Modal, forced vibration,substructure technique u Structures using ANSYS –Analysis Objects: Boom, arm, upper frame, lower frame –Analysis Type: Static,model,fatigue,life analysis u Noise & Vibration

6 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analysis Module Toolkit & Catalogs: Diverse Application Libraries in EASY5 From http://www.boeing.com/assocproducts/easy5/products/prod_libraries.htm as of 9/2001http://www.boeing.com/assocproducts/easy5/products/prod_libraries.htm

7 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analysis Module Catalog: Tire-roadway interaction on full-vehicle performance From http://www.adams.com/product/product_line/tire.pdf as of 6/20/2001 Different Behaviors Diverse Design Data Fidelities Various Environment / Boundary Condition Fidelities Diverse Analysis Modules

8 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analysis Template Methodology & X-Analysis Integration Objectives (X=Design, Mfg., etc.) u Goal: Improve engineering processes via analysis templates with enhanced CAx-CAE interoperability u Challenges: –Idealizations –Diversity: Information, Behaviors, Disciplines, Fidelity, Feature Levels, CAD/CAE Methods & Tools, … –Multi-Directional Associativity: Design  Analysis, Analysis  Analysis u Initial Focus: Capture analysis template knowledge in modular form for regular design usage u One Approach: Multi-Representation Architecture (MRA) using Constrained Objects (COBs)

9 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Multi-Fidelity Idealizations inboard beam Design Model (MCAD)Analysis Models (MCAE) 1D Beam/Stick Model 3D Continuum/Brick Model flap support assembly Behavior = Deformation

10 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC An Introduction to X-Analysis Integration (XAI) Short Course Outline - Highlights Part 1: Constrained Objects (COBs) Primer –Nomenclature Part 2: Multi-Representation Architecture (MRA) Primer –Analysis Integration Challenges –Overview of COB-based XAI –Ubiquitization Methodology Part 3: Example Applications »Airframe Structural Analysis (Boeing) »Circuit Board Thermomechanical Analysis (DoD: ProAM; JPL/NASA) »Chip Package Thermal Analysis (Shinko) –Summary Part 4: Advanced Topics & Current Research

11 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COB Structure: Graphical Forms Spring Primitive Basic Constraint Schematic-S Notation c. Constraint Schematic-S a. Shape Schematic-S b. Relations-S d. Subsystem-S (for reuse by other COBs)

12 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COB Structure: Lexical Form Spring Primitive Constraint Schematic-S Lexical COB Structure (COS) COB spring SUBTYPE_OF abb; undeformed_length, L 0 : REAL; spring_constant, k : REAL; start, x 1 : REAL; end, x 2 : REAL; length, L : REAL; total_elongation, ΔL : REAL; force, F : REAL; RELATIONS r1 : " == - "; r2 : " == - "; r3 : " == * "; END_COB;

13 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Example COB Instance Spring Primitive Constraint Schematic-ILexical COB Instance (COI) state 1.0 (unsolved): INSTANCE_OF spring; undeformed_length : 20.0; spring_constant : 5.0; total_elongation : ?; force : 10.0; END_INSTANCE; state 1.1 (solved): INSTANCE_OF spring; undeformed_length : 20.0; spring_constant : 5.0; start : ?; end : ?; length : 22.0; total_elongation : 2.0; force : 10.0; END_INSTANCE; Basic Constraint Schematic-I Notation example 1, state 1.1

14 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Traditional Mathematical Representation Two Spring System System Figure Free Body Diagrams Variables and Relations Boundary Conditions Kinematic Relations Constitutive Relations

15 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC spring2 spring1 Constraint Graph-S Two Spring System L 10 k1k1 L1L1 L1L1 L 20 k2k2 x 21 x 22 F2F2 L2L2 F1F1 x 11 x 12 u1u1 u2u2 P L2L2 bc4 r12 r13 r22 r23 bc5 bc6 bc3 r11 r21 bc2 bc1

16 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COB Representation Extended Constraint Graph-S: Two Spring System Extended Constraint Graph-S Constraint Graph-S Groups objects & relations into parent objects Object-oriented vs. flattened partial (BC relations not included)

17 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COB Representation Constraint Schematic-S: Two Spring System Constraint Schematic-S Constraint Graph-S Encapsulated form (hides details)

18 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COB Constraint Schematic-S Two Spring System System-Level Relations (Boundary Conditions) Analysis Primitives with Encapsulated Relations

19 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COBs as Building Blocks Two Spring System Constraint Schematic-S Lexical COB Structure (COS) COB spring_system SUBTYPE_OF analysis_system; spring1 : spring; spring2 : spring; deformation1, u 1 : REAL; deformation2, u 2 : REAL; load, P : REAL; RELATIONS bc1 : " == 0.0"; bc2 : " == "; bc3 : " == "; bc4 : " == "; bc5 : " == "; bc6 : " == + "; END_COB;

20 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC state 1.0 (unsolved): INSTANCE_OF spring_system; spring1.undeformed_length : 8.0; spring1.spring_constant : 5.5; spring2.undeformed_length : 8.0; spring2.spring_constant : 6.0; load : 10.0; deformation2 : ?; END_INSTANCE; state 1.1 (solved): INSTANCE_OF spring_system; spring1.undeformed_length : 8.0; spring1.spring_constant : 5.5; spring1.start : 0.0; spring1.end : 9.818; spring1.force : 10.0; spring1.total_elongation : 1.818; spring1.length : 9.818; spring2.undeformed_length : 8.0; spring2.spring_constant : 6.0; spring2.start : 9.818; spring2.force : 10.0; spring2.total_elongation : 1.667; spring2.length : 9.667; spring2.end : 19.48; load : 10.0; deformation1 : 1.818; deformation2 : 3.485; END_INSTANCE; Analysis System Instance Two Spring System Constraint Schematic-ILexical COB Instance (COI) example 2, state 1.1

21 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Spring Examples Implemented in XaiTools X-Analysis Integration Toolkit spring system: similar to state 1.1 (solved): spring: state 1.1 (solved) spring: state 5.1 (solved)

22 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Using Internet/Intranet-based Analysis Solvers Thick Client Architecture Client PCs XaiTools Thick Client Users Internet June’99-Present: EIS Lab - Regular internal use U-Engineer.com - Demo usage: - US - Japan Nov.’00-Present: Electronics Co. - Began production usage (dept. Intranet) Future: Company Intranet and/or U-Engineer.com (commercial) - Other solvers Iona orbixdj Mathematica Ansys Internet/Intranet XaiTools Ansys Solver Server XaiTools Ansys Solver Server XaiTools Math. Solver Server CORBA Daemon XaiTools Ansys Solver Server FEA Solvers Math Solvers CORBA Servers CORBA IIOP... Engineering Service Bureau Host Machines

25 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Constrained Objects (COBs) Representation Characteristics & Advantages u Overall characteristics –Declarative knowledge representation (non-causal) –Combining object & constraint graph techniques –COBs = (STEP EXPRESS subset) + (constraint graph concepts & views) u Advantages over traditional analysis representations –Greater solution control –Richer semantics (e.g., equations wrapped in engineering context) –Unified views of diverse capabilities (tool-independent) –Capture of reusable knowledge –Enhanced development of complex analysis models u Example Toolkit: XaiTools v0.5

26 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC An Introduction to X-Analysis Integration (XAI) Short Course Outline Part 1: Constrained Objects (COBs) Primer –Nomenclature Part 2: Multi-Representation Architecture (MRA) Primer –Analysis Integration Challenges –Overview of COB-based XAI –Ubiquitization Methodology Part 3: Example Applications »Airframe Structural Analysis (Boeing) »Circuit Board Thermomechanical Analysis (DoD: ProAM; JPL/NASA) »Chip Package Thermal Analysis (Shinko) –Summary Part 4: Advanced Topics & Current Research

27 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC X-Analysis Integration Techniques for CAD-CAE Interoperability http://eislab.gatech.edu/tools/XaiTools/ a. Multi-Representation Architecture (MRA)b. Explicit Design-Analysis Associativity c. Analysis Module Creation Methodology

29 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analysis Building Blocks (ABBs) Analysis Primitives Beam q(x) Distributed Load Rigid Support Cantilever Beam System Analysis Systems - Primitive building blocks- Containers of ABB "assemblies" Material Models     Specialized General - Predefined templates - User-defined systems Analysis VariablesDiscrete Elements Interconnections Continua Plane Strain Body Linear- Elastic Bilinear Plastic Plate Low Cycle Fatigue  N MassSpringDamper x y q(x) Beam Distributed Load Rigid Support No-Slip body 1 body 2 Temperature, Stress, Strain,   T Geometry Object representation of product-independent analytical engineering concepts

30 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COB-based Libraries of Analysis Building Blocks (ABBs) Material Model ABB Continuum ABBs modular re-usage Torsional Rod Extensional Rod 1D Linear Elastic Model

32 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analyzable Product Models (APMs) Solid Modeler Materials Database Fasteners Database Design ApplicationsAnalysis Applications FEA-Based Analysis Formula- Based Analysis Combine information Add reusable multifidelity idealizations Analyzable Product Model (APM)... Provide advanced access to design data needed by diverse analyses. Support multidirectionality

34 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Flap Linkage Example Manufacturable Product Model (MPM) = Design Description Product Attribute RiRi Product Relation Extended Constraint Graph COB Structure (COS)

35 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Flap Linkage Example Analyzable Product Model (APM) = MPM Subset + Idealizations flap_link critical_section critical_simple t2f wf tw hw t1f area effective_length critical_detailed stress_strain_modellinear_elastic E cte area wf tw hw tf R 3 R 2 R 1 R 8 R 9 R 10 6 R R7R7 R 12 11 R 1 R 2 3 4 5 R R R R Product Attribute Idealized Attribute RiRi Idealization Relation RiRi Product Relation Extended Constraint Graph Partial COB Structure (COS) effective_length, Leff == inter_axis_length - (sleeve1.hole.cross_section.radius + sleeve2.hole.cross_section.radius)

39 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC (1) Extension Analysis a. 1D Extensional Rod 1. Behavior: Shaft Tension 2. Conditions: Flaps down : F = 3. Part Features: (idealized) 4. Analysis Calculations: 1020 HR Steel E= 30e6 psi L eff = 5.0 in 10000 lbs 5. Conclusion: A = 1.125 in 2  allowable   18000 psi 1.025 (2) Torsion Analysis Flap Link Analysis Documentation b. 2D Plane Stress FEA... (1a) Analysis Template: Flap Link Extensional Model APM ABB CBAM SMM Tutorial Example: Flap Link Analysis Template (CBAM) * 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

40 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC (1) Extension Analysis a. 1D Extensional Rod 1. Behavior: Shaft Tension 2. Conditions: Flaps down : F = 3. Part Features: (idealized) 4. Analysis Calculations: 1020 HR Steel E= 30e6 psi L eff = 5.0 in 10000 lbs 5. Conclusion: A = 1.125 in 2  allowable   18000 psi 1.025 (2) Torsion Analysis Flap Link Analysis Documentation b. 2D Plane Stress FEA... Flap Linkage Extensional Model (CBAM) Example COB Instance Constraint Schematic Instance

41 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Flap Link Extensional Model (CBAM) Example COB Instance in XaiTools Detailed CAD data from CATIA Idealized analysis features in APM Explicit multi-directional associativity between design & analysis Modular generic analysis templates (ABBs) Library data for materials Focus Point of CAD-CAE Integration example 1, state 1

43 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Flap Linkage Plane Stress Model (with FEA-based ABB system) Higher fidelity version vs. Linkage Extensional Model ABB  SMM SMM Template

45 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC An Introduction to X-Analysis Integration (XAI) Short Course Outline Part 1: Constrained Objects (COBs) Primer –Nomenclature Part 2: Multi-Representation Architecture (MRA) Primer –Analysis Integration Challenges –Overview of COB-based XAI –Ubiquitization Methodology Part 3: Example Applications »Airframe Structural Analysis (Boeing) »Circuit Board Thermomechanical Analysis (DoD: ProAM; JPL/NASA) »Chip Package Thermal Analysis (Shinko) –Summary Part 4: Advanced Topics & Current Research

46 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Airframe Structural Analysis GIT Work in Boeing PSI Project Current Situation: Limited Analysis Integration Manually-Maintained Associativity Error-Prone, Labor-Intensive, Little Knowledge Capture flap support assembly inboard beam (a.k.a. “bike frame”) bulkhead assembly attach point diagonal brace attach point Analysis Documentation Design Objects

47 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analysis Tools Flexible High Diversity Design-Analysis Integration Phase 1 Airframe Examples: “Bike Frame” / Flap Support Inboard Beam Analysis Modules (CBAMs) of Diverse Feature:Mode, & Fidelity Design Tools Materials DB FEA Elfini* MATDB-like Analyzable Product Model XaiTools Fitting: Bending/Shear 3D 1.5D Modular, Reusable Template Libraries MCAD Tools CATIA Lug: Axial/Oblique; Ultimate/Shear 1.5D Assembly: Ultimate/ FailSafe/Fatigue* * = Item not yet available in toolkit (all others have working examples) Fasteners DB FASTDB-like General Math Mathematica In-House Codes Image API (CATGEO)

48 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Today’s Fitting Catalog Documentation from DM 6-81766 Design Manual Channel Fitting End Pad Bending Analysis Angle Fitting Bathtub Fitting Channel Fitting Categories of Idealized FittingsCalculation Steps

49 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Object-Oriented Hierarchy of Fitting ABBs Fitting Casing Body Channel Fitting Casing Body* Bathtub Fitting Casing Body Angle Fitting Casing Body Fitting System ABB Fitting Wall ABB Fitting End Pad ABB Fitting Bolt Body* Open Wall Fitting Casing Body Fitting End Pad Bending ABB Fitting End Pad Shear ABB* Open Wall Fitting End Pad Bending ABB Channel Fitting End Pad Bending ABB* e se tr P f 0 2   3 )2( b 1 teKC  2 1 e be ht P Cf  21 1 KKC  ),,,( 011 erRrfK  ),( 2we ttfK  ),,( 13 hbrfK   ba R   2 df Re   ),min( wbwaw ttt  bolt load Fitting Washer Body Specialized Analysis Body P ABB Specialized Analysis System washer casing * = Working Examples

52 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Bike Frame Bulkhead Fitting Analysis COB-based Analysis Template (CBAM) - in XaiTools Detailed CAD data from CATIA Idealized analysis features in APM Explicit multi-directional associativity between detailed CAD data & idealized analysis features Modular generic analysis templates (ABBs) Library data for materials & fasteners Focus Point of CAD-CAE Integration

53 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC An Introduction to X-Analysis Integration (XAI) Short Course Outline Part 1: Constrained Objects (COBs) Primer –Nomenclature Part 2: Multi-Representation Architecture (MRA) Primer –Analysis Integration Challenges –Overview of COB-based XAI Part 3: Example Applications »Airframe Structural Analysis (Boeing) »Circuit Board Thermomechanical Analysis (DoD: ProAM; JPL/NASA) »Chip Package Thermal Analysis (Shinko) –Summary Part 4: Advanced Topics & Current Research

54 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC ProAM Focus Highly Automated Internet-based Analysis Modules World Wide End User AMCOM Feedback, Products Atlanta Physical Simulation U-Engineer.com Internet-based Engineering Service Bureau Self-Serve Results Response to RFP, Technical Feedback, Products Missile Mfg. Prime 1 Tempe PWB Fabricator Life Cycle Needs Friona PWB Fabricator SME 2 Rockhill PWB Fabricator SME 1SME n … Idealized Product Data ProAM Focus RFP with Product Data (STEP, IPC, …)

55 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC ProAM Design-Analysis Integration Electronic Packaging Examples: PWA/B Analysis Modules (CBAMs) of Diverse Mode & Fidelity Design Tools Laminates DB FEA Ansys General Math Mathematica Analyzable Product Model XaiTools PWA-B XaiTools PWA-B Solder Joint Deformation* PTH Deformation & Fatigue** 1D, 2D 1D, 2D, 3D Modular, Reusable Template Libraries ECAD Tools Mentor Graphics, Accel* Analysis Tools PWB Warpage 1D, 2D Materials DB PWB Stackup Tool XaiTools PWA-B STEP AP210 ‡ GenCAM**, PDIF* ‡ AP210 DIS WD1.7 * = Item not yet available in toolkit (all others have working examples) ** = Item available via U-Engineer.com

STEP AP210 Models Assembly Models User View Design View Component Placement Material product Complex Assemblies with Multiple Interconnect Component / Part Models Analysis Support Package Material Product Properties “White Box”/ “Black Box” Pin Mapping Requirements Models Design Constraints Interface Allocation Functional Models Functional Unit Interface Declaration Network Listing Simulation Models Signals Interconnect Models User View Design View Bare Board Design Layout templates Layers planar non-planar conductive non-conductive Configuration Mgmt Identification Authority Effectivity Control Net Change GD & T Model Datum Reference Frame Tolerances R

57 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC ProAM Technical Team Circuit Express Atlanta ECRC Georgia Tech AMCOM S3 Missile supply chain SME PWB fabrication expertise Tool usage & feedback Electronic commerce resource center Mgt., ESB, computing support Research & development lab Program management Technical concepts Tool implementation Missile supply chain SME PWB design & fabrication expertise Tool usage & feedback Missile system end-users Supply chain context Technical oversight

58 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Iterative Design & Analysis PWB Stackup Design & Warpage Analysis Analyzable Product Model PWB Stackup Design Tool 1 Oz. Cu 2 Oz. Cu Tetra GF 3 x 1080 2 x 2116 2D Plane Strain ModelDetailed FEA Check 1D Thermal Bending Model Layup Re-design PWB Warpage Modules Quick Formula-based Check (TIGER extensions)

59 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC PWB Warpage Modules a.k.a. CBAMs: COB-based analysis templates PWB Thermal Bending Model (1D formula-based CBAM) PWB Plane Strain Model (2D FEA-based CBAM) APM

60 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC u Original design: –Six layer board –Unsymmetrical layup –Severe warpage –Analysis predicted thermal distortion u Alternate design: –Modeled construction variables –Analysis predicted improved distortion u New capability aided design improvement Example SME Usage

61 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC U-Engineer.com Self-Serve Engineering Service Bureau Lower cost, better quality, fewer delays in supply chain Analysis DocumentationReady-to-Use Analysis Modules

62 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Phase 1 Accomplishments u Conceptual architecture and roadmaps u Repository/PDM methodology in Metaphase u PWB stackup design tool extensions u Next-generation XaiTools PWA-B –Web-based mockup illustrating target extended capabilities u AP210/STEP-based tool methodology u Analysis module methodology & general-purpose tools –XaiTools FrameWork v0.5

65 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC An Introduction to X-Analysis Integration (XAI) Short Course Outline Part 1: Constrained Objects (COBs) Primer –Nomenclature Part 2: Multi-Representation Architecture (MRA) Primer –Analysis Integration Challenges –Overview of COB-based XAI Part 3: Example Applications »Airframe Structural Analysis (Boeing) »Circuit Board Thermomechanical Analysis (DoD, JPL/NASA) »Chip Package Thermal Analysis (Shinko) –Summary Part 4: Advanced Topics & Current Research

67 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Flexible High Diversity Design-Analysis Integration Electronic Packaging Examples: Chip Packages/Mounting Shinko Electric Project: Phase 1 (completed 9/00) EBGA, PBGA, QFP Analysis Modules (CBAMs) of Diverse Behavior & Fidelity FEA Ansys General Math Mathematica Analyzable Product Model XaiTools ChipPackage Thermal Resistance 3D3D Modular, Reusable Template Libraries Analysis Tools Design Tools PWB DB Materials DB* Prelim/APM Design Tool XaiTools ChipPackage Thermal Stress Basic 3D** ** = Demonstration module Basic Documentation Automation Authoring MS Excel

68 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Traditional VTMB FEA Model Creation Manually Intensive: 6-12 hours FEA Model Planning Sketches - EBGA 600 Chip Package VTMB = variable topology multi-body

70 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Example Chip Package Idealizations (PBGA) Idealization for solder-joint/thermal ball Idealization for thermal via Courtesy of Shinko - see [Koo, 2000]

71 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Generic COB Browser with design and analysis objects (attributes and relations) Customized Analysis Module Tool with idealized package cross-section COB-based Analysis Template Typical Input Objects for EBGA Thermal Resistance Module COB = constrained object

72 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COB-based Analysis Template Typical Highly Automated Results FEA Temperature Distribution Thermal Resistance vs. Air Flow Velocity Auto-Created FEA Inputs (for Mesh Model) Analysis Module Tool COB = constrained object

73 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Pilot & Initial Production Usage Results Product Model-Driven Analysis u Reduced FEA modeling time > 10:1 (days/hours  minutes) u Reduced simulation cycle > 75% u Enables greater analysis intensity  Better designs u Leverages XAI / CAD-CAE interoperability techniques –Objects, Internet/web services, ubiquitization methodology, … References [1] Shinko 5/00 (in Koo, 2000) [2] Shinko evaluation 10/12/00 VTMB = variable topology multi-body technique [Koo, 2000]

74 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Cost of Associativity Gaps Categories of Gap Costs u Associativity time & labor –Manual maintenance –Little re-use –Lost knowledge u Inconsistencies u Limited analysis usage –Few iterations/part –Limited part coverage u “Wrong” values –Too conservative: Extra costs, inefficiencies –Too loose: Re-work, failures, law suits

75 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Summary u Provides methodology for bridging associativity gap u Multi-representation architecture (MRA) & constrained objects (COBs): –Address fundamental issues »Explicit CAD-CAE associativity: multi-fidelity, multi-directional, fine-grained –Enable analysis template methodology  Flexibility & broad application u Increase quality, reduce costs, decrease time (ex. 75%) : »Capture engineering knowledge in a reusable form »Reduce information inconsistencies »Increase analysis intensity & effectiveness

76 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC u Today:- Monolithic software applications; Few interchangeable “parts” u Next Steps: - Identify other formal patterns and use cases (natural subsystems / levels of “packaging”) - Define standard architectures and interfaces among subsystems Towards Greater CAD-CAE Interoperability Target Analogy with Electronics Systems Generic Geometric Modeling Tools, Math Tools, FEA Tools, Requirements & Function Tools, … Product-Specific Simulation-Based Design Tools Linkages to Other Life Cycle Models Extended MRA SMMs ABBs CBAMs APMs Middleware

77 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Summary of Tools and Services offered via Georgia Tech Research Corp. http://eislab.gatech.edu/ u XaiTools FrameWork ™ –General-purpose analysis integration toolkit u Product-Specific Toolkits –XaiTools PWA-B ™ –XaiTools ChipPackage ™ u U-Engineer.com ™ –Internet-based engineering service bureau (ESB) –Self-serve automated analysis modules  Full-serve consulting  Research, Development, and Consulting –Analysis integration & optimization – Short courses –Product-specific analysis module catalogs –Internet/Intranet-based ESB development –Knowledge-based engineering & information technology »PDM, STEP, GenCAM, XML, UML, Java, CORBA, Internet, … –CAD/CAE/CAM, parametric FEA, thermal & mechanical analysis

78 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC For Further Information... u EIS Lab web site: http://eislab.gatech.edu/http://eislab.gatech.edu/ –Publications, project overviews, tools, etc. –See: X-Analysis Integration (XAI) Central http://eislab.gatech.edu/research/XAI_Central.doc http://eislab.gatech.edu/research/XAI_Central.doc u XaiTools ™ home page: http://eislab.gatech.edu/tools/XaiTools/http://eislab.gatech.edu/tools/XaiTools/ u Pilot commercial ESB: http://www.u-engineer.com/http://www.u-engineer.com/ –Internet-based self-serve analysis –Analysis module catalog for electronic packaging –Highly automated front-ends to general FEA & math tools

Techniques and Tools for Product-Specific Analysis Templates Towards Enhanced CAD-CAE Interoperability for Simulation-Based Design and Related Topics Russell.

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Techniques and Tools for Product-Specific Analysis Templates Towards Enhanced CAD-CAE Interoperability for Simulation-Based Design and Related Topics Russell.

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