2. An Introduction to X-Analysis Integration (XAI) Part 2: Multi-Representation Architecture (MRA) Primer Georgia Tech Engineering Information Systems Lab eislab.gatech.edu Contact: Russell S. Peak Revision: March 15, 2001 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.

3. 2 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 »Circuit Board Thermomechanical Analysis »Chip Package Thermal Analysis –Summary Part 4: Advanced Topics & Current Research

4. 3 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analysis Integration Objectives for Simulation-based Design Environments, Mfg. CAD/CAM, Measurements, etc. Conditions Analysis Results Ansys Abaqus CAE Improved Design / Process Selected Analysis Module (CBAM) Automated Idealization/ Defeaturization MCAD ECAD Design Product Model CBAM= context-based analysis model Highly automated Reusable, modular, extensible Product-specific Leveraging generic solvers Analysis Results Ansys Abaqus CAE Iterative Improvements Analysis Module Catalogs Analysis Results Ansys Abaqus CAE Ubiquitous Analysis Models

5. 4 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC X-Analysis Integration (X=Design, Mfg., etc.) u Goal: Improve product engineering processes by integrating analysis models with other life cycle models u Challenges: –Heterogeneous Transformations –Diversity: Information, Behaviors, Disciplines, Fidelity, Feature Levels, CAD/CAE Tools, etc. –Multidirectional Associativity: Design  Analysis, Analysis  Analysis u One Approach: The Multi-Representation Architecture (MRA) u Initial Focus: Automation of ubiquitous analysis for design

6. 5 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analysis Integration Challenges: Heterogeneous Transformations u Heterogeneous Transformation u Homogeneous Transformation Mentor GraphicsCadence STEP AP210 Mentor GraphicsAnsys STEP AP210 STEP AP209 ?? Design Model A Design Model B Design Model A Analysis Model A

7. 6 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analysis Integration Challenges: Information Diversity Environmental Conditions Specification Semantics Idealizations “Manufacturable” Description “Analyzable” Description “PWB should have low bow & twist” “Warpage < 7.5% when board is cooled from lamination to 25 o C” lamination temperature = 200 o C STEP AP220 STEP AP210

8. 7 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Diverse Analysis Disciplines Thermal Thermomechanical Fatigue Vibration Electromagnetic Electrical  N

9. 8 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Multi-fidelity Models Example: Supporting age in a people information model How old are you? u In years: –fidelity 1:age = current year - year of birth... –fidelity 2:also consider: is today before/after birthday? u In days: –fidelity 3:do not consider leap years –fidelity 4:consider leap years u In hours: –fidelity 5:consider time zone –fidelity 6:consider planetary orbit adjusments u In seconds: –fidelity 6:is sufficiently accurate data available? Model content depends on: a) questions to answer b) accuracy needed

10. 9 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Same Object... Multiple/Different Forms of Geometry Capture 1D Line (Curve) 3D Solid (Volume) 2D Surface (Shell) Geometric Idealization: Dimensional Reduction Beam Example: 1D, 2D, 3D Adapted from [Gordon, 2001]

11. 10 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Dimensional Reduction 1D Line (Curve) 3D Solid (Volume) 2D Surface (Shell) Geometric Idealization: Dimensional Reduction Beam Example: 1D, 2D, 3D (Exploded View) Adapted from [Gordon, 2001]

12. 11 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Mid-Surfaces (2D) Trimmed and Adjusted Mid-Surfaces Adapted from [Gordon, 2001] Category II Design - Solids (3D) Geometric Idealization: Dimensional Reduction Computer-Aided Mid-Surfacing (Solids-to-Shells) Issue: Matching seams in multi-part assemblies (capturing problem-dependent idealization decisions)

13. 12 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Multi-Fidelity Idealizations Behavior-dependent Idealized Geometries; Same Dimension Thermal Resistance Thermal Stress FEA ModelIdealized Geometry (3D) Common Design Model FEA Model Idealized Geometry (3D)

14. 13 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Multi-Fidelity Idealizations Same Behavior; Idealized Geometries of Varying Dimension inboard beam Design Model (MCAD)Analysis Models (MCAE) 1D Beam/Stick Model 3D Continuum/Brick Model flap support assembly Behavior = Deformation

15. 14 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Reusable Multi-Fidelity Geometric Idealizations: Bounding Shapes Design Model Multi-Fidelity Idealizations 2-D bounding box 3-D bounding box Multiple Uses Solder Joint Deformation Analysis Models PWA Cooling Solder Joint Deformation PWA Cooling Multiple Uses

16. 15 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Dimensions of Idealization Fidelity u Also: results idealization –How to “summarize” detailed analysis results back to product level value »Ex. Getting max. (or avg.) temperature on a surface to compute thermal resistance –Effectively a “results BC” u See [Gordon, 2001] regarding categories of analysis wrt geometric idealizations and directionality –S. Gordon (Jan. 16-18, 2001) An Analyst’s View: STEP-Enabled CAD-CAE Integration. NASA STEP for Aerospace Workshop, Pasadena, http://step.nasa.gov

17. 16 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Categories of Geometric Idealization for CAD-CAE Integration Category I - The CAD Geometry and the Simulation-Specific Geometry are the same (identical). This is the truly “seamless” case; there is no change in detail, no de-featuring, and no geometry gender changing required. Analysts and designers use the same (or duplicate copies of the same) geometry. Category II - Existing (available) CAD geometry has the wrong content; it is too detailed and/or of the wrong type to support the scale, scope, and purpose of the required or most appropriate type of analysis. Changes are required to add features or remove unnecessary detail from, and/or modify the gender of, the CAD geometry to create Simulation-Specific Geometry amenable to analysis. Automated and semi-automated procedures are required. Category III - Engineering analyses are performed first to define and refine a design concept using idealized geometry prior to establishment of the enterprise (CAD) product model. Simulation-Specific Geometry employed for analysis models will require modification and the addition of details and features to support drawings and manufacturing. Automated and semi- automated procedures are desirable. CAD-Centric Process CAE-Centric Process Adapted from [Gordon, 2001]

18. 17 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC “Three-Dimensional CAD Design and Analyzing with Shell Elements - A Soluble Contradiction?”, by M. W. Zehn, H. M. Baumgarten, & P. Wehner, NAFEMS 7th Int’l. Conf., Newport, RI, April 1999 “Don’t Change the Model Till the Simulation Finishes”, by Paul Kurowski, Machine Design, August 19, 1999 “Rookie Mistakes - Over Reliance on CAD Geometry”, by Vince Adams, NAFEMS Benchmark, October 1999 “Common Misconceptions About FEA”, by Vince Adams, ANSYS Solutions, Fall 2000 “Eight Tips for Improving Integration Between CAD and CFD”, by Scott Gilmore, Desktop Engineering, May 2000 Adapted from [Gordon, 2001] Recent Articles Showing Enlightened Views

19. 18 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COTS Vendor Report Card Category I A Mature, MCAD for solids good Category IIB-,C+Improving, recent mid-surfacing attention Category IIID,FVery little for CAE-centric ‘leading design’, need shell ‘thickening’ tools, or ‘solids-on-demand’ Overall: Still too CAD-Centric Continued role for traditional FEA pre- and post-processors AP209 is ready to support / enable more CAD-CAE integration AP209 is more appropriate for CAE than AP203 Need more vendor support for AP209 Vendor Status for CAD-CAE Integration Geometric Idealization Adapted from [Gordon, 2001]

20. 19 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Analysis at Diverse Levels of Product Structure Design Model (MCAD)Analysis Models (MCAE) Part Feature Level Model Assembly Level Model

21. 20 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC e se tr P f 0 2   2 1 e be ht P Cf  ),,( 13 hbrfK  Channel Fitting Analysis Design Geometry - Analysis Geometry Mismatch Analysis Model (with Idealized Features) Detailed Design Model Idealizations   1 : b = cavity3.inner_width + rib8.thickness/2 + rib9.thickness/2  “It is no secret that CAD models are driving more of today’s product development processes... With the growing number of design tools on the market, however, the interoperability gap with downstream applications, such as finite element analysis, is a very real problem. As a result, CAD models are being recreated at unprecedented levels.” Ansys/ITI press Release, July 6 1999 http://www.ansys.com/webdocs/VisitAnsys/CorpInfo/PR/pr-060799.html No explicit fine-grained CAD-CAE associativity

22. 21 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Missing Today: Explicit Design-Analysis Associativity CAD Model bulkhead assembly attach point CAE Model channel fitting analysis material properties idealized analysis geometry analysis results detailed design geometry No explicit fine-grained CAD-CAE associativity inconsistency little automation little knowledge capture

23. 22 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Multi-directional Relations “The Big Switch” u Sizing/synthesis during early design stages –Input: Desired results - Ex. fatigue life, margin of safety –Output: Idealized design parameters –Outputs then used as targets to guide detailed design u Analysis/req. checking during later design stages –Input: Detailed design parameters –Intermediate results: Idealized design parameters –Output: Analysis results - Ex. fatigue life, margin of safety –Outputs then compared with requirements

24. 23 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Inter-Analysis Associativity Flap Assembly FEA ModelFlap Support Assembly FEA Model Inboard Beam Bulkhead Channel Fitting Static Strength Model boundary conditions boundary conditions

25. 24 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 »Circuit Board Thermomechanical Analysis »Chip Package Thermal Analysis –Summary Part 4: Advanced Topics & Current Research

26. 25 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC X-Analysis Integration Techniques a. Multi-Representation Architecture (MRA)b. Explicit Design-Analysis Associativity c. Analysis Module Creation Methodology

27. 26 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Components of the MRA Analysis Integration Technique u Conceptual architecture: MRA u Methodology  General purpose MRA toolkit: XaiTools –Toolkit architecture –Users guide –Tutorials (work-in-process) u Product/company-specific applications –PWA/Bs (ProAM) –Aerospace structural analysis (Boeing PSI) –Chip packaging/mounting (Shinko) See http://eislab.gatech.edu/ for referenceshttp://eislab.gatech.edu/

28. 27 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Multi-Representation Architecture for Design-Analysis Integration u Composed of four representations (information models) u Provides flexible, modular mapping between design & analysis models u Creates automated, product-specific analysis modules (CBAMs) u Represents design-analysis associativity explicitly

29. 28 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Ubiquitous Analysis: Opportunity for Automation Potential Ubiquitous Analyses Performance EMI - Trace Spacing Variation Reliability Solder Joint Deformation - Thermomechanical [Engelmaier, 1989; Lau, et al., 1986; Kitano, et al. 1995] Solder Joint Fatigue - Component Misalignment Plated Through-Hole Fatigue [Sizemore & Sitaraman,1995] Manufacturability Reflow Soldering - PWA/B Warpage [Stiteler & Ume, 1996] Bed-of-Nails Test - PWA Deflection [Iannuzzelli, 1990] Solder Wave - Component Shadowing Conceptual Design Check Layout 1 2 3 Modified Layout Acceptable Layout Unacceptable Layout Develop PWA Layout Modify Layout Typical PWA Design Process The regular widespread use of an established analysis models.

30. 29 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Design-Analysis Integration Methodology u Provides technique to bridge CAD-CAE gap u Uses AI & info. technology: objects, constraint graphs, STEP, etc. Product Model Selected Module Analysis Module Catalogs MCAD ECAD Analysis Procedures Commercial Analysis Tools Ansys Abaqus Solder Joint Deformation Model Idealization/ Defeaturization Commercial Design Tools PWB Solder Joint Component APM  CBAM  ABB  SMM Ubiquitous Analysis (Module Usage) Ubiquitization (Module Creation) CAE Physical Behavior Research, Know-How, Design Handbooks,...

31. 30 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC XaiTools FrameWork X-Analysis Integration Toolkit Multi-Representation Architecture (MRA) Reference Implementation Analysis Modules & Building Blocks Constraint SchematicsImplementations TM CAD/E Integration Framework Product-Specific Applications u Airframe structural analysis u PWA-B thermomechanical analysis & design XaiTools PWA-B ™ u Electronic package thermal & stress analysis XaiTools ChipPackage ™ Leveraging commercial CAD & CAE tools

32. 31 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Idealization Tools* Libraries Synthesis Tools* ICAD,... SA, MCAD,... COB-Enhanced XAI Interoperability Framework Company/Product-Independent View XaiTools with Envisioned Extensions DBMS*, PDM*: Enovia, Metaphase... MCAD: CATIA I-DEAS*, Pro/E*, UG *, AutoCAD*,... ECAD: Mentor Graphics (STEP AP210) PWB Layup ADT, ChipPackage ADT Accel (PDIF, GenCAM)*,... FEA: Ansys, Elfini*, Abaqus*,... Math: Mathematica, MathCAD*, Matlab*,... Optimizers: ConMin, iSIGHT*, ModelCenter*,... In-House Codes Constraint Solver COB Schemas objects, x.xml* x.cos, x.exp Analysis Module Tools (product-specific) Mathematica Template Libraries: Analysis Packages*, CBAMs, ABBs, APMs, Conditions* Instances: Usage/adaptation of templates Solution Tools COB Instances objects, x.xml* x.coi, x.step Tool Forms (parameterized tool models/full* SMMs) Object Repositories Design Tools COB/Object Manager asterisk (*) = In-progress/envisioned extensions Simulation Mgt. Tools COB Mgt. Tools Navigators Editors (text & graphical*) Pullable Views*, Condition Mgr*,... API / Wrapper CORBA, SOAP*, Jini* CAD Tools Material Properties Mgr. MATDB*,Mvision*,... Std. Parts Manager FASTDB*,... * * * J2EE App. Server Accelis … + XaiTools

33. 32 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

34. 33 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC XaiTools CORBA Servers Installation at GIT EIS Lab as of March, 2000 Client PCs XaiTools Thick Client Internet Iona orbixdj Mathematica Internet/Intranet XaiTools Math. Solver Server CORBA Daemon Math Solvers CORBA Servers CORBA IIOP golden.marc.gatech.edu Sun UltraSPARC 1 Regular Users EIS Lab Pilot Users Phoenix AZ Huntsville AL Japan etc. Host Machines Iona orbixdj Mathematica Ansys XaiTools Ansys Solver Server CORBA Daemon XaiTools Ansys Solver Server FEA Solvers Math Solvers CORBA Servers hoogly.marc.gatech.edu Sun UltraSPARC 10

35. 34 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC “XAI Panorama” Flexible High Diversity Design-Analysis Integration Tutorial Examples: Flap Link (Mechanical/Structural Analysis)

36. 35 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Multi-Representation Architecture for Design-Analysis Integration

37. 36 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

38. 37 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

39. 38 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Extensional Rod Constraint Graph 1D Linear Elastic Model (COB re-usage)

40. 39 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Multi-Representation Architecture for Design-Analysis Integration

41. 40 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

42. 41 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Flap Link Geometric Model (with idealizations) 28b

43. 42 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)

44. 43 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)

45. 44 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC 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 : " == "; pir9 : " == "; pir10 : " == "; pir11 : " == "; pir12 : " == "; pir13 : " == "; pir14 : " == "; pir15 : " == "; pir16 : " == "; pir17 : " == "; END_MULTI_LEVEL_COB; Detailed Design Cross-Section Idealized Cross-Sections Associativity Relations between Cross-Section Fidelities

46. 45 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC APM Interface with Tagged CAD Models (in CATIA v4) APM COB Tool 7) Solve idealizations 8) Use in analysis part_number : “9162”; hole1.radius : ?; hole2.radius : ?; length1 : ?; tk/tcl CATGEO wrapper CATIA v4 (CAD tool) part_number : “9162”; hole1.radius : 2.5; hole2.radius : 4.0; length1 : 20.0; 1) 2) request 4) 5) 6) response GIT Interface program 0) Designer - Creates design geometry - Defines APM-compatible parameters/tags 3) 3 and 4 similar to other CAD APIs COB instance format

47. 46 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Flap Link Tagging Dimension Entity Approach - CATIA v4 inter_axis_length sleeve2.width sleeve2.inner_diameter

48. 47 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Flap Link Tagging Parametric Entity Approach - CATIA v4 inter_axis_length sleeve2.width sleeve2.inner_diameter

49. 48 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC DesignIdealizations A B D = h = 2D h/2 (PI^0.5)0.5*D Design Model - Idealized Model Assoc. inside CATIA v5 (work in process)

50. 49 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Target Situation: CAD Model w/ associated idealized features Idealized Features (to scale in CATIA v5) Idealized bulkhead attach point fitting Design Model (in CATIA v5) Idealized rear spar attach point fitting Idealized diagonal brace lug joint

51. 50 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Multi-Representation Architecture for Design-Analysis Integration

52. 51 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COB-based Constraint Schematic for Multi-Fidelity CAD-CAE Interoperability

53. 52 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

54. 53 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Test Case Flap Linkage: Analysis Template Reuse of APM Linkage Extensional Model (CBAM) Flap link (APM) reusable idealizations material effective length, L eff deformation model linear elastic model L o Extensional Rod (isothermal) F  L  A L  E x 2 x 1 youngs modulus, E cross sectionarea, A al1 al3 al2 linkage mode: shaft tension condition reaction allowable stress t s1 A Sleeve 1 A t s2 d d s1 Sleeve 2 L Shaft L eff  s stressmosmodel Margin of Safety (> case) allowable actual MS

55. 54 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Test Case Flap Linkage: Analysis Template Reuse of ABBs modular reusage Extensional Rod (generic ABB) Linkage Extensional Model (CBAM) material effective length, L eff deformation model linear elastic model L o Extensional Rod (isothermal) F  L  A L  E x 2 x 1 youngs modulus, E cross sectionarea, A al1 al3 al2 linkage mode: shaft tension condition reaction allowable stress t s1 A Sleeve 1 A t s2 d d s1 Sleeve 2 L Shaft L eff  s stressmosmodel Margin of Safety (> case) allowable actual MS

56. 55 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC 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 : " == "; al2 : " == "; al3 : " == "; al4 : " == "; BOUNDARY_CONDITION_ASSOCIATIVITIES al5 : " == "; OBJECTIVE_ASSOCIATIVITIES al6 : " == "; al7 : " == "; END_COB; Desired categorization of attributes is shown above (as manually inserted) to support pullable views. Categorization capabilities is a planned XaiTools extension.

57. 56 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC material effective length, L eff deformation model linear elastic model L o Extensional Rod (isothermal) F  L  A L  E x 2 x 1 youngs modulus, E shaft critical_cross _section al1 al3 al2 linkage mode: shaft tension condition reaction allowable stress stressmosmodel Margin of Safety (> case) allowable actual MS description area, A basic example 1, state 1 steel 10000 lbs flaps mid position 1.125 in 2 18000 psi 30e6 psi 1.025 5.0 in 8888 psi 1.43e-3 in Flap Link #3 Flap Linkage Instance with Multi-Directional I/O States Design Verification - Input: design details - Output: i) idealized design parameters ii) physical response criteria Design Synthesis - Input: desired physical response criteria - Output: i) idealized design parameters (e.g., for sizing), or ii) detailed design parameters

58. 57 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COB-based Constraint Schematic for Multi-Fidelity CAD-CAE Interoperability

59. 58 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC FEA-based Analysis Subsystem Used in Linkage Plane Stress Model (2D Analysis Problem) Higher fidelity version vs. Linkage Extensional Model ABB  SMM SMM Template

60. 59 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC COB-based Constraint Schematic for Multi-Fidelity CAD-CAE Interoperability

61. 60 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Flap Linkage Torsional Model Diverse Mode (Behavior) vs. Linkage Extensional Model

62. 61 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Modular Reusable COBs Flap Link Tutorial APM Example

63. 62 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Multi-Representation Architecture for Design-Analysis Integration

64. 63 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Typical Solution Tool Processes Preprocessor Model Preprocessor Control Solved Mesh Model Postprocessor Control Processed Results Preprocessor Solver Postprocessor Unsolved Mesh Model A 3 11 10 9 8 4 3 2 7 5 6 1 A A 2 1 C L extrema, graphics Model Data Tool Control Results Solution Tool

65. 64 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC ABB-SMM- Solution Tool Interaction 1 Solution Method Model 2 Analysis Building Block Solution Tool inputs & control outputs A 1 3 2 A A 11 10 9 8 4 3 2 7 5 6 1 preprocessor model mesh model 4 body ABB SMM results extrema  u 1 body 3 2 ABB  SMM 1 Solution Method Model Solution Tools preprocessor model mesh model results extrema  u A 3 11 10 9 8 4 3 2 7 5 6 1 A A 2 1 C L Files Operating System Object Environment Tool Agent inputs & control outputs FEA Tools

66. 65 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC ABB Mappings to Diverse Tool-Specific SMMs Plane Strain Model Example ABB Plane Strain Bodies System Ansys SMM Cadas SMM  Cadas  Ansys Vendor Variation Challenges Feature set of modeling language Region decomposition Numbering & composition of entities Element type designations body 3 2 1 4 T 0

67. 66 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Parameterized FEA Preprocessor Model Fixed Topology - Ansys /PREP7 ! body1 Material Properties MP,EX,1,@EX1@ ! Young's modulus MP,ALPX,@ALPX1@ ! CTE MP,NUXY,1,@NUXY1@ ! Poisson's ratio (minor)... LA = @LA@ ! Geometric Parameters LB = @LB@ L3 = @L3@ T0 = @T0@ ! Load Parameters T1 = @T1@ T2 = @T2@ T3 = @T3@... K,1, 0.0, 0.0 ! Key Points K,3, LB, H2 K,5, (LA-L3), H2... NLB = 10 ! Mesh Density Parameters NH2 = 4 NH3 = 4... L,1,2,NLB ! 1 ! Lines L,2,3,NH2,0.5 ! 2 L,3,4,NLB/2 ! 3... AL, 10, 8, 11, 12, 13 ! 1 - body 1 ! Areas AL, 1, 2, 3, 4, 5, 6 ! 2 - body 2 AL, 4, 7, 8, 9 ! 3 - body 3... ! Assign materials, Assign loads, Automesh, etc. ANSYS Prep7 Template @EX1@ = Parameters populated by context ABB Preprocessor Model Figure rectangular body 3

68. 67 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Ansys SMM Implementation Plane Strain Model - Example Instance solder joint deformation w/ detailed sj: case 3

69. 68 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Parameterized FEA Preprocessor Model Fixed Topology - Cadas addbasp 0.0 0.0 ! key points addbasp @L5@ 0.0 addbasp @L3@ 0.0... addlin2 1 2 ! lines addlin2 2 3 addlin2 3 15... addsurfp 1 2 6 5 ! areas addsurfp 2 3 7 6 addsurfp 3 15 16 7... ! materials matmger edit 21 @mat1_name@ -99 close matmger edit 102 @mat1_E@ -99 close... atrsurf 30 31 group 1 ! groups atrsurf 26 27 28 32 group 2 atrsurf 29 33 34 group 3 atrgrp 1 2 3 etype s 81 ! element type atrgrp 1 material 1 ! assign materials atrgrp 2 material 2 atrgrp 3 material 3 divset 2601 nodiv 3 1.0 ! line divisions divset 2603 nodiv 3 1.0... mergnode all 1.000E-5 ! merge tempload group 1 v @T1@ ! temperatures tempload group 2 v @T2@ tempload group 3 v @T3@ fixsuprt node 40 v 23 ! fixed origin bc fixsuprt line 4 15 v 1 ! symmetry bc dbsave smm.pre Cadas Preprocessor Model Template @EX1@ = Parameters populated by context ABB Preprocessor Model Figure rectangular body 3

70. 69 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Other ABB-SMM Mapping Considerations Finite Element SMM Cadas SMM Ansys SMM Nastran SMM Vendor-Specific ABB Neutral ABB Finite Element SMM Symbolic SMM Boundary Element SMM Finite Difference SMM ABB Vendor-Specific Finite Element SMMs ABB  SMM Cadas SMM Ansys SMM Nastran SMM ABB  SMM Solution Method Variation Vendor Variation (e.g., STEP AP209)

71. 70 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC SMM Status u Template approach works well for fixed topology cases –Relatively simple –Leverages current parametrized FEA models u Further needs: –Aid complex cases: Ex. variable toplogy multi-part/body –Enable multi-vendor / vendor-neutral representations See Advanced Topics re: Current Work

72. 71 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 »MRA Summary –Ubiquitization Methodology Part 3: Example Applications Part 4: Advanced Topics & Current Research

73. 72 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Evaluation Test Case Statistics: COB Structure Test CasesCOB Libraries Used# of Entities, Attributes, Relations

74. 73 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Evaluation Test Case Statistics: COB Structure Flap Link Test Case Supports reusability Supports complex large problems

75. 74 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Evaluation Example COB Reuse as Modular Building Blocks

76. 75 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Major Types of Analysis Objects CBAM = why + how = Analysis Context + Analysis Subsystems (ABBs, etc.) + Associativity Linkages Can be new, reused, or adapted template Instance can contain one or more runs Analysis Context Analysis specification (why vs. how) Definable during early planning stages analysis problem a.k.a: template, context-based analysis model (CBAM), analysis module

77. 76 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC MRA Summary u Multiple representations required by: –Many:Many cardinality –Reusability & modularity Self-Test: Consider impact of removing a representation u Similar to “software design patterns” for CAD-CAE domain –Identifies patterns between CAD and CAE (identifies new types of objects) –Other needs: conditions, requirements, next-higher analysis –Captures explicit associativity u Distinctive CAD-CAE associativity needs –Multi-fidelity, multi-directional capabilities

78. 77 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 »Circuit Board Thermomechanical Analysis »Chip Package Thermal Analysis –Summary Part 4: Advanced Topics & Current Research Recommended Approach Skim the methodology, then review Part 3 first, then come back for a more detailed look.

79. 78 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Classes of Analysis

80. 79 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Desired Characteristics of Designer* Analysis Tools u Tools that are easy to use and that automate tasks as much as possible u Predefined catalogs of common product-specific analysis models, along with usage guidelines u Product-specific terminology for model interaction (e.g., product-specific variable names) u Linkages with COTS and in-house design tools that have selective multi-directional associativity u Ability to leverage COTS general purpose CAE tools, as well as in-house specialty tools u Ability to utilize analysis tools without becoming a tool expert u Insulation from analysis model details (e.g., node numbers), but access if needed *Note: Some organizations categorize two types of “design” product team members: a) Those who develop the product architecture and plan the design of subassemblies and piece parts (at the feature level). Commonly used names for this type of team member include engineers, physical designers, etc. b) Those who utilize CAD tools to capture these designs in detailed manufacturable form. Commonly used names include designers, CAD users, etc. In these slides the term “designer” is used loosely for both groups. Generally, Type a) team members need to use analysis modules earlier in the design process to help “size” the designs and evaluate alternatives. Then Type b) users can employ analysis modules to guide and check the detailed design. This is the typical progression of who has more training to judge the inner workings and limitations of the analysis modules (and thus an increasing class of design cases that they can be called on to analyze): Type b), Type a), and Analyst. Thus if Type b) encounters a border line case or odd analysis results, they might ask the Type a) person to take a look at it. If Type a) feels it is beyond their scope, they can then ask the Analyst to take a look. If the Analyst is also not certain about it, then physical tests and analysis module extension studies may be needed.

81. 80 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Increasing Design Space & Analysis Utility Applicable Design Space (Comfort Zones) Use Design Guides Use Analysis Module Use Analyst (not automated)

82. 81 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Ubiquitization Process Template Creation & Usage Phases Other Developer/Integrator Roles: Product Modeler, Parts Librarian, Materials Librarian, CAD & CAE Tool Specialist(s)

83. 82 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC MRA Foundation for Product-Specific Tools Generic MRA Foundation Product-Specific Tool i i=1...n Product-Specific Entities 1234 j product = product domain (e.g., airframes, PWBs, chip packages, …) Specific APMs Specific SASs Abstract APMs SMMs General Purpose ABBs Abstract CBAMs SAS= specialized analysis system (with possibly specialized procedures - Ex. a VTMB algorithm) XaiTools PWA-B XaiTools ChipPackage XaiTools FrameWork Examples

84. 83 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Typical Sources of Ubiquitous Analysis Models u Corporate technical memos u Unpublished notes & know-how u Example CAD & CAE model files u In-house computer programs u Handbooks u Journal papers u Conference proceedings u Textbooks

85. 84 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Informal Description of a Ubiquitous Analysis Model (Analysis Procedure) u Model Purpose - A brief statement about the model and what design needs it fulfills. It should indicate what design stages best benefit from the model, (typically based on model accuracy versus computational cost). u Major Analysis Steps and Variations - A high-level, top-down view of the major analysis steps in the form of a tree/network diagram or an IDEF0 process model. Variations such as directionality, loading conditions, and product configurations should be identified. u Analyst Sketches & Idealizations - Sketches of analysis models noting types of idealizations used: bodies, loads, and material models in product-specific terms. u Relations and Variables - A list of relations and variables. For models that require solution tools such as finite element analysis (FEA) programs, the list should contain a relation whose variables are the inputs and outputs for that tool. u Model Limitations - Guides for the end user, including model assumptions and acceptable ranges of inputs and outputs. u Model References - Background information about the model, including application to the product type at hand, as well as descriptions of product-independent analysis concepts. u Representative Datasets - Example values for input, intermediate, and output variables for each major variation. These datasets should include related solution tool input and output files (e.g., FEA preprocessor models and results files). If possible, tool files should be parameterized according to their relations and variables identified above

86. 85 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Observations to Date u Need to ensure proper usage (highly automated!) –Must capture limitations & validity criteria u Knowledge capture technique u Synergy of specialists; communication aid u Catalyst for more analysis research u Usage by designers & non-designers (e.g., mfg.)

87. 86 Engineering Information Systems Lab  eislab.gatech.edu © 1993-2001 GTRC Observations (continued) u Delivery by network-based engineering service bureaus (ESBs) –Internet-based:Commercial ESB w/ self-/full-serve consulting –Intranet-based:Internal ESB (for shared corporate usage) –Extranet-based: Internal ESB, with controlled access for customers & suppliers u XaiTools status: –Focus to date: »Toolkit for developers & analysts to create analysis templates (ubiquitization process, but non-interactive ) »Support automated template usage by end users (ubiquitous analysis) - fixed topology; non-field relations –Next: Aid interactive adaptive analysis (template creation / one-of-a-kind analysis)

88. 87 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 »Circuit Board Thermomechanical Analysis »Chip Package Thermal Analysis –Summary Part 4: Advanced Topics & Current Research