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Restricted © Siemens AG 2016 All rights reserved. siemens.com/mdx
Virtual Product Development using advanced
CAE and Design Exploration
Daniel Scuzzarello, M.Sc.
Restricted © Siemens AG 2016 All rights reserved.
2016-10-31Page 2 Siemens DF PL CD PDT
Agenda
• Challenges for Product Development
• Product Development with CAE
• Virtual Product Development with Advance CAE and Design
Exploration
• Teamcenter for Simulation
• Design Exploration
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2016-10-31Page 3 Siemens DF PL CD PDT
Challenges for Product Development
Increasing product complexity and requirements
More product variants and configurations
Greater collaboration needs for multiple location dispersed teams
Increasing CAE simulation usage
Greater variety and complexity of simulations
Vastly greater amounts of simulation data
Lack of resources can not be solved with more resources, but with strategy!!!
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2016-10-31Page 4 Siemens DF PL CD PDT
Product Development with CAE
In a Nutshell
Data Storage
(Models & Results)
Product Data
PDM
Configuration
Requests
Analyst
Requirements
Program Managers
Analysts
Simulation
Applications
Typical Unmanaged Analyst Environment
Validate Troubleshoot Predict
Typical CAE Analyst Environment
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2016-10-31Page 5 Siemens DF PL CD PDT
Product Development with CAE
Analysts are spending significant amount of time on
searching for data and providing data to others.
Lack of traceability & pedigree.
Huge volumes of data
Inefficiencies in Product Development
Typical Unmanaged Analyst Environment
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Product Development with CAE
Multiple engineering teams
Collaboration is manual
Simulation tasks are outsourced to external suppliers
Protecting IP is a big issue
Poor Collaboration and IP Protection
Typical Unmanaged Analyst Environment
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Product Development with CAE
Start from scratch every time
Redo analysis, Redo geometry simplification, Redo
meshing, Redo load case definition etc
Don’t know, don’t trust …
Do More Simulations … (With Less)
Typical Unmanaged Analyst Environment
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Product Development with CAE
Different processes, different types of analysis, and
different applications
Integrating & capturing data seamlessly without adding
much overhead
Repeatability issues
Lost know-how
Lost process knowledge
Disparate Processes and Tools
Typical Unmanaged Analyst Environment
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Product Development with CAE
Typical CAE Analyst Environment
ImportGeometry Mesh Select
Physics Solve and
Post-Process
Change Design(geometry and physics)
Design #N+1 Design #N
Manual and Laborious Process
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Virtual Product Development with Advanced CAE and Design Exploration
Data Storage
(Models & Results)
Product Data
PDM
Configuration
Requests
Analyst
Requirements
Program Managers
Analysts
Simulation
Applications
Requests
Product Data
Teamcenter
Configuration
Simulation Data
Simulation Tools
Simulation Workflows
Requirements
Analysts
Schedules
Simulation
Applications
Program Managers
Typical Unmanaged Analyst Environment Managed & Streamlined Analyst Environment
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Virtual Product Development with Advanced CAE and Design Exploration
Typical CAE Analyst Environment
Validate Troubleshoot Predict Explore Optimize
Discover Better Designs… Faster
= Feasible = Infeasible
Objective 1
Obje
ctive 2
Virtual Product Development
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VA
LU
E
EXPLORE DIGITALLY, CONFIRM PHYSICALLYPROACTIVEREACTIVE
Validate Troubleshoot Predict Automate Explore
Redefining Simulation Strategy for Innovation
SIMULATION PURPOSE
Most companies operate here
to reduce time and cost
Discover Better Designs, Faster!
Our customers operate here
to design better products
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2016-10-31Page 13 Siemens DF PL CD PDT
Virtual Product Development with Advanced CAE and Design Exploration
Managed & Streamlined Analyst Environment
Teamcenter Simulation
Virtual Product Development
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Teamcenter Simulation
Simulation Data Management
Simulation Lifecycle Management
Closed Loop Product Validation
Simulation Structure Management
Simulation Structure Automation
Simulation Process Management
Simulation Visualization
Design and
Simulation Process
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Teamcenter Simulation: Simulation Data Management
15
CAEModel
Solver(number cruncher)
CAEResult
CAD ItemCAEGeometry
Bulk data deck
Named Reference
Binary output file
Named Reference
CAEAnalysis
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Illustration
Teamcenter provides complete
traceability between product and
all the simulation data (simplified
geometry, models, load cases,
results, reports etc.) in both
directions.
Teamcenter Simulation: Simulation Data Management
Simulation Pedigree
Multiple Model Structures builtMultiple Analysis
run by different attributes
CAD Structure
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Illustration
Capture & Manage Lifecycle of
Simulation Data
Perform lifecycle operations on the
simulation data (Create, Revise,
Update, Delete, Release, Archive etc.)
Manage simulation lifecycle
independent from the product lifecycle,
while maintaining the relationship
Revise the geometry, models, analysis
and results independent from each
other (for example multiple meshes on
the same geometry, multiple analysis
with different load cases using the
same mesh etc.)
Move data into cheaper storage
mechanisms for long-term archival
while maintaining associativity and
access (using Hierarchical Storage
Management capabilities).
Teamcenter Simulation: Simulation Lifecycle Management
Simulation Lifecycle Management
Product
Evolution
Analysis
Evolution
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Execute CAE Packages (optional)
Teamcenter Simulation: Closed Loop Product Validation
Design Engineer
Create Validation
ContractWorkflow
Define Contract
Product Revision
Configuration (variants)
Requirements
TEAMCENTER
Analyst
Retrieve
Validation Data
Create / Reuse Mesh
Models
Run the solverPost-ProcessCreate Reports
Apply connections,
Load cases etc.
Simulation Reports
Product Revision
External Simulation
Applications
Simulation Tool Launch Framework
Validation Contract in the context of 3D simulation
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Illustration
Capture and manage all
the product performance
requirements, product
validation requirements,
validation procedures etc.
related to simulation.
These requirements are
associated to the simulation
data for complete
traceability.
Analysts can validate
requirements against
simulation results to close
the loop.
Teamcenter Simulation: Closed Loop Product Validation
Link with Requirements
Requirements
Simulation Results
Traceability Report
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Illustration
Business Process Automation
Formalize communication of
requirements, design data, results etc.
between various disciplines (systems
engineers, design team, CAE attributes
etc.).
Capture and document simulation
process steps, resulting in repeatable
and standardized processes, which
provide guidance to the users.
Capture and execute workflows at user
level, group level or across disciplines.
Establish traceability between
processes and the data captured.
Teamcenter Simulation: Simulation Process Management
Process Automation
Example customer simulation business
process captured as a workflow
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Teamcenter Simulation: Simulation Process Management
Initiate
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Illustration
Teamcenter provides different
types of dashboards to Analysts,
Program Managers, IT Managers
etc. for different purposes.
These dashboards are supported
through powerful data mining
techniques.
These include:
Simulation Data Monitor
BOM Reporting
Analysis Reporting
Reporting & Analytics
Teamcenter Simulation: Dashboard and Signoff
Dashboards
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Monitor Results
Domain Architect
Engineer
Incorporate Proposed Solution
Create Validation Package
Domain Architect
Study Alternate
Approaches
Approve Proposed
Solution
20%
Simulation
Engineer
Initiate and Run Simulation
Perform Analysis / Report Results
8%
Teamcenter Simulation: Systems Driven Product Development (SDPD)
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Teamcenter Simulation
Benefits
Speed-up simulations and deliver results faster
Remove clerical tasks
Eliminate rework
Improve collaboration
Capture knowledge
Process Automation
Make better product decisions
Deliver simulation results on time
Improved confidence in simulation results
Minimize implementation costs and risk
Configure applications and capture data
Leverage out-of-the-box capabilities with configuration
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2016-10-31Page 25 Siemens DF PL CD PDT
Virtual Product Development with Advanced CAE and Design Exploration
Managed & Streamlined Analyst Environment
Teamcenter Simulation
Virtual Product Development
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2016-10-31Page 26 Siemens DF PL CD PDT
VA
LU
E
EXPLORE DIGITALLY, CONFIRM PHYSICALLYPROACTIVEREACTIVE
Validate Troubleshoot Predict Automate Explore
Redefining Simulation Strategy for Innovation
SIMULATION PURPOSE Discover Better Designs, Faster!
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2016-10-31Page 27 Siemens DF PL CD PDT
Airbus Static Air Mixer
• Use STAR-CCM+ to gain insight into pre-conditioned air supply for
climate control and de-icing equipment
• Quickly and simply generate and test a design variant
• Automate this change to intelligently search the design space
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Challenge:•Find vehicle ride elements that:•Satisfy 40 constraints• Improve 44 ride factor variables•Subject to 7 vehicle maneuvers•Minimize sum of absorbed power
and max vertical acceleration•Previously, after 12 man weeks
of manual effort using DOEs, no feasible designs were found
Results:•After 200 evaluations, HEEDS
discovered 61 feasible designs
• Identified design with best performance after 123 evals
•Stellar vehicle performance!
Pratt & Miller - Military Vehicle Design
“HEEDS® is superior to anything else on the market today.” - Jesper Slattengren, Pratt & Miller
Simulation Constraint #
10" half-round GCW Vertical accel 4
10" half-round CVW Vertical accel 4
Drop-off GVWRide frequencies 4
Ride damping 4
Drop-off CVWRide frequencies 4
Ride damping 4
Offroad CVW Absorbed power 4
Offroad GVW Absorbed power 4
Step steer
Yaw overshoot 1
Roll overshoot 1
Yaw damping 1
Roll damping 1
Constant radius
Understeer gradient 2
Max lateral accel 1
Roll gradient 1
Total 40
Factors
Front
Dual rate spring 5
Position sensitive damper 12
Anti-roll bar 3
Geometry 3
Rear
Dual rate spring 5
Position sensitive damper 12
Anti-roll bar 3
Geometry 1
Total 44
“That’s the best vehicle I’ve ever ridden in.” - Frank Sturek, Infantry Battalion Commander
Designed with HEEDS!Baseline Best run
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Challenge:
• Improve plant exhaust filtering
•Maximize velocity uniformity through filter
•Constraints
•Largely frozen plant design
•Design variables
•Geometry of limited region with
or w/o deflectors
Results:
• Increased flow uniformity from 75% to 91%
Customer Example: Concrete Plant Exhaust Treatment
Gas
inflow
Gas
outflow
filter
Plant design is frozen, can only modify parts in “red”
80 % 85 % 91 %
76 % 95 % 96 %
Co
nce
pts
Exp
lore
d
Ideal
Current
UNIFORM ACHIEVED: from 75% to 91 %
• 60 runs , 10 minutes
ExtrudeDistance2
ExtrudeDistance1
TranslationVector
Uniformity improved from 75 to 91%
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Challenge:
•Minimize Body-In-White weight
•Maintain manufacturability
•Obtain the same or better performance
•System-level requirements
•Full vehicle requirements
•Constrain increases in cost
•Previous complex optimizations (with 484 variables)
were not possible
Results:
•After 250 evaluations, found 49 feasible designs
• Identified the best design with an 18% reduction
in weight and less than 5% increase in cost
EDAG - Full Vehicle Weight Reduction
TARGET WEIGHT
(20% saving) TARGET COST
(10% up)
BODY NVH
FRONT CRASH (all
load cases)
OCCUPANT
RESTRAINTS (all
load cases)
SIDE CRASH (all
load cases)REAR CRASH
(all load cases)
ROOF CRUSH
(all load cases)
DURABILITY
BODY STIFFNESS
(global and local)
MDOPERFORMANCE
ASSESSMENT
BASELINE
“HEEDS® allowed us to meet DFSS requirements in record time.” – Javier Rodriguez, EDAG
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EDAG - Full Vehicle Design
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2016-10-31Page 32 Siemens DF PL CD PDT
Virtual Product Development using Advanced CAE and Design Exploration
Lack of resources can not be solved with more resources, but with strategy!!!
SELECT GET STARTED EXTEND
Project 1
Project 6
Quick Start
Baseline Design Space Better Designs
TODAYYour Innovation
Goal
Project 3
Project 4
Project 5
Project 2
Project 7
EXPLORE 1ST SUCCESS INNOVATE
Teamcenter Simulation
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2016-10-31Page 33 Siemens DF PL CD PDT
Daniel Scuzzarello
Sales Director
Phone: +55 (11) 4228 7600
Mobile: +55 (11) 9 8415 5332
E-mail:
siemens.com/mdx