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Robust Design: The Future of Engineering Analysis in Design
Gene Allen and Brett Malone
Future of Engineering Analysis
COMPUTATION IS A COMMODITY
• GIVEN:– IMPROVING COMPUTATIONAL CAPABILITIES– BETTER COMMUNICATIONS CAPABILITIES– HIGHER CUTOMER EXPECTATIONS
• HOW DO YOU DO BETTER ENGINEERING?– IS PRODUCT UNDER-ENGINEERED?– OVER-ENGINEERED?
Future of Engineering Analysis
OBJECTIVE – DESIGN A ROBUST PRODUCT
MINIMIZE THE IMPACT VARIABILITY IN DESIGN PARAMETERS HAS ON PRODUCT PERFORMANCE
ATTRIBUTES:• Reduced performance sensitivity to product
and use variability• Performance repeatability• Designed-in product reliability, durability and
operability• Safety even under malfunctions
Assembly Models
Process Models
Material Models
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..Cycles
AltStrain
Inspection Models
Probability ofdetection
(e.g., flaws)
Loads
Historical data and models Operating conditions
CapabilityPredictedto occur
HARDWAREENVIRONMENT
CHARACTERIZATION
HARDWARE ASSEMBLYAND MATERIALS
CHARACTERIZATION
INTEGRATED CALCULATION OF• RISK • RELIABILITY• ROBUSTNESS • LIFE
MANUFACTURING
MATERIALS QUALITY ASSURANCE
LIFE CYCLE LOADS,TEMPS, ETC
OPERATIONS
Risk Measure
Fre
quen
cy
Performance Parameter
Variability Management Attacks Fundamental Causes of Failure
Robust Design
ROBUST DESIGN
PROVIDES ENGINEERS THE ABILITY TO:• Anticipate and Prevent Design Problems • Improve product and process Quality• Reduce time to market and number of prototypes
REPLACES TRIAL and ERROR WITH DESIGN DISCIPLINES
• Provides a structured method for engineering decision making.
Future of Engineering Analysis
Future of Engineering Analysis
HOW DO YOU DO BETTER ENGINEERING TO
GET A ROBUST DESIGN?
• FOLLOW METHODOLOGICAL ENGINEERING PROCESSES that provide:– COHERENT DESIGN EXPLORATION– QUICK RESULTS– EASY TO USE
Future of Engineering Analysis
PROCESS:• CAPTURE A DESIGN ANALYSIS PROCESS• RUN HUNDREDS OF INSTANCES OF THAT
PROCESS– FOLLOW COHERENT METHODS FOR EXPLORING DESIGN OPTIONS
• DO QUICKLY WITH COMPUTE CAPABILITIES AVAILABLE – INTRANET NOW – INTERNET TOMORROW
Future of Engineering Analysis
DESIGN ANALYSIS PROCESS MODEL (MATH MODEL)
• A NETWORK OF ONE OR MORE INDEPENDENT SOFTWARE APPLICATIONS (FUNCTIONAL MODELS)– REPRESENTS ONE INSTANCE OF THE DESIGN ANALYSIS
PROCESS– USED TO DETERMINE ONE POINT IN THE DESIGN SPACE.
• ONE OR MORE DESIGN EXPLORATIONS METHODS WILL BE USED TO RUN HUNDREDS OF INSTANCES OF THE DESIGN ANALYSIS MODEL – BY METHODOLOGICALLY VARYING THE INPUT
VARIABLES
Green boxes represent independent software applications called FUNCTIONAL MODELS
Design Analysis Model (Math Model)
Geometry Variables
Heat Transfer Variables
Mechanical LoadVariables
Material PropertyVariables
GeometryEngine
MechanicalStress
Analyzer
Life (F.S.)Analyzer
Rapid Developed Links
Response Variables (R’s)
Mass Max.Temperature Max.Combined StressF.S.
Input Variables (X’s)
Thermal Stress + Mechanical Stress
ThermalAnalyzer
ServicePallet
MSC.RD Design Analysis Model
• Customizable Service Pallet; Click and Drop Services
Connector
ModelCenter Process Integration
DESIGN EXPLORATION METHODS
• TYPICAL/EXTREME DETERMINISTIC ANALYSIS
• DESIGN SCANS
• SENSITIVITY ANALYSIS
• DETERMINISTIC OPTIMIZATION
• PROBABILISTIC (STOCHASTIC) SIMULATION
• TAGUCHI ANALYSIS
Future of Engineering Analysis
VIEW RESULTSTAGUCHI ANALYSIS RESULTS
Local MinimumGlobal Minimum
RESPONSE SURFACES
Design Exploration with
Methods
• Taguchi• Monte Carlo• Design Scans• Sensitivity Analysis• Optimization• Single point
Engineering Simulation with Distributed Computing
• Mechanical Design• Manufacturing• Stress• Dynamics• Risk• Support
• Intranet• Web
MSC.ROBUST DESIGNENABLES
RAPID DESIGN EXPLORATIONBY LINKING
MSC.Robust Design Service Process
• Work with Users to establish design-analysis process input
• Integrate MSC.Software RD with the User’s IT infrastructure
• Ensure integration of functional models• After services complete, User left with:
– Software and process that provides capability to conduct Robust Design for a family of products/parts with significant increase in use of installed software tools and hardware
ESTABLISH PROCESS PARTNERSHIP
MSC HAS:
WORLD CLASS MULTI-DISCIPLINE ENGINEERS WHO KNOW SOFTWARE AND ENGINEERING ANALYSES
CUSTOMER HAS:
WORLD CLASS EXPERTISE IN MAKING WHATEVER
BOTH ARE NEEDED TO PROVIDE A ROBUST DESIGN CAPABILITY
THAT CUSTOMER’S PEOPLE CAN USE TO IMPROVE THEIR PRODUCTS
MSC.Software - Phoenix PartnershipPhoenix • Has BEST NT-based process capture tools:
- Easy to use- Easy to install- Easy to learn
• CATIA V5 Development Environment
MSC.Software• Has BEST process analysis capability:
- Selection of design exploration methods- Parallel analysis through distributed computing- Structural analysis applications
• Dassault Strategic Partnership
