GOM Verification Of Finite Element Simulations

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Verification of Numerical Simulations GOM March 28, 2014

2-Frame Setup / Frame 2 2-Frame Setup / Frame 1

3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3

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Page 2 Verification of Numerical Simulations GOM

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GOM – Industrial 3D Measuring Techniques Company Overview

· Development, manufacturing and sales

· Over 300 employees

· 7 GOM branch offices in Europe

· 45 dedicated partner offices worldwide

· More than 7,000 installations

· Measurement technology for companies from the automotive and aerospace industries as well as from the consumer goods sector

GOM is a global partner for optical 3D metrology with over 20 years' experience



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GOM Customers (Extract)

Automobile manufacturers · Audi D

· Avtovaz RU

· Bentley UK

· BMW AT, D, UK

· Chrysler USA

· Daimler D

· Fiat IT

· Ford BE, D, UK, USA, BR

· Freightliner USA

· General Motors AU, AT, BR, USA

· Honda CN, JP, USA

· Hyundai KR

· Isuzu JP

· Jaguar UK

· Kia KR

· Land Rover UK

· McLaren UK

· Modenas MY

· NAZA MY

· Nissan JP, UK, USA

· Opel D

· Porsche D

· PSA FR

· Renault FR, ES, TR

· Seat ES

· Skoda CZ

· Subaru JP

· Suzuki CN

· Tata Motors Limited IN

· Toyota D, J, TR, USA, CA

· Volkswagen CN, D, MX, PL

· Volvo SE

· Temsa TR

Automotive suppliers · Autopal CZ

· Batz ES

· Bertone IT

· Bertrandt D

· Bosch D, CH

· Bridgestone JP

· Carcoustics LI

· DAAZ RU

· Delphi JP

· Faurecia D, FR

· FES D

· Goodyear USA

· Hella Leuchtensysteme D

· IAV D

· Italdesign-Giugiaro IT

· Kautex Textron D

· Läpple D

· LUK D

· Magna CA, AT

· Mahle D

· Matador SK

· Matrici ES

· Metalbages ES

· Michelin FR

· Montupet FR

· Nothelfer DE

· OLHO Technik DE

· Pierburg Kolbenschmidt AG, D

· Pininfarina IT

· Solvay BE

· ThyssenKrupp D

Aerospace · Airbus D

· Airforce Research Laboratories USA

· Aselsan TR

· Boeing USA

· Cessna USA

· Chrom Alloy USA, TH

· DLR D

· EADS D, FR

· ELBAR SULZER NL

· Eurocopter D

· Federal Aviation Administration USA

· FOI SE

· Gorbynov Aviation Production RU

· Honeywell IE, USA

· Howmet UK, USA, JP

· IMA Dresden DE

· IMPO RU

· Lockhead Martin USA

· MTU D

· NASA USA

· Northrop Grumman Systems Corp. USA

· ONERA FR

· Pratt & Whitney USA, NO

· RollsRoyce UK, USA

· Saturn RU

· Snecma Propulsion Solide FR

· Solar Turbines USA

· Triumph USA

· Turbine Services USA

· Vulcan Air IT

· VZLÚ CZ



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Material manufacturers · ACTech DE

· Alcan (Alusuisse) CH

· Arcelor BE

· BASF DE

· Bayer DE

· DuPont US

· Hydro (VAW) DE

· Salzgitter DE

· Tata Steel IN

· Thyssen Krupp DE

· Thyssen Nirosta DE

· Tokai Rubber Industries JP

· Voest Alpine Stahl AT

Others · Alfa Laval SE

· Bundeskriminalamt DE

· Corning US

· EXXON US

· Hidrostal CH

· Sea Ray Boats US

GOM Customers (Extract)

Consumer goods · 3B Scientific DE

· Adidas DE, USA, KR + 13 suppliers

· Apache Footwear DE

· Asics JP

· Balda CN

· BenQ CN

· Blaupunkt DE

· Bosch DE, CH

· Braun DE, CN

· Ching Luh Shoes CN

· Ecco DK

· Embraco BR

· FisherPrice USA

· Fuji JP

· Green Point CN, TW

· Head Tyrolia AT

· Hitachi Taga JP

· Lego DK

· LG Electronic KR

· Luxottica IT

· Mattel Tools MY

· Microsoft USA

· Nolato SE

· Oakley US

· Olympus JP

· Playworks USA

· Samsung, KR

· Siemens DE, DK

· SonyEricsson SE

· Sony JP, USA

· Sun Microsystems USA

· VDO DE

· Vertu UK

· Villeroy+Boch LU, DE

· Walt Disney USA

Research · BAM DE

· EPFL Lausanne CH

· ETH Zürich CH

· Forschungszentrum Karlsruhe DE

· Fraunhofer DE

· GKSS Geestacht DE

· Imperial College UK

· Int. Automotive Research Centre, UK

· Istanbul Technical University TR

· IUC SE

· Kaitech KR

· KTH SE

· KU Leuven BE

· Laurence Livermore National Labs USA

· Max Plank Institute DE

· Nagasaki Industrial Research Center JP

· Naval Research Lab USA

· Nottingham University UK

· PCC Leoben AT

· Queen Mary College UK

· RWTH Aachen DE

· Sandia National Lab USA

· Shenyang Aircraft Research Inst CN

· TU Delft NL

· TU Dresden DE

· TU Eindhoven NL

· TU Graz AT

· TU München DE

· Uni Padova IT

· US Army Research Lab USA

· Warwick University UK



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GOM – Industrial 3D Measuring Techniques Measurement systems

Full-field

3D Digitizing

ATOS

3D Shape and Dimension Inspection

Material Testing

Dynamic Component Testing

Full-field

3D Strain Measurement

ARAMIS

Deformation Analysis in Sheet Metal Forming

ARGUS

Mobile

Optical CMM

TRITOP

Dynamic

3D Analysis

PONTOS



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GOM – Industrial 3D Measuring Techniques Measurement systems

· Material Testing · 3D Coordinate Measurement · Component Testing

ATOS

ATOS ScanBox

TRITOP

ARAMIS

PONTOS

PONTOS

ARAMIS

TRITOP ARGUS

· Viewing and evaluation software



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GOM – Industrial 3D Measuring Techniques Measurement systems and results

· Material Testing · 3D Coordinate Measurement · Component Testing



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GOM – Industrial 3D Measuring Techniques Company Overview

Benefits of optical metrology

Optical metrology enables and supports

· High information density

· Fast measurement and provision of results

· High degree of flexibility regarding task, place and parts

· High process safety

Optical metrology is used complementary or as an alternative to

· 3D CMM

· Checking fixtures, gauges

· Displacement- and acceleration sensors

· Extensometers

· Strain gauges

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Verification of Numerical Simulations Webinar Overview



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· Following topics will be discussed during the Application Webinar “Verification of Numerical Simulations”

· Introduction in GOM’s optical measuring systems

· Determination of input parameters for numerical simulations

· Verification procedures for numerical simulations

· Including example applications in

· Sheet metal forming

· Composite component testing

· Biomedical applications

· Fluid dynamics in the Automotive and Aerospace industry

· Supported numerical simulation software packages and formats

Verification of Numerical Simulations Overview

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Verification of Numerical Simulations Optical Measuring Techniques



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Verification of Numerical Simulations Example Applications



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Verification of Numerical Simulations Overview Finite Element Simulation

Input Geometry (Mesh)

Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing



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Verification of Numerical Simulations 3D-Shape Measurements

Reverse Engineering

FEA-Simulation

CFD-Analysis

3D-Shape / STL-mesh



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Verification of Numerical Simulations Dynamic Deformation and Strain Analysis

FEA-Verification

Material Parameters

Shape / Displacement / Strain



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Boundary Conditions

Verification of Numerical Simulations Dynamic Deformation Analysis

Position / Displacement Dynamic

FEA-Verification



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Boundary Conditions

Verification of Numerical Simulations Static 3D-Coordinate Measurements and Deformation Analysis

Position / Displacement Static

FEA-Verification



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Verification of Numerical Simulations Sheet Metal Forming Analysis

FEA-Verification

Shape / Strain



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Verification of Numerical Simulations GOM System Applications

Results Application for FEA

ATOS Geometry / Shape 3D coordinates

Full field, static Input for Mesh Generation, Verification of Shape Spring-back, Thickness

ARAMIS Deformation Coordinates, Displacements,

Strain

Full field, dynamic Material Parameter Verification of Shape, Displacement, Strain

ARGUS Forming Analysis Coordinates, Displacements,

Strain

Full field, static

Verification of Shape, Displacement, Strain

PONTOS Deformation Coordinates, Displacements, Velocity

Point wise, dynamic Boundary conditions, Verification of Position,

Displacements

TRITOP Deformation Coordinates, Displacements

Point wise, static

Boundary conditions, Verification of Position, Displacements, (Geometry)

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Verification of Numerical Simulations Determination of Input Parameters



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Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing



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Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing

Input Geometry



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· Input geometry for numerical simulation

· Numerical simulations are initially depending on 3D input geometries which are usually taken from construction models (CAD)

· Due to differences in the 3D shape of CAD data sets and prototypes the reliability of numerical simulations are sometimes questionable

· Thus the accuracy and reliability of numerical simulations can be improved using the real parts geometry



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· Generation of input geometries for numerical simulations



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Section based reverse engineered CAD model from scan data



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· Computational fluid dynamics



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Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing



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Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing

Material Parameters



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· Material parameter models as input for numerical simulation

· The accuracy and reliability of numerical simulations are strongly depending on accurate material parameter models

· With optical measuring techniques advanced material parameter models are developed utilizing different applications and testing procedures, such as

· Tensile tests (quasi-static, high speed, etc.)

· Young’s modulus, R-value, N-value, Poisson ratio, etc.

· Nakajima and bulge tests

· Forming limit curves and bi-axial yield curves

· Torsion tests

· Bending tests

· Compression tests

· ...



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Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing



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Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing

Boundary Conditions



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· Boundary conditions as input for numerical simulations

· Numerical simulations strongly depend on the input of boundary conditions which represent manufacturing and testing conditions



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· Inhomogeneous / unknown material behavior

· E.g. Bones



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· E.g. Bones



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· E.g. Bones

PONTOS Measurement

FEA Input Geometry



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· E.g. Bones

FEA Result Meshes



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· E.g. Bones

· Process parameters

· Tool behavior and press motion during stamping, cutting, etc.

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Verification of Numerical Simulations Common Verification Procedures



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Verification of Numerical Simulations Verification Procedures

· Point wise comparisons used for

· Displacement transducers

· Accelerometers

· Strain gauges

· Etc.



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· Point wise comparison

· Section based comparison



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· Point wise comparison

· Section based comparison

· Visual comparison of color plots



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· Summary

· No automatism, manual work




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· Summary


· Due to user interaction very fault-prone

· Definition of points, sections, etc. in correct corresponding positions in FEA and measurement results




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· Summary


· Due to user interaction very fault-prone

· Definition of points, sections, etc. in correct corresponding positions in FEA and measurement results

· Limitations

· Comparison only possible for local areas

· Points

· Sections

· Visual comparison of color plots

· Inaccurate matching between FEA and measurement results


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Verification of Numerical Simulations Verification Procedure using 3D Data



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Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing



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Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing

FE Verification



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· Verification procedure in ARAMIS and ARGUS




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· Import of result data set from numerical simulation




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· The result data set from the simulation need to be exported into the correct format from the numerical simulation software package

· Direct export functions available in

· LS-Dyna, Pamstamp and Autoform

· Export scripts are available for

· ANSYS, ABAQUS and NASTRAN




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· 3D coordinate system alignment

· Usually the 3D coordinate system is not aligned between results from numerical simulation and measurement

· Manual pre-alignment

· Best-fit alignment




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· Surface Comparison

· Deviations between FEA and measurement




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· Deviations between FEA and measurement

· With “small enough” deviation between the two surfaces the comparison of further result data, such as displacement and strain, is useful




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· Result data comparison

· Due to the issues that the nodes in the simulation are not at the same 3D positions as the measured 3D coordinates from the measurement a mapping of these two datasets is required to enable the direct comparison between FEA and measurement




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· Due to the issues that the nodes in the simulation are not at the same 3D positions as the measured 3D coordinates from the measurement a mapping of these two datasets is required to enable the direct comparison between FEA and measurement




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· Further post-processing and reporting functions are available in ARAMIS for measurement and FEA data

· Point evaluations

· Section

· Statistics

· Interpolation

· Filtering

· etc.


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Verification of Numerical Simulations Application Examples Rotor Blade



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· Test Specimen

· Carbon fiber rotor

· Blade length: 1540mm

· Numerical simulation

· Linear simulation model

· Used to define positions for the application of strain gauges

· ARAMIS is used in this application to

· Verify the numerical simulation

· Verify strain gauge positions

· Replace strain gauges

Verification of Numerical Simulations Application: Rotor Blade Bending test



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· Rotor blade bending test

Positions of strain gauges




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· Full-field strain evaluation in X-direction of coordinate system




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· Full-field strain evaluation in X-direction of coordinate system

· Strain gauge positions not in maximum strain areas

Non homogeneous strain distribution in root area of the rotor blade

Further measurement only focused on the root area




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· Measurement of rotor blade root using a smaller measuring area to raise the local resolution for a better understanding of the local deformation behavior

· Strain in X-direction




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· Measurement of rotor blade root using a smaller measuring area to raise the local resolution for a better understanding of the local deformation behavior

· Strain in X-direction

· Non homogeneous local deformation behavior

Strain gauges were not applied on the areas of maximum deformation as predicted in the numerical simulation




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· Strain gauge were applied to measure in X-direction

· Comparison ARAMIS against strain gauges




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· Verification of numerical simulation from rotor blade

· Alignment


Initial Shape from FEA

incl. measurement results

(measurement projected to FEA surface)



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· Alignment

· Import FEA Strains


Result from ANSYS simulation Result from ARAMIS measurement



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· Difference between ANSYS simulation and ARAMIS measurement result


Difference between Simulation (ANSYS) and measurement (ARAMIS)



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· FEA-comparison module

· Included in ARAMIS and ARGUS

· Comfortable alignment and mapping

· Determination of full field deviations for

· Geometry

· Displacements

· Strains (Major, Minor, …)

· Easy and comfortable FEA verification including result evaluation and reporting

Verification of Numerical Simulations Summary



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Material Parameters

FE Verification

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing

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Thank you for your attention

[email protected]

www.gom.com

GOM Verification Of Finite Element Simulations

Software

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