Insights May June 2010

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INSIGHTS6

2010

10

Dassault Systmes Realistic Simulation Magaz

TechnipCustom Umbilicals for Deep

Offshore Wells

Amcor

Light-Weight Containers with FE

Abaqus 6.10

New Capabilities for Fluid-

Structure Interaction and More

HCL AnalyzesPaper Jams withAbaqus FEA


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The New Decade Ahead Focusing on CustomerSuccess and Connecting Our Global Communities

EXECUTIVEMESSAGE

INSIGHTS May/June 2010 3www.simulia.com

In my last letter for INSIGHTSin October 2008, I stated that Dassault Systmes SIMULIAwas well positioned to increase the business value of realistic simulation technology and thatour business momentum was based on the fundamental principles of technology innovation

and customer satisfaction. I am pleased that this statement continues to hold true and, as

we enter a new decade, more relevant than ever. Our strategy of providing robust simulation

technology and excellent technical support has helped sustain and drive the business value of realistic simulation

gained by our customers..

During the past few years, we have expanded our product portfolio which now includes Abaqus Unied FEA, Isight,

and solutions for Simulation Lifecycle Management our R&D team is also responsible for development of the

DesignSight, SolidWorks Simulation, and CATIA Analysis products. We remain committed to enhancing the core

mechanics technology of Abaqus, even as we expand our portfolio and add new multiphysics capabilities such as

computational uid dynamics in Abaqus 6.10. The latest release of Abaqus, demonstrated during the recent SIMULIA

Customer Conference, provides improvements in fracture and failure, linear dynamics, performance, modeling and

visualization (page 14).

The business value of realistic simulation is also being driven by an increasing number of users of our realistic

simulation solutions. I believe the growth of our user community is a direct result of our close working relationships

with customers and our focus on developing innovative technical capabilities that support industry-specic workows.

This combination is enabling more users to leverage realistic simulation technology on a wider range of industry

applications such as BMWs use of Abaqus for automotive safety and crashworthiness (page 22), Amcor evaluating

reliability of product packaging (page 16), InnerPluse analyzing the potential of new medical devices (page 22), and

HCL analyzing the behavior of paper feeding for printers (page 12).

I would like to thank the more than 1,200 customers who recently took time to respond to our annual customer

survey. Your feedback is ensures that we continue to meet your requirements and expectations. I am pleased to

report that, while there is still room for improvement, the overall results of the survey indicate that our customers

continue to be highly satised with the quality of our products and business practices.

Your participation at the international SIMULIA Customer Conference and Regional User Meetings (page 23) offers

an opportunity to interact with SIMULIA and our vibrant community of users. Later this year, the RUMs will be held in

more than 30 cities all over the world. The meetings will enable you to learn about the new capabilities in our realistic

simulation solutions, discover how your peers are using realistic simulation to accelerate product development, and

provide input on your requirements directly to SIMULIA management.

I look forward to meeting as many of you as possible in the next few months as we continue our strategy of

developing innovative simulation technology, providing excellent technical support, and delivering quality products

and services that ensure customer satisfaction and success.

Scott BerkeyChief Executive Ofcer,

SIMULIA

2010

2009

2008

2007

2006

SATISFACTION PRODUCT QUALITY INNOVATION100%

90%

80%

70%

60%

40%

50%

30%

20%

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0%

2010 CUSTOMER SATISFACTION SURVEY RESULTS

94% 95%94% 94% 93% 91% 91%92% 90% 90% 93% 93%93% 94% 92% 95% 96%95% 95% 97%

BUSINESS ETHICS


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4 INSIGHTS May/June 2010 www.simulia.com

Take a good look at the automobile of today:Despite the overall downturn in consumerdemand from that of 3 to 4 years ago, whenoverall U.S. new car and truck productionreached volumes in excess of 16 million, toabout 10 to 11 million adjusted annuallyand still there are the serious economicchallenges across the industry before fullrecoveryvehicles have clearly becomequieter, safer, and more durable over the pastdecade. Many of these improvements cameabout partly due to increasing sophisticationin the design and simulation tools availableto engineers, particularly nite element

analysis (FEA) software.

In my years as a vehicle computer-aidedengineering (CAE) manager at a majorautomotive OEM, I experienced the growthof FEA in both capability and applications.The software helped my design anddevelopment teams model, simulate, andanalyze the behavior of automobiles undera wide range of loads and conditions. Ourexpertise evolved along with FEA, goingfrom classic linear contact simulations tocomplex, nonlinear analyses such as full-

body noise and vibration (N&V) completewith rolling tires, wind loads, and more.

These advances in FEA enabled ourengineers to identify, earlier in the designphase than ever before, any necessary xes

needed to achieve consumer and regulatorytargets. The CAE models delity became

so good that over time we found less andless need to build physical prototypes forvalidation and comparison. High-qualitysimulation results helped us present realisticcost forecasts to our senior management

before they signed off on any productiongo-ahead.

Such simulation-driven advantages willcertainly continue to prove their worth to theautomotive industry as it focuses on vehicleredesign as the foundation of its revivalstrategy; however, the future potential ofCAE is certainly not limited to automakers.Given the economic environment of today,manufacturing companies across the boardare being pressed more than ever to improveengineering efciency, lower development

costs, and accelerate product innovation.Simulation will play an increasinglyprominent role in helping every industryachieve those goals, and the evolutionof FEA continues. With the release ofeach new version, simulation software

enables engineers to get ever closer to trulyrealistic behavior through the renement

of nonlinear effects of materials includingrubber, plastics, metal, and composites.Simulation results are also sharpening theengineers vision by incorporating othernonlinear mechanical attributes embeddedin a product due to the design, materials ormanufacturing processsuch as pre-stress,pre-strain, and/or pre-stiffness. The result isa thorough understanding of physics at play,less prototyping and testing, and much bettercorrelation between FEA results and thereal-world.

Although faster, cheaper, more powerfulcomputer hardware is certainly supportingthe evolution of FEA, the software itself isbecoming so well integrated that the latestversions can run certain complex problemson fewer computer cores, rather thanmore. The sophistication of the software isalso allowing engineers to create modelswith increasingly ner meshes; therefore,

more accurate delity. As compute power

increases, the models become ner and ner

and the software becomes better aligned,resulting in better all around integration.

Eventually, engineers wont see anythingexcept 3D realityat all.

The automotive industry has certainlybeen one of the major staging grounds forlarge-scale use of FEA. The application of

N&V analysis alone has grown tenfold inthe last decade. Automotive engineers eagerto share their results have spread the newsof these capabilities at regional and globalengineering conferences. The CAE lessonslearned in automotive are feeding into otherindustries including construction, heavyvehicle, military, off-highway, aerospace,and shipbuilding engineering.

Newer mechanized industries, such aslife sciences, are learning that the designchallenges they face in N&V control ofmachinery and devicessuch as oxygen

delivery breathing apparatuses or hearingaidscan also benet from such knowledge.The overall downturn adjustment in laborforce in the automotive industry will likelycause an acceleration of N&V knowledgetransferred to medical, pharmaceutical, andother industries that are in a better positionto hire skilled engineers.

So whats in the future for simulation withinautomotive engineering, particularly in theU.S.?

First, the explicit FEA methods that havebecome part of crash and safety simulations

Evolution of Finite Element AnalysisHelps Fine-Tune Product Development

Simulation expertise from automotive now benets other industriesDr. Bijan K. Shahidi, Principal Consultant, Engineering Products, Inc.

CUSTOMERVIEWPOINT

The usage of stationary or rolling tire substructures in the full vehicle N&V simulations.


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5INSIGHTS May/June 2010www.simulia.com

in recent decades (and have played a majorrole in helping engineers to design safer carsand trucks) will be increasingly applied toapplications. This advancement will result ina greater demand for even faster computinghardware and better integration of implicitand explicit FEA techniques to help designlighter-weight, efcient, yet comfortable

vehicles of tomorrow.

Second, and admittedly further off in thefuture, is the advent of isogeometric analysis(a technique using NURBS and T-Splinesas a basis for constructing element shapefunctions) championed by Prof. TomHughes at the University of Texas. Thisapproach heralds a whole new way ofthinking about how nite elements are

created which seeks greater accuracies tocompute stresses, velocities, pressures, and

buckling loads.

Those automotive companies willing andable to continue investing in realisticsimulation technology and skilled staff will

certainly benet as they develop the next

generation of Green vehicles. But the cat isout of the bag; engineers who excel at using

N&V simulation technology will be in highdemand, not only in the automotive industry,

but also as innovation leaders needed toapply their knowledge of FEA across manyother industries.

Dr. Shahidi is currentlyPrincipal Consultant forEngineering Products,Inc. and has over 20years of experience asa professional engineerspecializing in CAE.He holds a Ph.D. in

Theoretical Mechanics and an M.B.A fromMichigan State University and holds an M.S.and B.S. in Aerospace Engineering from theUniversity of Michigan.

Technology BriefsInspired by real-world projects,Technology Briefs provide detailedapplication examples on the use of

SIMULIA solutions in a wide range ofindustries. Over 40 Technology briefsare available at our website. Below arethe newer additions:

High Fidelity Anti-Lock BrakeSystem Simulation Using Abaqusand DymolaA co-simulation approach using Abaqusand Dymola is used to achieve a realisticsystem-level simulation of an anti-lock

brake system (ABS). The tire, wheel,brake caliper mechanism, and road aresimulated with a detailed Abaqus nite

element model while the brake systemcontrol algorithm and hydraulics and aresimulated with Dymola.

Modeling the Interaction ofSubsea Pipelines with the SeabedThe understanding and prediction of theinteraction of a subsea pipeline withthe seabed is a complex phenomenacrucial for subsea pipeline design. ThisTechnology Brief describes how theCoupled Eulerian-Lagrangian (CEL)method in Abaqus/Explicit can be used

to calibrate the parameters that dene thepipeline-soil frictional behavior. Theseparameters are then used in the pipeline-soil friction user subroutine in Abaqus/Standard (available on Abaqus Answer4094) as part of predicting the in-servicebuckling deformations of the pipeline.

Simulation of AdaptiveBone RemodelingThe long-term success of an orthopedicimplant can be better predicted byincluding the adaptive bone remodelingprocess. This Technology Brief

demonstrates the Abaqus/Standardimplementation of one of the leadingbone remodeling algorithms. Usersubroutine USDFLD is employed tocapture solution dependent materialproperties, and the approach is used inthe analysis of a total hip replacementdesign.

For More Informationwww.simulia.com/techbriefs

For More [email protected]

(Top) A 2-D FEA simulation is used to model and then verify sound pressure levels in and around a hearing

aid design, helping engineers to improve hearing aid performance while shortening development time.

(Bottom) Realistic simulation is used to compute the natural frequencies of a desktop computer enablingengineers to determine which parts to modify and where to add damping materials in order to make the

computer quieter and more durable.

Images courtesy of Lenovo

Images courtesy of GN ReSound


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As the depth of a deep-sea well increases,the tension and the crush load required tohold the weight of the lengthening umbilicalalso increase. Up to 30 tons per meter ofradial load can be applied to a steel tubeumbilical during deep-water installation.

Needless to say, this kind of pressure on theumbilical can cause deformation to the tubes,which have point contact (where tubes inadjacent counter-rotating layers cross) dueto the umbilicals helical construction. DNV(Det Norske Veritas), Norwegian risk-management specialists, recommends thatthree percent residual ovality (permanenttube deformation following crushing) isacceptable; higher levels of deformationcan negatively affect the umbilical tubesresistance to hydrostatic pressure as depthsincrease. Residual ovality can also impairfatigue resistance to pressure cycling overtime. As a result, understanding umbilicalcrush behavior in detail is critical toensuring product integrity, establishing loadlimits, and designing out failure.

As projects get more expensive, there ismore risk, and customers want more of theengineering work done up front. Beingable to prove that the design ts the purpose

is critical, Probyn says. With realisticsimulation, were able to see inside theumbilical. Thats something you cant dowith physical testing. FEA provides thatlevel of detail.

Simulation customization fordesign flexibilityU.K-based DUCO rst chose Abaqus FEA

for their umbilical R&D in 2005. We didan evaluation, says Dave Fogg, R&D teamleader, and Abaqus stood out because ofits Explicit solver capability for analyzinghighly nonlinear, dynamic behavior. Thiscapability is important, he adds, given the

helical structure of the umbilical, interactionbetween the components, and bendingstiffness due to friction.

Abaqus also provides the ability to customizescripting tools. This customization isimportant because each client comes toDUCO with its own unique umbilicalrequirements. Since each product isessentially one-of-a-kind, the FEA tooland simulation process need to be exible

enough to accommodate this high degree ofdesign variability.

Umbilicals are the lifelines of deep-seaelds, connecting the well to the mother ship,

offshore platform, or onshore terminal. Theyare criticalproviding the power, control,communication, and uid injection that

keep deep-water wells healthy and pumpingaround the clock (see Figure 1).

Durability is essential whether the umbilical

is hanging in the water column (dynamic),resting on the sea bed (static), or connectingimportant eld infrastructure. Thats

because pressure and temperature extremes,wave and current action, and sour uids all

conspire to break, or at least damage, theumbilical and its contents.

Due to their important role in deep-seahydrocarbon extraction, the cost ofinstallation, the difculty of on-site repair,

and the expense of a eld being down,

umbilicals need to be designed and builtto last. Typical umbilical design life is

25 years, but at Technip Groups DUCOLtd.considered the world leader inumbilical design and manufacturethey usethe ISO standard and set design fatigue lifeat 10 times the design life. For a 25-yeardesign life, we design for 250 years in termsof fatigue, says Ian Probyn, senior engineer,R&D, at DUCO. With offshore umbilicals,failure is not an option.

Deep-water installationBuilding failure-proof umbilicals isdifcult enough, but challenges of deep-

water installation further complicate thetask. Wound onto storage reels and thenmounted on a specialized installation vessel,the umbilicals need to deploy in a highlycontrolled manner to reach a precise targeton the ocean oor.

The umbilical is fed through a Vertical LaySystem (VLS) that controls the unspoolingby applying a holdback tension to theumbilical as it hangs from the ship. Fourcaterpillar tracks with V-shaped padstypically create the hold back tension,applying a radial crush force to the umbilicalusing friction to control the deployment.

Figure 1. Umbilicals deployed from an installation vessel provide deep-water oil and gas elds with power,

communication, and the necessary uids required for hydrocarbon extraction.

CUSTOMERSPOTLIGHT

Longer Life for Deep-Sea LifelinesAbaqus FEA helpsTechnip engineers

custom design umbilicalsfor deep offshore oil andgas wells


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DUCO, in collaboration with French-basedIFP, a public-sector research and trainingcenter, developed a proprietary, validatedengineering software toolFEMUS ornite element model of an umbilical

structure. This tool interrogates a database

that includes all of the information requiredto build a model (think of the databaseas containing the DNA for any umbilicaldesign, such as the component, material,and dimensional data). It then automates3D-model building by gathering all of thedata into a Python script (programmablelanguage le used by Abaqus), which it then

executes within Abaqus/CAE to create theFEA model.

Once the data is loaded in Abaqus, thescript does the rest: It builds the umbilical-specic geometry; constructs the assembly;

applies the section properties, element typesand materials; and creates the load steps,contacts and request for history and eld

output data. Developed specically for

Abaqus and for use by non-FEA experts, theinterfaces goal was rapid model buildingusing proven techniques. That goal wasrealized: In approximately 10 minutes theteam can have a run-ready base modelinside Abaqus.

Inside the umbilicalDuring the VLS installation, the umbilical

is subject to tension, bending, and thecrushing load from the caterpillar pads. Forthe crush load portion of the analysis, theDUCO team used the 3D model in Abaqus/Explicit to capture all of the interactionsin the helically-oriented structure. The 3Danalysis gave them the relationship betweenthe crush load and the resulting ovality ofthe tube while under that load.

When the umbilical leaves the caterpillar,the crush load is relieved and the tubeselastically relax, resulting in a reductionof tube ovality. For the recovery of thetube, a simpler 2D analysis in Abaqus/Standard proved efcient. In the 2D

environment, the team conducted a numberof analyses for each tube and built up therelationship between the maximum ovalityunder load and the residual ovality of thetube following elastic recovery. They thencombine the results from the 2D and 3Danalyses to determine the overall residualovality of a tube for a given caterpillar crushload.

For further efciency, all analyses were

run on models constructed from a singlepitch of the umbilicalthe length at which

For More Informationwww.technip.comwww.simulia.com/cust_ref

Figure 2. Comparison of the results of the umbilical FEA analysis (left) with the full-scale physical test

using the four-track caterpillar crush rig (right) is used to validate the umbilicals residual ovality following

the application of varying crush loads.

the helical pattern starts to repeatwhichin this case was several meters. The teamused shell elements for the tubes and solidelements for the polymer sheath, outersheath, and llers. For the crush pads, they

used rigid elements and dimensions thatmatched the umbilical pitch length.

In the umbilical installation analysis, theDUCO R&D team considered the keyvariables: tube wall thickness, VLS crushload, internal tube pressure, and caterpillar

pad geometry. To gain condence in the

simulation results, they ran four simulationsthat matched the conditions of four full-scale physical tests for a combination ofinternal tube pressure and caterpillar padangle.

Validated simulation processprovides confidenceEven streamlined, an umbilical installationsimulation can be compute-intensive. Arecent DUCO analysis had approximatelyhalf a million nodes and a similar numberof elements. To handle this complexity theteam used a cluster of CPUs with signicant

capacity. The goal was to deliver ananalysis in a reasonable time, adds Probyn,

and weve succeeded.

Comparing results, the team found goodagreement between the FEA predictionsand the physical tests (see Figure 2). Formost loads, the differences between theFEA and test results were well withinthe measurement tolerances. The FEA

predictions also showed the same trend asthe test data in predicting reduced residualovality as the geometry of the caterpillarpad V-angle was altered from a high to

low angle. In addition, the model andtests were in agreement when an internalpressure was present in the steel tubesduring application of the crush load. Allresults indicated that residual ovality wasbelow the recommended 3 percent limit forall loadswell within the nominal crushloads. This gave the team condence that,

in specic cases, crush loads beyond the

typical values could be applied.

Overall, the analyses demonstrated to theDUCO team that FEA could accurately

simulate complex loading conditionsinvolving multiple component contact andnonlinear material behavior. Now thatweve fully validated the FEA, simulationcan be employed as a virtual prototypeto perform additional analyses, such asoptimization and reliability studies, saysR&D team leader Fogg.

With a validated realistic simulation process,DUCOs customers can have condence

that their oil and gas lifelines will be healthylong into the future.


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Smaller devices withmore memory and features,

environmental constraints,global sourcing, increased

speed and decreased

costthese demands pose

significant challenges for the

electronics manufacturers

who, arguably, have the

shortest product lifecycle of

any industry. Delivering the

latest, greatest, smallestand next "must have" tech

toy requires design and

engineering solutions that will

help the industry evaluate and

improve product performance

on the fly.

When I last wrote an Electronics StrategyUpdate forINSIGHTSmagazine in October2007, I discussed the industry need forunied Finite Element Analysis including:

For example, an industry-standard moisturesensitivity test for a semiconductor mighttake several hours to completethat is afterwaiting up to one month for a prototypepart to be made and another week to pre-condition the specimens. A virtual test withAbaqus can replicate this physical test andcan be completed within a matter of hours.This approach provides huge time and costsavings, while allowing the consideration ofmany more design alternatives.

Plus, realistic simulation can often revealmore than a physical test. Consider a cellphone drop testsimulation can provideviews inside the device during the dropevent that would be impossible to achievefrom physical tests. Simulation also allows

results from any location in the model and atany point in time during the analysis.

Unified FEA & multiphysicsEngineering work groups in the electronicsindustry need to perform a wide array ofsimulations. Abaqus FEA enables engineersto use a common simulation model andunderlying technology to evaluate manydifferent workows.

In the case of cell phone manufacturingcompanies, engineers are doing more thanjust drop test simulation with Abaqus. They

tools to capture and share simulationworkows, multiphysicsincluding multi-

eld simulation, advanced capabilities for

material modeling, as well as technologyfor fracture and failure. Today, the industrychallenges have only intensied. The good

news is that SIMULIAs strategic R&Dplans are on target and are helping ourcustomers meet their product developmentdemands. Consider some of the new andenhanced features added into the Abaqusproducts over the last two years such as:XFEM, low cycle fatigue, implicit dynamics,subcycling, and co-simulation. (See page 14of this issue to learn more about the latestrelease of Abaqus 6.10)

In addition to expanding the capabilities

in Abaqus, our R&D organization is nowresponsible for the development of anexpanded portfolio of simulation solutionsincluding Isight, Simulation LifecycleManagement, DesignSight, CATIAAnalysis, and SolidWorks Simulation. Ourelectronics strategy now encompasses all ofthese solutions, and is bringing signicant

business value to the industry.

Our customers motivation for usingrealistic simulation often focuses onreducing or replacing time-consuming andexpensive physical tests with virtual tests.

STRATEGYOVERVIEW

Accelerating Innovation in

Electronic Product DevelopmentDavid Cadge, Electronics Industry Lead, SIMULIA Technical Marketing


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variety of applications, including commercialCAD/CAE software, internally developedprograms, and Excel spreadsheetsinorder to automate the exploration of designalternatives and identication of optimal

performance parameters.

Isight enables users to automate simulationprocess ows and leverage advanced

techniques such as Design of Experiments,Optimization, Approximations, and Designfor Six Sigma to thoroughly explorethe design space. Advanced, interactive

postprocessing tools allow engineers toexplore the design space from multiplepoints of view.

Managing simulation IPElectronic product development companiescontinue to expand their use of coupledmodels for multi-eld, multiphysics, and

multi-scale applications resulting in databeing transferred from one model to the next.They are also performing more simulationsdue to faster computing resources and theneed to reduce physical testing. This activity

is driving the need for solutions that allowengineers to capture and share simulationworkows while managing applications,

computing resources, and simulation results.SIMULIA has responded to this industrydemand by developing a product suite forSimulation Lifecycle Management (SLM).SLM accelerates product developmentby providing timely access to the rightinformation through secure storage, search,and results visualization.

Customer engagementsSIMULIA is proactively engaged in theelectronics industry. Our global team andcustomers present regularly at industryconferences (visit our website to downloadseveral of these papers). Our customersalso participate in SIMULIA customer

review meetings to provide input on theirsimulation requirements. We are respondingto their requests by enhancing our productportfolio with robust technology formultiphysics, design optimization, andsimulation lifecycle management. As aresult, our customers are solving morecomplex engineering problems with fewersimplifying assumptions. Our goal is to helpour customers create the next must-haveelectronic device faster and more affordablythan ever before.

David Cadge

Electronics Lead, SIMULIADavid is responsible fordeveloping and promotingour strategy for simulationwithin the Electronicsindustry. He has worked

at SIMULIA since 1995 (initially in theUK ofce and then at the Providence, RI

headquarters). David has worked in variouscapacities within the customer serviceand marketing teams. He has visitedElectronics customers around the worldto understand their simulation workows

and requirements. Information gatheredduring these visits helps SIMULIA provideenhancements for advanced technology,usability, and productivity so that simulationcan become an integral part of Electronicsdesign practices.

are also using its range of capabilitiesfor coupled structural-acoustics, thermalloading, bending/twisting, and exible

multi-body dynamics for mechanismsallleveraging the same, underlying FE model.

Semiconductor companies are using Abaqusto perform virtual tests for thermal andpower cycles (see page 20), vibration,moisture, and stress. They are looking atsimulations covering the complete lifecycleof the component, from manufacture, toassembly, right through to consumer usageand nal failure.

As components become smaller and morecomplex, designing to avoid fracture,delamination, and failure grows ever moreimportant. SIMULIA is the technologyand industry leader for modeling and

analyzing fracture and failure. We extendedour leadership by delivering the rst

commercial release of the Extended FiniteElement Method (XFEM) in Abaqus 6.9.This method enables users to study crackinitiation and propagation along an arbitrarysolution-dependent path without needing toremesh. It can also perform evaluations foran arbitrary stationary crack. This capabilityhas been further enhanced to supportcontour integral output, to run in parallel onmultiple cores, and to support the implicitdynamic option for transient analyses likethermal shock.

Abaqus 6.9-EF added the option toread multiple nodal output variablestemperature, normalized concentration,and electric potentialfrom previousAbaqus analyses. This technique enablescustomers to get the total stress state causedby coupled-elds with a single stress

analysis; for example, the coupled responseto temperature and moisture for a moisturesensitivity test or to temperature and cureshrinkage for a warpage simulation.

In Abaqus 6.10 we are releasing Abaqus/

CFD which enables users to performconjugate heat transfer simulations. TheAbaqus/CFD solver can be easily coupledto an Abaqus/Standard model that hasbeen created for thermal cycling and solderjoint creep simulation, and used to performcooling simulations.

Simulation automationand optimizationIsight, which became part of our productportfolio in 2007, provides engineers witha suite of interactive tools for creatingsimulation process owsconsisting of a

A process simulation for a Notebook power button

is performed using Abaqus to analyze the stress

caused when pushed. Realistic simulation enables

design engineers to evaluate whether the Notebooks

power button meets performance requirements.

Image courtesy of ASUSTeK Computer, Inc.

Virtual drop tests of a cell phone are performed

using Abaqus to analyze the stress and strain of

main parts as the phone strikes a surface fromvarious directions. Realistic simulation enables

design engineers to evaluate whether the stiffness

of the phones components meets performance

requirements. Image courtesy of Lenovo.

Download Electronics-related customerpapers at: www.simulia.com/cust_ref


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SOLUTIONBRIEF

Car manufacturers are now legally obligatedto certify the effects of crash events onthe humans involved. As a result, crashdummies for front-impact (Hybrid),side-impact (SID), and rear-impact (RID)have been developed with engineers fromaround the world contributing over theyears to their evolution. A major challengein the ongoing development of physical

crash dummies is the need to reasonablyrepresent how the human body respondsin an automotive accident. The ultimategoal of crash dummy research is to aidin creating design improvements for bothvehicles and occupant restraint systemsto reduce injuries and save lives. Today,physical crash dummies are a valuable partof every automotive OEMs product design,development, and testing arsenal.

Smart investment, big price tagA very valuable part: A single physicalcrash dummy can cost more than $200,000.

Made from a variety of different materials,including custom-molded urethane andvinyl, crash dummies are based on true-to-life human dimensions (a typical dummyfamily includes several different dummies,ranging in size from a toddler to a largeadult male). They have ribs, spines, necks,heads, and limbs that respond to impact inrealistic ways. They are loaded with sensors(44 data channels on the current front-impact standard, the Hybrid III) that recordup to 35,000 items in a typical 100-150millisecond crash.

As the market for each countrys vehiclesbecomes increasingly global, automotivecompanies and government organizationscontinue to collaborate toward theacceptance of international safety standards(a WorldSID project is now underway)and harmonize methods of testing. Physicaltest dummies are only a part of the crashand safety certication process. As

computer-aided engineering software andcomputing resources rapidly advance, thereis increasing emphasis being placed ondeveloping ever-more-accurate virtualcrash dummies.

Abaqus FEA crash dummy model of a thorax.

Crash Course in Data ManagementSpeeds Up Huge Simulation Task

Simulation Lifecycle Management (SLM)cuts qualication process for Abaqus FEAcrash dummy models from weeks to days

Simulating the crash simulatorGiven the power of FEA to cost-effectivelyreduce real-world testing, in the case ofexpensive crash dummies, and even moreexpensive vehicle prototypes, it denitely

pays to simulate the simulator. You cancrash a virtual car and dummy many times,much faster, and at far less cost than a singlephysical test.

Standardization of FEA models is critical.Each virtual dummy must exhibit responses

to crash impact loads and accelerations in aprecise, repeatable manner that mirrors whathappens to its corresponding physical crashdummy.

Whats more, the simulation must continueto run smoothly as each new and improvedversion of a physical crash dummy comeson the market and as each new versionof crash simulation software is released.Simulation software companies go to greatlengths to validate the consistency andaccuracy of their software in a process

called qualication. In the case of creating

a new virtual crash dummy or updatingan existing one, the software qualication

process involves evaluating large quantitiesof FEA data, gathered from multiplesimulations of various crash scenarios, runon different versions of simulation software,and in turn, correlated with new physicaltest data.

Data, data everywhereAt SIMULIA headquarters, a team of

engineers qualify and support a range ofvirtual crash dummy models developedfor their Abaqus FEA software by FirstTechnology Safety Systems (FTSS), a leaderin crash dummy innovation for over 40years. The SIMULIA group also separatelydevelops and qualies its own virtual crash

dummy models, which are versions of theBioRID (Biodelic Rear Impact Dummy)

and WorldSID (Worldwide Side ImpactDummy). We need to make sure that everynew version of each dummy model thatsreleased will work accurately and give thesame response no matter which version of

Abaqus we, or our customers, are using,says Sridhar Sankar, Manager, AutomotiveUnied FEA, SIMULIA.

A typical FEA dummy model will haveabout 100,000 elements, 150,000 nodesand 500,000 degrees of freedom. Toensure, within engineering tolerances, thatyou get the same results from the virtualdummies as from the physical tests ofthe real ones, we have to run component,sub-assembly, and full-model tests on eachone, says Sankar. A component test is usedto evaluate an individual FEA model of a


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For More Informationwww.simulia.com/products/slmwww.ftss.com

dummy neck being bent, a lumbar spinebeing shoved sideways, or a head beingdropped on a hard surface. A sub-assemblytest assesses the stresses on a full rib cagemodel hit from the side by a pendulum, with

the ribs being individually deformed andpossibly intruding into the body cavity. Afull-body test incorporates an entire dummymodel being hit from the side by a virtualsolid barrier or subjected to a simulated sledtest. Different testing standards (NHTSA,IIHS, etc.) require a variety of tests. With30 to 60 of these validation tests per dummymodel, we end up with a very large numberof outputs to generate and then compare,says Sankar.

Manual qualification slows down theengineering teamUntil recently, dummy qualication took the

SIMULIA engineers about four weeks foreach updated Abaqus virtual dummy model.

These kinds of challenges meant a lot ofman-hours for our team, says SIMULIAcrash engineering specialist George Scarlat.

Before even begining the analysis, Scarlatsgroup had to create its databases bymanually modifying each of the previousvalidation test responses to add properltering (which has to meet industry

standards, such as J211 or ISO 6487) tothe variables so that the results betweendifferent versions of Abaqus could becompared.

Next, the engineers had to manually launchand run the simulations for the 30-60 testsin the current and previous versions ofAbaqus (usually four or ve total). Once

they completed the various manual analyses,the team then had to run a post-processingstep to generate the curve plots describingthe analysis results. The amount of datacontinues to multiply at this point becausethe results of a single FEA analysis ofdummy rib cage intrusions, for example,could produce up to 200 output variables(forces, displacements, etc.) per test.

Finally, a second post-processing step wouldtake the analysis curves, two at a time, andgenerate statistical comparisons to quantifythe agreement between the same variables indifferent versions of Abaqus. So in termsof data you could have 60 tests multipliedby 200 variables multiplied by ve different

versions of Abaqus, says Scarlat. This wasa lot of manual work. To meet our deadlines,we really needed to improve the efciency

of the entire process.

SLM brings the power of PLM toVirtual Crash Dummy QualificationAs a result the group decided to apply acombination of SIMULIAs own SimulationLifecycle Management (SLM) tool andIsight software for simulation automationand design optimization to automateand manage the tasks. The results weredramatic. By using our own tools, whichwe also provide to our customers forautomating and managing their simulationprocesses, we went from four weeks to fourdays for the qualication process, says

Scarlat.

Using SLM as both a database and aprocess controller, the engineers could saveand manage their simulation data, reusesimulations, retain performance metrics,protect intellectual property, and shortendesign cycles. They used Isight softwarewithin SLM as an add-on tool for drivingsimulation process automation.

The crash dummy qualication team

used SLM as the underlying driver for

running each of the three main dummyqualication tasks (preprocessing, analysis

and postprocessing) sequentially. SLMautomatically exported all the necessaryles from its database for each task

(activity). It then automatically importedback into its database any specied result

les after the activity was run.

Isight automates the qualificationprocess furtherSLM also leverages the capabilities ofIsight, in this case for process automation.The crash group engineers rst used Isight

to create a workow that enabled them to

simultaneously launch all of the Abaqusanalysis tasks on a compute cluster. Asecond Isight workow was employed in the

nal postprocessing task to help determine

the correlation between results fromdifferent versions of Abaqus software onidentical dummy tests. A Python script wasused to modify input les, compare results

and generate comparison reports.

Automating our tasks was a big help,

says Scarlat. No user intervention wasneeded during the complicated workow

execution, which resulted in a signicant

reduction of our process time for the wholeproject. Scarlats team qualied ve FTSS

dummies in the rst year of using the new

workowtaking about the same number

of man-hours needed to nish only one

dummy qualication project before.

The automobile safety engineering worldis getting ever closer to the perfect crashdummy. Hybrid IV, also known as THOR,is a dummy currently under development

with biomechanical and measurementenhancements that will generate more datathan ever. With such complicated, data-rich FEA in the pipeline, the use of SLMand Isight to automate and manage it all willbe even more crucial to the efciency of our

engineering team, predicts Sankar.

Screenshot shows how SLM and Isight are used to qualify a crash dummy FEA model for two versions

of Abaqus software.


12/24


13/24


Simulating the effects of all these variableshelps HCLs engineers predict and rectify

potential paper ow roadblocks at the earliest

stages of design development. EmployingAbaqus FEA in a feedback loop with the

design department, they can quickly ne-tuneand perfect their virtual prototypes beforebuilding and validating the nal physical

prototypes for their customers.

Geometric simplicity,analytical dynamismTo chart and then analyze the path of a virtualpiece of paper, the engineers begin with aCAD model (see Figure 1) of the componentsof a proposed ow path design, including the

paper itself.

The CAD model is then meshed using

Abaqus/CAE to prepare for an explicitdynamic analysis in Abaqus. This part of theprocess is fairly straightforward: Neither apiece of paper, nor the components of thepaper path, are geometrically complex. Thepaper is modeled as beam elements withrectangular section properties when 2Danalyses (generally side views of papermovement) are being run, and shell elementsfor 3D (more detailed problems likebuckling and skewing). The paper materialis considered to be linear elastic isotropic.The bafes, guides and plastic rollers are

considered to be rigid. A hyperelastic Neo-

Hooken material model is used for the rubberrollers to capture their deformation.

Straightforward, yes, but when the simulationmodel is set in motion, it becomes a nely

choreographed dance in which the correctfunction of each component is dependenton the proper operation of the previous step.Its a fast-evolving, highly nonlinear FEAproblem that has to account for a host ofvariables: grade of paper, complexity of ow

path, roller pre-loads, roller rotation speed,transport velocity and acceleration, materials,friction, even the effect of gravityat speeds

approaching two meters per second (up to100 pages a minute). The analysis time isestimated as per ow path length and roller

RPM.

Fixing the virtual paper jamWithin this multifaceted engineeringenvironment, HCLs engineers can focus inon the behavior of a particular piece of paperas it travels along a proposed design ow

path conguration (see Figure 2) . They can

simulate what happens when the paper getsout of alignment (skew), and is correctedagain by guides. They can study the effects

of paper weight and roller drive on bends(buckle) in the paper that lead to potentialstubbing points (paper jam!), and they canmeasure the amount of slippage at the rollerinterface.

With their Abaqus simulation results inhand, the engineers can then modify designvariables, and combinations of variables,within a ow path. They can vary the

distance between rollers, roller positioning,and circumference, the angle of the guides,and so forthand then run the virtual pieceof paper through it all over again. Theycan also modify the characteristics (weight,thickness, composition) of the paper itselfto test the full range of capabilities of each

proposed path design.

Abaqus FEA passes the reality testin record time

Abaqus advanced contact algorithmcapabilities and extensive material modelssupport our simulations for a broad range ofcustomer needs, says Mayil. To ensurethat our nal designs are robust enough

for a particular printer conguration, we

build and test physical prototypes. Whenwe compare our results against the FEA,we see very good correlations. Andthey accomplish all this with signicant

time savings: Weve been able to cutthree months off overall project time for

designing and validating a typical A4 printerusing simulation, says Mayil.

Realistic simulation will continue to playa pivotal role for HCLs global CAE team.

Future work will focus on the effects ofinducing electrostatic charges on paper (astep inherent to the laser-printing process),and consideration of environmentalconditions like humidity and temperature.

With a constant drive for product innovation,cost and weight reduction, the highlycompetitive high-tech electronics industryis continuously challenged to updateproducts in a very short design cycle, saysMayil. Reliable functionality is one of themajor goals for information technologyand electro-mechanical products. Realistic

simulation helps us achieve that for ourcustomers.

For More Informationwww.hcltech.comwww.simulia.com/cust_ref

Figure 2. Results from 3D paper buckling contour analysis using Abaqus FEA. When paper ow and roller nip

forces are imperfectly balanced, a buckle of paper can rise up, lling the paper path and resulting in paper

slip and/or stubbing (paper jam). HCLs engineers use such data to examine the relationship between such

forces in different printer designs so they can make modications that resulting in optimum paper ow.

Buckle contours


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The Abaqus 6.10 release delivers on morethan 100 customer-driven enhancements

for modeling, performance, usability,visualization, multiphysics, and coremechanics.

Abaqus 6.10 introduces a new multiphysicscapability for performing ComputationalFluid Dynamics (CFD) simulation. Thisenhancement enables users to performcoupled physics simulations with Abaqus/Standard and Abaqus/Explicit, such asuid-structure interaction between a medical

device and uid ow; thermal analysis of

electronic systems undergoing convectioncooling; or transient thermal analysis of

engine exhaust systems.

In order to simulate performance ofengine components in a closer-to-realityenvironment, we are pleased that Abaqus6.10 provides the Computational FluidDynamic capabilities for uid-structure

interaction which will enable us to performaccurate uid and solid co-simulations,

says Dr. Fred Yang, technical leader ofbearing analysis from Federal-MogulPowertrain Sealing and Bearings GroupUSA. The new solution certainly givesus signicant enhancements to explore

multiphysics interaction in our designs andoptimize our products to reduce enginepower loss and lower overall material costs.

The release also reinforces SIMULIA'scommitment to providing an openmultiphysics platform throughimprovements to the direct co-simulationcoupling interface. This capability allowsSIMULIA partners and customers to coupletheir applications directly with Abaqus forbest-in-class multiphysics simulation.

With this release, SIMULIA also extends

its leadership in the simulation softwareindustry by delivering innovativetechnology for realistic fracture andfailure analysis. Abaqus 6.10 featuresenhancements to the extended nite

element method (XFEM) that improve theprocess for modeling fracture of compositematerials. It also provides dramaticperformance improvements for parallelprocessing of simulations that use XFEM,allowing more simulations to be performedin less time.

It is important to use the best technologiesand methods available to assess the safetyof nuclear power plant components," statesDipl.-Ing. Axel Schulz, TV Nord. "TheXFEM capabilities in Abaqus 6.10 will makeit easier to perform virtual safety evaluationsof nuclear power plant piping systems andpressure vessels. With this new release,realistic simulation of crack propagationbased on both the cohesive segments methodand linear elastic fracture mechanics is nowfeasible, while using the implicit dynamicprocedure for improved stability.

Key Features:

MultiphysicsInterface for CFD modeling, execution,and visualization in Abaqus/CAE

Coupling with Abaqus/Standard orAbaqus/Explicit for Fluid-StructureInteraction and Conjugate Heat Transfer;Incompressible (transient or steady)Flows; Turbulence modeling

Co-simulation interface for third partiesto integrate their software to Abaqus forcoupled multiphysics simulation

MechanicsImproved performance and extendedfeature coverage for general contact inAbaqus/Standard

Enhanced modeling of fracture ofcomposite materials with XFEM

Parallel processing improvementsfor simulations that use XFEM or theimplicit dynamic procedure

A new iterative equation solver offerssignicant performance enhancements

for simulations involving large blocky

Abaqus 6.10 Native CFD Capability for Fluid-Structure Interaction,Plus More than 100 Customer-Driven Enhancements

For More Informationwww.simulia.com/products/abaqus_fea

PRODUCTUPDATE

structures such as oil reservoirs andengine blocks

Enhanced coupled temperature pore-pressure displacement for modelingheat transfer in porous materials. This isuseful for analyzing petroleum reservoirs,nuclear waste repositories, or freeze/thawcycles in buried pipelines

A new model for capturing high-rateimpact of ceramics and other brittlematerials, based on the well-acceptedJohnson-Holmquist formulation

New capability to analyze structuressubject to air blast loading

Modeling and MeshingExpanded set of geometry edit toolsfor creating midsurface representationsof thin solid parts for more efcient

simulations

General 3D sweep capability for creatingcomplex, curved geometric features,including solid, shell, or cut geometricfeatures such as exhaust manifolds ofengines, or window frames in aerospacestructures

Several meshing improvements forquality and robustness of surface and tet

meshing

Improved interface for controllinglocal mesh gradation and density withenhanced usability and additionalcontrols including double-biased seedingoption

Usability and VisualizationPart- or assembly-based view cutscapability for both meshes andgeometry allows interior of models tobe visualized which makes it easier toposition assembly components and assign

attributesEnhanced overlay and vector symbol plotcapabilities and multiple view cuts forresults visualization

Numerous performance improvementsin Abaqus/CAE including faster handlingof a large number of connectors, setsand surfaces and faster loading of largedatabases

Abaqus 6.10 provides native CFD analysis capabilities

for uid-structure interaction and conjugate heat

transfer simulations. This image depicts the transient

thermal analysis of an engine exhaust system.


15/24


PRODUCTUPDATE

SIMULIA continues its commitment toenhancing Isight, the market-leadingsimulation process automation and designoptimization solution, as well as SIMULIAExecution Engine (formerly Fiper) fordistributing Isight simulation process ows

across compute resources.

Isight provides designers, engineers, andresearchers with an open system forintegrating design and simulation models,created with various CAD, CAE and othersoftware applications, to automate theexecution of hundreds, or even thousands,

of simulations. It allows designers to savetime and improve designs by optimizingagainst performance or cost variablesthrough statistical methods such as Designof Experiments or Design for Six Sigma.

Users of SIMULIAs Abaqus Unied FEA

will benet from a new licensing policy

that dramatically reduces the cost for usingAbaqus Unied FEA in automated design

studies with Isight. Using the combinationof these products allows customers to reducetheir Abaqus token usage by as much as 60percent.

In their presentation at the SIMULIACustomer Conference, engineers from BakerHughes, a top-tier oileld services company,

shared their experience in using Isight withAbaqus to optimize downhole expandabletubulars. Historically, at leasttwo months of analysis had been requiredto ascertain an acceptable geometry, statedJeff Williams, Project Engineer, BakerHughes Inc. With Isight, the developmentperiod was reduced to two days.

Isight 4.5 provides new scalable parallelalgorithms for leveraging multicorecomputing resources; enhancedapproximation and reliability methods toevaluate product performance across arange of real-world operating variables;improvements to multi-objectiveoptimization and data mining whichprovides deeper insight into performanceattribute tradeoffs.

The new features and enhancements inIsight 4.5 will enable our customers toexplore design options that were previouslyimpossible, due to time and cost constraints,stated Steve Crowley, director of product

management, SIMULIA, Dassault Systmes.By leveraging the new parallel algorithmand optimization features in Isight combinedwith the distributed computing capabilities ofSimulation Execution Engine, our customerswill be able to evaluate more designalternatives in less time, resulting in betterproducts at lower cost.

Key Features of Isight 4.5Parallel version of Pointer andMulti-Objective Particle swarm

Kriging approximations

Consumption of Abaqus tokens is reducedin automated Isight studies

Key Features of SIMULIA ExecutionEngine 4.5

Library enhancements: Add, delete, move& copy folders and enable folder accesscontrol (ACL)

Database size monitoring and control

Planned SEE shutdown, restart andrecovery

New Release of Isight and SIMULIA Execution EngineParallel Algorithms and Enhanced Optimization Methods, PlusNew Abaqus Token Usage Policy

For More Informationwww.simulia.com/products/isight

Several SIMULIA customers presentedtheir successful use of Isight at the 2010SIMULIA Customer Conference.

Advanced Body in White Architecture

Optimization

Pan Asia Technical Automotive Center

Benets of Simulation Process

Automation for Automotive ApplicationsINERGY Automotive Systems Research

How Can We Make Best Better: Using

Abaqus and Isight to Optimize Tools for

Downhole Expandable TubularsBaker Hughes Incorporated

Integrating Business and Technical

Workows to Achieve Asset-Level

Production OptimizationHalliburton

Isight-Abaqus Optimization of a

Ring-Stiffened CylinderGeneral Dynamics Electric Boat

Simulation Driven Design Enabling

Robust DesignRolls-Royce

Download papers atwww.simulia.com/cust_ref

Isight enables users to connect various applications into a simulation process ow to accelerate design

optimization.

Historically, at least two months of analysis had been required to

ascertain an acceptable geometry, stated Jeff Williams. With Isight,

the development period was reduced to two days.

Jeff Williams, Project Engineer, Baker Hughes Inc.


16/24


failing, and too much can cost us a fortune.Lightweighting our products is one of thekey things that has sustained Amcor againstour competition during these tough times,and computer-aided engineering (CAE),within a PLM environment, has been criticalto achieving that.

The goal of lightweighting resonates withengineers in every industry, from aerospace

to cell phones. But the weight savingsof plastic over glass have dramaticallytransformed the liquid container business inrecent decades. While glass has been usedfor centuries, and its physical properties arewell known, the move to PET in the 1970srequired a step-up in sophistication on thepart of manufacturers.

Simple product, complicateddesign challenge

A PET container is a simple product, but itsa complex design problem to make it right,says Krishnan. For example, the popular

two-liter carbonated soft-drink bottle,seen on supermarket shelves everywhere,has to be custom-designed to individual

brand specications and must retain its

blow-molded shape during cold-lling,

carbonation, sealing, labeling, packingand shipping (hot-lled containers need to

withstand additional temperature, vacuumand pressure uctuations). No container

should fail if accidentally dropped, norexcessively dent or lean when stacked.

To cost-effectively produce such a high-performance product, Amcors Advanced

CASESTUDY

The dynamic, competitive landscape ofthe consumer packaged goods (CPG)industry demands nimble, adaptativestrategies. PET (polyethylene terephthalate)plastic container manufacturers arejuggling business consolidation, increasinggovernment regulation, and the needto demonstrate corporate and socialresponsibility. At the same time, ever-

changing consumer preferences as well asenergy and raw material costs are driving anexponential expansion of product portfolios.The PET customer is demanding thatmanufacturers develop a wider variety oftop-quality, innovative containers in ever-shorter time periods and at lower unit prices.

To meet these challenges, the worldslargest supplier of PET containers,Amcors Rigid Plastics Division (renamedfrom Amcor PET after its parent boughtAlcan in late 2009), has found a way tosignicantly reduce costsfrom product

design to materials parameters to methodsof productionwhile adhering to strictindustry performance standards. They useProduct Lifecycle Management (PLM)solutions from Dassault Systmes tointegrate 3D virtual design, nite element

analysis (FEA), and collaborative productdevelopment software into their productdesign and development process.

The results: a 50 percent drop in designcycle times, enhanced communicationbetween designers and engineers, lessphysical prototyping, and faster time-

to-market. Plus quicker, more creativeresponse to customer requests fornew ideasand lighter-weight, high-performance product solutions that lowereveryones costs all along the supply chainfrom raw materials to transportation.

A few grams shavedmeans millions savedAmcors Rigid Plastics Division has 63facilities in 12 countries that providepackaging for many of the worlds leadingbrands of carbonated soft drinks, juices, teas,water, condiments, salad dressings, sports

drinks, soaps, shampoos, pharmaceuticaland health care products. The Michigan-based division produces about 25 billionunits of bottles, jars, cans and other productcongurations per year. Multiply that

number by even a few grams saved per unitand the sustainability impact is staggering.

A container made with too much, or toolittle, material can be very expensive, saysAmcors Advanced Engineering Services

group manager Suresh Krishnan. Toolittle material can lead to containers

Lighten up! Amcor Uses Realistic Simulationto Stay on Top in Plastic Container Market

Abaqus FEA helps industry giant slashdesign cycle time, reduce unit weightand enhance product performance

Origami concept vacuum panels are included in a

PET container for designed collapse that compensates

for shrinkage during cooling to maintain structural

strength and integrity. Original shape is clear, nal

shape is green.

Imageco

urtesyofAmcor


17/24


Continued on page 18

Kicking the container aroundwith simulationIt offers quite a range of disciplines. Thegroup began with top loading and vacuumpressure simulations. They moved on todrop-testing, blow molding, conveyance,denting, and leaning. They are currentlyworking on pasteurization and retort(heating during sterilization) simulations.They're even starting in on ergonomics, tosimulate the effects of a human hand puttingpressure on a container. Being able tosimulate multiple load conditions at thesame time is very important to us, saysKrishnan. You have to take into account anumber of parameters simultaneously, suchas uid-structure interaction, temperature,

pressure, and material strain rate.

With their FEA results in hand, theAdvanced Engineering Services group has aclear vocabulary for discussing the viabilityof a design with the industrial designers.Using multiple iterations between CATIAand Abaqus, the parties can collaborate toarrive at the best solution that validates theappearance, performance and functionality

of a particular container. Such improvedcommunication pays off: One of ourperformance metric targets was to reducethe number of design revisions we made by20 percent in a year, says Krishnan. Rightnow we are well ahead of that goal.

The benets from virtual testing can extend

beyond the testing laboratory all the wayto manufacturing, Krishnan says. Whenwe achieve an optimum top load value viasimulation, we can use that data to provideactual section weights to the processengineers in the plant, so they can more

easily produce the container that gives thedesired performance.

PET plastic behavior is complexThe PET material itself brings uniquechallenges to this whole process. PET ishighly nonlinear, with biaxial propertiesthat vary with the amount of stretching itundergoes. A semi-crystalline thermoplastic,PET softens at a glass transitiontemperature of approximately 76 degrees C.Above that, it becomes elastic and can beformed, a property effectively utilized in the

stretch blow molding process.

But when PET containers are lled with a

hot liquid, they are susceptible to shrinkageback towards their remembered previousshape (the preform), a characteristic thathas to be taken into account when designingthe initial container conguration. The

bottles also collapse slightly due to vacuumpressure resulting from cool-down afterhot-lling. So the design for a hot-ll PET

bottle includes vacuum panels for designedcollapse. We can now easily model thesekinds of physics-based characteristics with

Abaqus FEA, using a customized script forhydrostatic uid elements that enables us

to accurately simulate the behavior, saysKrishnan.

The contents of every type of PET containermust also be taken into account in Amcorssimulations, from adjustments in the densityand viscosity values of liquids (from purewater to sticky paint) to the internal pressureuctuations inherent to carbonated soft

drinks.

Engineering Services group uses computermodeling to simulate, or virtually test, thebehavior of a bottle under these diverseloads and stresses while its still in thedesign stage. At the core of their regimen

is Abaqus Unied FEA software. Amcoremploys Abaqus to generate simulationdata that can guide design modications,

material thickness parameters, evenmanufacturing processes, in order to reachthe lightest possible result that satises both

customer and regulatory requirements.

Visualizing the challengesBased on an initial concept that theindustrial design department has workedout with the customer, the design engineersstart by building a 3D virtual model inCATIA. They then use customized scripts

and knowledge templates within CATIA toaccurately determine the critically importantsurface area, volume and weight for thebottles nal design. CATIAs capabilities

save us a lot of time, says Krishnan.Whenever the analysis shows that we needto make a design change, we can do so andthe model automatically adjusts to reect

that. And instead of starting a new designfrom scratch, we can begin with an existingdesign and quickly modify it.

Next, the engineers mesh the geometry ofthe virtual bottle with either Hypermesh

or Abaqus/CAE (our designers areincreasingly using Abaqus/CAE becauseit has a CATIA-like look so its easier forthem to work with, says Krishnan), thenbring it into Abaqus Unied FEA for

physics-based performance simulation.A typical Abaqus model for a top loadanalysis (such as bottle capping, orcontainer stacking) has about 150,000shell elements and about 350,000 degreesof freedom. A more complex, CoupledEulerian-Langrangian drop analysis(which simultaneously shows the uid-

structure interactions between a container,its contents, and the oor) can have up to800,000 d.o.f. The group runs its analyseson a Microsoft Windows HPC Server.

Amcor tried a different FEA softwarein the past, but realized they were notgetting satisfactory results and switchedto Abaqus, a change that empowered thegroup to begin exploring the full scope of itsdesign challenges. Abaqus was the betterchoice for us because it offered a breadthof simulation disciplines that cover moresignicant performance requirements for

PET containers, says Krishnan.

(a) This vacuum deformation test shows how the original PET bottle shape

(gray line) shrinks after lling (green line) as the heated product cools. (b) A

side view of an Abaqus FEA analysis of a vacuum deformation test similar to

(a) shows that the greatest load (red) occurs at the bottom of the container.

(a)(b)


18/24


cycle down to nine months from 12 to 18,which has signicantly reduced our product

development costs. And weve gained a lotof management buy-in to our methodology.

CAE promotes creativityThe use of CAE has proved of value forAmcor when proposing new ideas to clients,Krishnan says. We include animationsof our Abaqus simulations in all ourpresentations. We can demonstrate howwe create a design, perform FEA on it, andtry out as many options as we want. Anyindustrial design proposal can be quicklysimulated; if a customer puts in a requestin the morning, animations can ready by

that evening. It really frees the designersto explore whatever ideas they have, says

Krishnan.

Its a fast-changing business and the nextnew design is just around the corner, headds. Somebody else is always looking tocapture that design so we have to be reallyfastand with CAE in our arsenal, we are.

Amcor continues working on advancedmaterial properties for their models. WhilePET is 100 percent recyclable, containersmade from recycled PET (RPET) may haveslightly different material properties thanthe originals. Initiatives also are underway

in the industry to develop biodegradablePET using ethanol. Although we are notsimulating either of these materials at thetime, this is certainly a consideration for thefuture, says Krishnan.

Managing all that dataIt all adds up to a vast amount of simulationdata. Amcor keeps track of everything theAdvanced Engineering Services groupgenerates by using Dassault SystmesENOVIA solution for collaborativeproduct development, which facilitates theorganization and easy retrieval of all CATIA

and Abaqus data for each container designwhile managing all processes to keep themin synch.

Whoever in our organizationfromthe Advanced Engineering Servicesgroup of 14 engineers all the way to ourmanufacturing plantsneeds informationabout a specic project, they can pull up

the report in ENOVIA and nd the latest

version, completely standardized, which isvery helpful, says Krishnan. ENOVIAautomatically saves the history of everyprevious iteration as well, allowing for easy

reference, tracking and communicationamong our project teams.

Results rise to the top withsimulation-driven lightweightingThe growth of Amcors physics-basedsimulation capabilities has been the drivingforce behind the companys lightweightinginitiative. Krishnan cites one example wherea 63-gram container design was reducedto 43. We used realistic simulation tovalidate performance while trying outvarious Amcor-developed technologiesand eventually met all performancerequirements with the lighter design, hestates. Simulation helped us try manymore options than we normally would andcompare multiple designs with one another.

Although Amcor still validates their virtualtests with physical testing, the ever-increasing accuracy and renement of their

computer predictions has allowed them todecrease physical prototyping dramatically.

We see a close match between the curvesthat Abaqus provides and the test results soweve got a lot of condence in simulation

now, says Krishnan. Weve cut our design

CASESTUDY

For More Informationwww.amcor.com

Abaqus FEA container drop test uses a Coupled Eulerian-Lagrangian analysis to show the interaction

between the container, the uid it holds, and the surface it impacts. The top must stay on even when the

container is dropped 3 feet to a hard oor.

Graph of empty vented top load response test results shows how accurately Abaqus FEA (red line)

predicted the behavior of the container.

0.00 0.10 0.20 0.30 0.40

60

50

40

30

20

10

0

Displacement (in)

Load(lbf)

Specimen 1 Specimen 2 Specimen 3 Specimen 4 Specimen 5 FEA

Empty Vented Top Load Response: ES22A


19/24


For More Informationwww.geo.ua.edu/faculty/Masterlark.php

Abaqus analysts work with nonlinearsimulation and experimental data that

often has non-ideal aspects such asnoise, discontinuities, and drifting. AtAtrium Medical, David Heims CAEteam frequently uses Bodie TechnologysKornucopiasoftware to provide aconsistent means of interpreting measureddata from testing of implantable medicaldevices. Using a combination of trimming,shifting, smoothing and derivative functionsfrom Kornucopia, they efciently clean

measured data providing a more accurateand reliable basis for correlation whichultimately improves the delity of their

Abaqus models. Additionally, their reusable

worksheets provide clear and traceabledocumentation of their data cleaningprocesses.

At BD, engineers developing medicaldevices often work with polymeric snap-t

features that endure highly nonlinear post-yield behavior. To obtain efcient and robust

simulations, BD uses Abaqus/Explicit inconjunction with Mathcad and Kornucopiafor post-processing and correlation to largevolumes of physical test data. According toDr. Arun Nair, CAE Project Engineer, BD,

We utilize several easy-to-use Kornucopia

DSP and data processing functions toseparate out assembly and disassemblyresponses, analyze frequency content, andsmooth data. All the methods, data andplots, including subsequent evaluationsof dimensional and material changes, arestored in one Kornucopia worksheet whichprovides clear traceability to each of theindividual procedures. The advancedfunctionalities in Kornucopia have enabledus to condently and quickly post-process

FEA and physical test data to make accurateand important engineering decisions.

Streamline Model Correlation, Snap-Fit Simulations, andRepetitive Shock Analyses with Kornucopiaand Abaqus

Designing construction equipment capableof withstanding severe repetitive shock is

another challenging problem being tackledby combining Abaqus with Kornucopia. Inthis customer case, applying Kornucopiasdecimation feature to the experimentalacceleration data driving the modelcut simulation time by 50 percent, yetmaintained essential frequency contentand random characteristics. Initial day-long Abaqus implicit transient dynamicsimulations were further reduced to a couplehours by switching to modal transientanalyses while still achieving 80 percent ofthe desired response metric for accuracy.

Other keys to success were additionalKornucopia-based modications to

the driving signalusing rampedwindows, highpass lters, and integration/

derivative functions to minimize thearticial discontinuity of an abbreviated

experimental signal which would otherwisecause improper ringing and drifting.

ALLIANCES

Exploring the Interior of an Active Volcano with Abaqus and CrayThe recent eruption of the Eyjafjallajkullvolcano in Iceland caused the worst air travelbottleneck in history. For Dr. Tim Masterlark,Assistant Professor at The University ofAlabama, and his fellow researcherswhostudy the physical behavior of earthquakesand volcanoes using Abaqus FEA, satelliteimagery, and seismometer datait was asignal that their work is critical and moreurgently needed than ever before.

Due to the recent seismic activity andhistory of volcano eruptions in Iceland,Masterlark and his colleagues are in a raceagainst time. To help accelerate their Abaqussimulations, they acquired a Cray CX1.

Estimating the parameters that best describethe magmatic behavior is numericallyintensive, states Masterlark. Thisprocess involves automated algorithms thatincrementally adjust and improve the Abaqusmodel congurations until the simulations

accurately predict observations. This canrequire thousands of simulations to obtainan optimal set of parameters. Our new Cray

CX1 provides the computational repower

to achieve this goal in an acceptable amountof time.

The teams Cray CX1 conguration was

setup specically for running Abaqus

simulations. It includes 40 cores and 120GB RAM in a standalone conguration that

is fully dedicated to simulating volcanodeformation. The scalability of the Cray CX1system accommodates future expansion ofDr. Masterlark's research group.

The University of Alabama team isextending the concepts learned in previousstudies (an exercise in hindsight) to attemptto forecast the timing of a future eruptionof Hekla, one of Iceland's most activevolcanoes. Researchers believe that Hekla'snext eruption is imminent and presents anarrow window of opportunity to forecastthe specic timing of the upcoming eruption.

We are planning an expedition to Hekla to

deploy seismometers and collect seismicdata to construct tomographic images,which will help us design and constrainAbaqus-based simulations of magmaticmigration, states Masterlark. Thesesimulations will ultimately guide ourforecasts for the upcoming eruption. If weare successful, Abaqus will play a key rolein eruption hazard assessments for activevolcanic systems.

For More Informationwww.BodieTech.com

Reusable, self-documenting Kornucopiaworksheet.

Erika Ronchin, Dr. Tim Masterlark, and Dr. Wei Tao.


20/24


(Top) A 500 micron-long silicon wafer being cut by a diamond grain.The gure illustrates the von Mises

stress distribution during grinding. (Bottom) Stress distribution near the tool tip and damage localization

near the surface of a silicon wafer during back grinding.

ACADEMICUPDATE

Simulation of Back Grinding Process for Silicon WafersSemiconductor devices are key componentsfor a wide range of electronic applications.Silicon wafers are commonly used assubstrates to build the vast majority of

semiconductor devices. Part of the reason fortheir success has been the ability to reducecosts year upon year while meeting stringentsize and weight specications for electronic

packages.

As consumers continue to demand smaller,lighter, and higher capacity devices at lowprice points, meeting shrinking weight andsize requirements poses signicant challenges

in the development of modern electronicdevices. Silicon wafer thickness greatlyaffects package size, thus thinner wafersresult in smaller packaging dimensions. To

manufacture the thinnest wafers possiblerequires a process called back grinding ofthe wafer, which also poses engineeringchallenges.

In the Mechanical and Electrical EngineeringDepartments at the University of Idaho,Professors Potirniche and Barlow withgraduate student Abdelnaby worked incollaboration with the researchers fromMicron Technologies to simulate the backgrinding operation of silicon wafers in orderto predict residual stresses and achievea thorough understanding of the plastic

deformations and damage processes during agrinding operation. The numerical simulationsinvolve varying grinding parameters todetermine optimum conditions that willminimize the residual stresses and surfacedamage.

Traditionally, researchers have usedmacro-scale or the micro-scale approachto simulating the grinding process. Macro-scale models consider the overall wheelworkpiece interaction which captures theaggregate effects of the abrasive wheel onthe workpiece and makes no attempt tostudy the deformation and damage at the

crystallographic grain level of the wafer. Onthe other hand, micro-scale models focus onthe individual grain-workpiece interactions.These models attempt to elucidatemechanisms involved in the materialremoval at the micron length scale. Theysimulate the micro-scale grinding process,which includes the high delity modeling

of a single diamond crystal (abrasive grain)cutting through successive silicon layers.Micro-scale models have the potential toestimate the grinding forces directly, withoutresorting to measurements or empiricalmeasurements.

The University of Idaho and MicronTechnologies corporation researchers havebuilt a two-dimensional model to simulatethe cutting process of a silicon wafer bya small diamond particle. Using parallelprocessing capabilities of Abaqus/Explicitand a set of properly dened boundary

conditions, accurate simulations of thegrinding process at the micro-scale wereachieved.

The residual stress eld, as obtained from

the numerical simulations, was comparedwith experimental data from Ramanspectroscopy measurements and excellentagreement was obtained. This exampleshows the robustness and the availability ofa wide range of material models providedby Abaqus/Explicit. These extensivecapabilities allowed accurate simulation ofgrinding in order to better understand andimprove this challenging manufacturingprocess.

A.H. Abdelnaby1, G.P. Potirniche1, F. Barlow1,A. Elshabini1, R. Parker2, T. Jiang2

1University of Idaho, 2Micron TechnologiesResearchers Abdelnaby (left) and Potirniche in

their computer lab.

For More Information

www.uidaho.edu/engr


21/24


The need to integrate more devicetechnology in a given board space for

handheld applications such as mobilephones and medical devices has driven theadoption of innovative packages whichstack such devices in the vertical or thirddimension (3D). Further reduction ofsize, thickness, and cost of this Package-on-Package (PoP) solution was possiblethrough the development of Fan-in Package-on-Package (FiPoP) technology whichenabled more device integration whilemaintaining reliability requirements oftypical handsets.

One common mode of failure of FiPoPs

occurs due to thermal conditions in the stack.Providing a thermal path for heat dissipationis the only option to maintain the junctiontemperatures in these packages due tospace and cost constraints. Though variousfactors affect package thermal performance,graduate student Nandini Nagendrappa withguidance from Professor Nicole Okamotoand Professor Fred Barez of San Jose StateUniversity, chose to focus on varying theinternal design parameters only to observethe change in thermal performance.

Based on the research of earlier generation

models, the parameters chosen for analysisin this work included (a) number of thermalvias (b) solder ball Input/Output (I/O)density and (c) die size. Geometrical andmaterials parameters for a typical FiPoPwere acquired from STATS ChipPac Ltd.The stacked package within FiPoP chosenfor analysis included two metal layers, 14x 14 mm body size, 9 mm x 9 mm die size,0.075 mm thickness for both top and bottompackages, and 0.5 mm solder ball pitch.

For this study a test package was modeledin Abaqus/CAE, as it provides the ability

to create intricate parts at the micron level,which was required to model the packageinvolving vias, traces, and wirebonds.

JEDEC-specied standards and environment

were applied to carry out the steady-statenite element thermal analysis. Thermal

boundary conditions applied were powerdissipation, ambient temperature, anda combined heat transfer coefcient for

natural convection and radiation (typical ofstill air conditions). Also, changes in thermalresistance were examined from one test runto another rather than absolute values.

The simulation on the stack was carriedout by either powering (loading) the top orbottom package one at a time or by poweringboth. This was done to study the effect ofthermal loads separately and combined.

In development of mobile handsets andmedical devices, designers must payparticular attention to the design of efcient

heat paths to the die package. Heat ows

from the silicon die to the ambient throughtwo main mechanisms. One is throughconduction from the silicon die of both top

and bottom packages through the die attach,substrate, and solder balls to the PCB. Theother is through conduction from the diethrough the mold compound to the top andsides of the package. From the packagethe heat is transferred to the surroundingsthrough convection and radiation. A surface-to-surface contact approach was adopted inAbaqus to dene the electrical/thermal I/O

path. The contact detection toolset in Abaqus/CAE automatically generated all the requiredsurfaces and interactions making it very easyto dene the extensive thermal contacts in

this model.

San Jose State University Simulates the Thermal Characterizationof Fan-in Package-on-Packages

For More Information

www.engr.sjsu.edu

ACADEMICUPDATE

(Top) FiPoP model with stacked top and bottom package. (Bottom) Bottom package with interposer close-up

copper traces and wire bonds.

The importance of the analysis results lies inthe change in resistance from one simulationto the next rather than the absolute value,since the total resistance includes theconvection resistance which is a constantfor all cases. For each case, absolute valuesof results were obtained and percentagechanges between simulations were tabulated.

The analysis predicted that the thermalresistance of the bottom package of a FiPoPdecreases with the increase in the numberof thermal vias and solder balls placed

under the package. As expected, the thermalresistance of the entire package increases asthe die size drops.

The article is based on the paper presented at the

26th IEEE Semiconductor Thermal Measurement &

Management Symposium - 2010, entitled Thermal

Characterization of Fan-in Package-on-Packages, by

Nandini Nagendrappa, Nicole Okamoto, and Fred Barez

from San Jose State University, San Jose, California,

USA.


22/24


INTHENEWS

Leading German AutomakerSelects SIMULIA Solutionsfor Passive SafetyAs an extension to the recent ve-year partnership with DassaultSystmes, BMW Group has renewed its commitment to use AbaqusUnied Finite Element Analysis (FEA) software for the engineering

of passive safety in the automakers virtual design process.

BMW rst began employing Abaqus as its exclusive tool for crash

simulation in 2004, when vehicle development projects were largelysupported by hardware testing and the focus of simulation was onglobal vehicle behavior. More recently, BMW has begun a strategicshift toward a more complete virtual development process.

Following extensive evaluations conducted by BMW, ranging from

component-level to full-vehicle simulationsand involving keyapplications in car body technology as well as occupant restraintsystemsresults showed Abaqus FEA consistently delivered higherlevels of predictiveness and repeatability against physical tests thanother simulation software. This robustness and reliability is criticalas BMW moves toward a more efcient and cost-effective virtual

vehicle development process that depends less and less on physicalprototyping.

The strong correlation between physical test and simulation resultsobtained with Abaqus enables BMW to achieve its aggressive processimprovement goals, resulting in substantial cost and time savings foreach vehicle project, while meeting stringent safety requirements.

>> www.simulia.com/cust_ref

InnerPulse AcceleratesMedical Device Innovationwith SIMULIA SolutionsFounded in 2003, InnerPulse is a medical device company pioneering anovel technology for those patients with cardiac rhythm disorders. UsingAbaqus FEA to assist in development of their technology designedin SolidWorks CAD software, InnerPulse has developed a new, trulyminimally invasive treatment for patients with cardiac rhythm disorders.

According to the Sudden Cardiac Arrest Association, approximatelyone American life is lost every two minutes due to cardiac arrest, withan estimated more than 7,000,000 lives lost per year worldwide. Anoverwhelming majority of these deaths are caused by ventricularbrillation, or rapid, uncoordinated contractions. InnerPulse's new

device, a percutaneous implantable debrillator (PICD), allows simple

implantation of the debrillator within a patient's vasculature using

a catheter procedure. InnerPulse leveraged SolidWorks design andsimulation capabilities in Abaqus FEA software, providing engineersaccurate analysis for simultaneous device and tool designultimatelylowering costs and saving development time.

With new technology allowing the development of industry-changingdevices, InnerPulse and SIMULIA help lead the way for new proceduresin the advancement of saving lives.

>> www.inner-pulse.com

BMW Group, Predictive Crashworthiness Simulation in a Virtual Design Processwithout Hardware Testing, 2010 SIMULIA Customer Conference


23/24


Register Today!www.simulia.com/scc2010

EVENTS

Asia Pacific

Date Location

September 78 Tsingdao, China

September 10 Korea

September 16 India

October 2829 Kuala Lumpur,

Malaysia

November 23 Taipei City, Taiwan

November 17 Tokyo, Japan

Americas

Date Location

September 28 Chicago, IL

October 19 Houston, TX

October 2021 So Paulo, Brazil

October 25 Southern CA

October 26 Canada

October 27 Northern CA

October 28 Beachwood, OH

October 29 Pacic Northwest

November 10 Plymouth, MI

Europe/Middle East/South Africa

Date Location

September 2021 Germany

September 23 Athens, Greece

Septem

Insights May June 2010

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