Simulation and Optimization of Structures under Real Operating Conditions using Nonlinear FEA Ted B. Wertheimer MSC.Software.

Simulation and Optimization of Structures under Real Operating Conditions using Nonlinear FEA Ted B. Wertheimer MSC.Software Vision for the 21 st Century Integrated Adaptive Optimized Nonlinear Analysis Nonlinear Solutions Available from MSC MSC.Nastran - Mildly Nonlinear MSC.Marc - General Nonlinear MSC.Dytran - High Speed Dynamics and Fluid Interaction MSC.AutoForge - General Bulk Forming MSC.SuperForge - Fast Forging Flow Solution MSC.Construct - Linear Optimization Requirements For Nonlinear Analysis Material Behavior Large Deformation / Large Strain Contact Robust Solutions Multi-Physics Optimization and Design Sensitivity Improve Product Design Improve Product Behavior Reduce Product Cost Reduce Design/Testing Iterations What are the Design Objectives? Minimize Mass Minimize Cost Minimize Manufacturing Costs Minimize Noise Optimization Examples in Aerospace Turbine Disk Sheet Panels Shape Optimization of a Turbine Disk LPT Rotor without Blades Courtesy of Cutaway Optimization Examples for the Rubber Industry Seals Tires Parametric Analysis of Closure Pressure on a Rubber Seal Rubber Remeshing with New Triangular Elements Force Vs. Distance for Different Rubber Materials Applications - Door Sealing Loads Applications - Acoustic Transmission Optimization Examples in Manufacturing Defect Prediction Minimizing Number of Tools Rolling Forming Defect (initial forming sequence) Another Forming Defect after 1st modification The Process of Ring Rolling 10x Speed How Many Rollers ? What Shapes ? and When ? 3D Sector Results Plastic Strain Contours To be Repeated ~50x Note: Increasing Radius Project to Target Increase in Ring Radius [in] 2D-GPE Simulation Rolled Versus Design Shape Preform 2D Rolled Near Net Shape Machined Shape Sloshing in Automotive Fuel Tanks Modeling Rigid or flexible tank boundary & partitions Rectangular Euler mesh covers tank motion range General coupling Define fuel level Tank Fuel Euler domain Sloshing Tire Hydroplaning Elements 154,490 Nodes 164,522 V groove Backward rotation V groove forward rotation Rotatio n directio n COURTESY OF THE YOKOHAMA RUBBER CO., LTD. Comparison Tire Hydroplaning Lift force Contact force Contact force, dry Forward rot Backward rot COURTESY OF THE YOKOHAMA RUBBER CO., LTD. Contact and lift forces Tire Hydroplaning Backward RotationForward Rotation FLOW COURTESY OF THE YOKOHAMA RUBBER CO., LTD. Foot Print MSC.Dytran Test As a Result of the Evolution of Numerical Methods and Computer Performance Engineering Design Structural Analysis Manufacturing Hardware Virtual Manufacturing We are Witnessing A Revolution in Design and Manufacturing