3dcs compliant modeler, add fea to your tolerance analysis
DESCRIPTION
3DCS Compliant Modeler is the easy way to add Finite Element Analysis to your Tolerance Analysis. This add-on accounts for deformation in parts and assemblies from force, gravity, heat, clamping, welding, springback and other effects. Working with FEA Mesh, a simple output from any FEA Solver, 3DCS Compliant Modeler makes it easy to add greater depth to your analysis. Use simulation to resolve issues upfront in the design phase, and reduce the rework and flexible problems caused by many new materials. Let us show you how you can reduce variation and avoid a major headache from working with flexible materials. Email DCS today at [email protected] for a free demonstration.TRANSCRIPT
Advanced Compliant Variation Analysis
FEA Compliant Modeler for 3DCS Variation Analyst Suite
Clamp/Weld Clamp/Weld
Agenda
• Rigid Body Modeling• Compliant Modeling• 3 Compliant Cases
–Aircraft Wing–Car Hood–Rail Assembly
• FEA Interfaces• Q & A
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2008
Rigid Body Tolerance Analysis
Inputs• Assembly Strategy• Part Tolerances (GD&T)• Desired Measurements
Outputs• Datum Locating Scheme• Tolerance Sensitivity• 6sigma Variation
*Assumption: Parts do not bend or morph to meet over-constraining targets
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2008
Compliant (Flexible) Parts
What Parts are Compliant?• Structures • Interiors• Power Train• Suspension
Why?• Size & Thickness• Gravity• Heat• Force
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2008
04/10/2023 © Dimensional Control Systems Inc. 2008
5
Compliant Tolerance Analysis
Uses Finite Element Methods to simulate variation with deformable parts
Additional Model Inputs• FEA Data
o Mesho Material Propertieso Stiffnesso Masso Thermal
• Compliant Processeso Clampingo Weldingo Bendingo Springbacko Etc.
Compliant
FEA Data
Compliant Processes
Analysis Results3DCS Model
Rigid Body
Assembly Method
Part GD&T
Measurements
Compliant
FEA Data
Compliant Processes
Compliant Tolerance Analysis
Uses Finite Element Methods to simulate variation with deformable parts
Confidential – Please do not distribute.04/10/2023 © Dimensional Control Systems Inc.
2008
Methods for Modeling Compliant Parts
User Experience Difficulty Level Relative # of Moves
Locating Points in Example
Relative Timing / Part Software
Rigid-Body 3DCS® training Beginner 1 5 1.0 3DCS® Analyst
Bend Routine 3DCS® Advanced 1 17 2.0 3DCS® Analyst + User DLLs
Compliant Modeler 3DCS®, FEA Intermediate 3 18 1.5 3DCS® Analyst + 3DCS® FEA CM AddIn +FEA Software
Accuracy
1.Rigid-Body Traditional Moves - part does not deform2.Bend Routines User DLLs - part deforms about defined bend lines 3.Compliant Modeler using Finite Element Analysis (FEA) - part
deforms to target points
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2008
Compliant Modeling Benefits
• More Accurate Analysis• Faster to build Model• Limited FEA interaction • Analyze Assembly Sequence• Optimize Clamp, Fasten, Weld,… Sequence• Analyze Gravity and Thermal effects
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2008
Use Cases Overview
AIRCRAFT: Ground Clearance
AUTOMOBILE: Hood to Fender Flushness
Rail Model
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2008
Aircraft Engine Ground Clearance
Examples of Very Low Ground Clearance
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2008
DCS Model
Gravity acting on Wing and Engine
Effect of Gravity On Distance (mm)
Wing Tip 29.17
Ground Clearance 5.97
1. Gravity
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2008
*min & max position measurements are relative to nominal position
nominal
minmax
Effect of Engine Position On Min Position (mm) Max Position (mm)
Tip Displacement - 0.30 + 0.36
Ground Clearance - 70.17 + 68.76
2. Engine PositioningEngine moved from min to max position
Confidential – Please do not distribute.04/10/2023 © Dimensional Control Systems Inc.
2008
Tolerances were added to simulate imperfect parts
3. Dimensional Variation
Measurement Nominal Range with Variation
Wing Tip 29.18 264.48
Ground Clearance 5.97 57.62
Results: Engine Placement1st Tolerance Scenario:• Engine at nominal• Fuselage Tol- 5mm
5 mm
2nd Tolerance Scenario:• Engine at nominal• Fuselage Tol- 3mm
Measurement 1st Scenario 2nd Scenario % Change
Tip Displacement 264.48 158.71 40
Ground Clearance 57.62 35.12 39
Results: Fuselage Tolerance Scenarios
3 mm
Automobile Bumper Placement
Problem
Hood Fender
Hood is under-flush to Fender with high variation
Add a pair of bumpers to contour the Hood to the Fender and reduce flush variation…
Suggested Solution
but where?
1. Front 2. Mid 3. Mid2 4. Upper
Determine the location of lowest flush variation between Hood and Fender.
Simulate the placement of Bumpers at (4) locations:
Bumper Positions
5000 Simulated Builds in 3DCS
Flush variation measured at these locations
1 2 3 4 5 6 7 81.2
1.4
1.6
1.8
2
2.2
2.4
2.6
2.8
3
3.2
NoFrontMidMid2UpperAvg
Rear - Mid - Front
Est.
Rang
e Va
riatio
n (m
m)
Mid2 and Upper Bumper placement result in least f lush variat ion
Hood to Fender Flush
1 2 32.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
NoFrontMidMid2Upper
Front - Mid - Rear
Est.
Rang
e Va
riatio
n (m
m)
Hood to Fender Gap
Hood to Fender Gap is Independent of Bumper Location
1. Front
2. Mid
3. Mid2
4. Upper 2.173 mm
2.172 mm
2.305 mm
2.328 mm
2.483 mm0. None
Conclusions
Mid2 bumper location is best for Hood to Fender flushness.
Avg. Est. Range at Bumper Locations
Pushing the Envelope…• Real Time Diagnosis of Manufacturing issues• Mechanical System Analysis
– Analysis through a range of motion– Effects of Rubber Bushings on Variation
• Fuel Efficiency Impacts– Tolerances on Mass– Number of Shims on Mass– Surface Quality on Wind Drag
• Plant Layout \ Cycle Times– Clamps and welds required per station– Machining stations required
• Design & Manufacturing Optimization– Fit and Finish based on Perceived Quality– Design Interfaces, Cut Lines & Locators– Tolerances– Number of parts and Sequence of Assembly and Fastening
• Non Linear Sensitivity Analysis
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2008
Thank you, Questions?
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2008
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How is the model Created?
2. Using the 3DCS FEA CM Modeler create clamp, weld, unclamp operations.
1. Create Model utilizing the standard DCS Moves, Measures, and DCS Tolerances and/or FTA
3. Generate FEA Input Deck and Stiffness Matrix using your FEA Pre & Processor and Solver.
4. Link 3DCS FEA CM to Input Deck and Stiffness Matrix and run Visual and Statistical Study.
© Dimensional Control Systems Inc. 2008
How does it work?The 3DCS FEA Compliant Modeler deforms the parts during simulation based on the part stiffness matrix for each compliant part that has been imported into the 3DCS model.
The FEA Mesh and stiffness matrix is acquired from software like Abaqus, Hypermesh and NASTRAN. The part stiffness matrix defines how a deformation at one point will affect other areas of the part – where, and how severely.
Clamp/Weld Clamp/Weld
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Causes
Moves method
Sequence
Rigid moves
Compliant moves
Clamping method
Joining type
N° clamping points
FEA files
Input data
Type and size elements
Pre-processor and solver
SOFT 1DOF vs HARD 3DOF
CM Model Influences
Product Mesh File Extension Stiffness Matrix Extension
Abaqus .inp .mtx
Nastran .bdf, .blk, .dat, .nas .bdf
Optistruct .fem, .parm .dmig
MSC Nastran .dat .pch
Supported FEA Solvers*DCS is constantly adding new features and functions, making this list subject to change
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What Process are Supported?• Clamping• Spot Welding• Unclamping • Spring Back• Bolting• Riveting• Joining• Clipping• Heat Staking• Compliant to Rigid• Compliant to Compliant
• Single Stage Assemblies• Multi Stage Assemblies• Force Application • Gravity• Thermal Expansion \
Shrinkage• Distortion • Load Sequence • Clamp, Weld and Un-Clamp
Sequence• 3+ thickness welding• Nearly anything supported by
the state of the art FEA tools.