CAE Model Research Articles

Development of parallel explicit finite element sheet forming simulation system based on GPU architecture

Sheet forming simulation is very important for vehicle body design. Due to the increase of complexity and scale of the CAE model, a tradeoff between the accuracy and efficiency become the bottleneck for application. Therefore, a parallel explicit finite element (FE) based on graphics processing unit (GPU) architecture for sheet forming is developed. Implementation details with computer unified device architecture (CUDA) are considered in this work. A pre-index strategy is suggested for parallelization of nodal force assembling. Parallel reduction method is introduced to calculation of the global time step. To ensure the reliability and accuracy of the GPU-based program, double precision floating and intrinsic functions are implemented for the explicit FE computing. The simulation results based on a commercial NVIDIA GTX285 device can obtain about 27X speedup than on a Intel Q8200 CPU, which demonstrates the efficiency of the parallel sheet forming simulation system.

Electromagnetic Force Principles Study and Numerical Simulation of Permanent Magnet Synchronous Motor (PMSM) for Electric Mobile

Motors of electric automobile with low noise characteristics are increasingly in demand due to environmental considerations. The primary source of noise is attributed to electromagnetic noise, mainly affected by electromagnetic radial force. To obtain a better understanding of origination and components of radial force, in this paper, theoretically, calculate and analyze electromagnetic radial force principles; and establish 2-dimension CAE model of PMSM subsequently. After simulation and data analysis, in terms of time and frequency domain, respectively, calculate the numerical radial air-gap flux and radial force. Compare the theory with numerical results. To some extent, ratify the radial force theory of PMSM in electric vehicles.

Automatic Generation of the CAE Parametric Model from the CATIA Model for an Aircraft Hydraulic Tube Structure

In order to help the designers estimate the dynamic response of the aircraft hydraulic tubes in the working environment, a design and simulation software is developed based on CATIA and ANSYS using VB as the developing tool. This paper concentrates on the part of auto-modeling and introduces the key technologies to automatically extract the CATIA model data and build the CAE parametric model of aircraft hydraulic tube structure in ANSYS. It provides an approach to transfer a CATIA model into a CAE model conveniently which reduces the time for FE (Finite Element) analysis and makes the designers be free from the repetitious data transmission, modeling and so on.

An automatic model calibration method for occupant restraint systems

Computer models are widely used to simulate dynamic systems in automobile industry. It is imperative to have high quality CAE models with good predictive capability. This requires CAE engineers to conduct model calibration with physical tests. The challenges in the occupant restraint system model calibration are: (1) the dynamic system usually consists of multiple responses, (2) most of the responses are functional data or time histories, and (3) the traditional trial-and-error calibration approach is time consuming and highly depends on analyst's expertise. These call for the development of an automatic and effective model calibration method. This paper presents a newly developed automatic model calibration method, based on the Error Assessment of Response Time Histories (EARTH) metric. The EARTH metric is used to perform model assessment on various important features of the functional responses. A new multi-objective optimization problem is formulated and solved by a Non-dominated Sorting Genetic Algorithm to automatically update CAE model parameters. A real-world example is used to demonstrate the use of the proposed method.

Parametric CAD/CAE integration using a common data model

This paper proposes a CAD/CAE integration method using a “common data model” (CDM) containing all the required parametric information for both CAD modeling and CAE analysis. CDM is automatically generated by a knowledge embedded program code. The CDM is used as a parametric data model repository and the supply source of input for those associative entities of CAD and CAE models and thus maintaining the associative dependences among them. The structure as well as the data flow in the CDM is governed according to the general and widely used design processes. Thus designers can relate the expected scenarios with the engineering changes proposed and can take the parametric actions accordingly. CDM acts as the centralized parametric input for computer modeling software tools through their APIs. Throughout the design process the common data model gets modified during each development cycle according to designer’s intent, the changes in it are consistently reflected in both CAD and CAE models through regenerations and analysis iterations semi-automatically. The same data model in a suitable file format can be used to work with different CAD and CAE packages. As CDM, CAD and CAE work as different modules interconnected through a develop software prototype package which integrates APIs and knowledge rules embedded in the engineering procedures. However, each of the software tools used for each purpose can vary as per the original data requirement without hindering the process structure. The data model is reusable and the whole process is automated as far as possible so that the embedded expertise in the cycles of the adaptive design and manufacturing can be consistently applied iteratively during product development processes. Also being a data file in a suitable format generated via computer programming, the CDM is convenient to record and store information associated to all the product design revisions.

Application of Reverse Engineering to Product Development

This 3D optical metrology has become a standard tool in industrial process chains by providing fast and precise full-field 3D data for quality control, rapid manufacturing and reverse engineering applications. In this report, the trend that 3D optical metrology has widely used by the product development is described. Concretely, it is described to inspect shape on the free-form surface, to digitize the design model, to manufacture solid shape without CAD model, to define CAE model from real shape, to make analysis for sheet metal components, and to make real-time strain measurement for tensile tests.

멀티 캐비티 실린더 기어 개발

The cylindrical gear in power window motor assembly is important to doors of automobile. This study is performed for the purpose of getting a manufacturing technique instead of large quantities import and six-cavity mold production. This multi-cavity cylindrical gear is produced under five procedures. The first, mold design of mass-production, the second, making a CAE model for mass-production, the third, manufacturing of sample mold, the fourth, trying-out and measuring of 3 dimensional design, the fifth, acquisition of data analysis and mold modification. Among them, analysis of mass-production using CAE, designing and manufacturing of multi-cavity are successfully performed. In the results, it is concluded that the mold for one gate and eight-cavity based on hot-runner is suitable for making a cylindrical gear.

A Kind of CAD/CAE Integrated Modeling Technology Based on FEATURE

A kind of CAD/CAE integrated modeling method based on feature is proposed. Firstly, analysis features are attached to CAD model of part and standard part library is formed. Secondly, the CAD model is created using standard parts. Thirdly, geometry information of analysis features is extracted from CAD model and is reconstructed automatically under CAE environment. Finally, based on feature-based meshing and combination technique, CAE model is built quickly. A prototype software for large-scale antenna structure (LSAS) CAD/CAE integrated modeling has been developed and used in performance analysis of a 16-meter-diameter LSAS. The method has been proved to be useful for improving speed, accuracy and consistency of complicated structure CAE modeling notably.

CAD/CAE System for Shaping Process of Three Dimensional Complicated Surfaces in Electrochemical Machining

The paper presented a computer aided design and engineering (CAD/CAE) system that can be used to simulate and analyse three-dimensional complicated workpiece’s shaping process in electrochemical mahining. In the CAE model the finite element method was applied to analysis the electric-field distribution in inter-electrode gap. Factors affecting the electric-field distribution, such as flow factors and passivating electrolyte, are also taken into account by using database technology. The results of simulation and experiments showed that the system was of high precision.

Efficiency Improvement of Parameter Design by Means of Simplifying CAE Model in the Case of Deep Drawing Process

Efficiency Improvement of Parameter Design by Means of Simplifying CAE Model in the Case of Deep Drawing Process

301 アルミ矩形中空押出しのCAEモデルについて(アルミニウム合金およびマグネシウム合金の創製と加工)

301 アルミ矩形中空押出しのCAEモデルについて(アルミニウム合金およびマグネシウム合金の創製と加工)

AN INTEGRATED INTELLIGENCE DEVELOPMENT DESIGN CAE MODEL UTILIZING NEW JIT: APPLICATION TO AUTOMOTIVE HIGH RELIABILITY ASSURANCE

With a view to assisting corporations to survive in the "worldwide quality competition", the author has proposed the "Integrated Intelligence Development Design CAE Model" utilizing New JIT. This model consists of the "Total Quality Assurance (QA) High Cycle-ization Business Process System", the "Stratified Intelligence CAE Management System", and the "Intelligence CAE Development Design Approarch System". In an effort to verify the validity of this model, the author has analyzed an issue of worldwide concern, the oil seal leakage mechanism on an automobile transaxle with the cooperation of the Toyota and NOK, and has created the "Intelligence CAE Software-Oil Leakage Simulator" that incorporates CG Navigation in order to ensure "high reliability assurance of the automotive transaxle".

「シミュレーションとSQC」研究会第４分科会最終報告（１）‐開発設計高品質保証CAEモデルの創案とその有効性‐

「シミュレーションとSQC」研究会第４分科会最終報告（１）‐開発設計高品質保証CAEモデルの創案とその有効性‐

HIGHLY RELIABLE CAE MODEL, THE KEY TO STRATEGIC DEVELOPMENT OF ADVANCED TDS

In recent years, the advanced manufacturing industry is engaging in a "global production strategy — for simultaneous achievement of QCD". A close look at the development designing and production process stage reveals an excessive repetition of "experiment, prototyping, and evaluation" that prevents the "scale-up effect" generated in the bridging stage between prototyping, experiment, evaluation, and mass production. Consequently, what is urgently needed, is innovation to promote the advance from the conventional evaluation-based development, that uses the prototyping and experiment process which had long supported highly reliable designing, to a CAE prediction-based designing process. To accomplish this, a new development designing technique was established, the "Highly Reliable CAE Model. This is the key to strategic promotion of the "Total Integrated Development Design model — Advanced TDS" which utilizes the core element of the "Total Development System, TDS" of "New JIT". In an effort to realize this, the author has proposed the "high quality assurance model for super short period development designing, a "Highly Reliable CAE Numerical Simulation" and demonstrated its effectiveness. As an application example, a simulation technology was developed for molding urethane foam and it was implemented as the "Production of CAE Software for Molding Automotive Seat Pads — Urethane Foam Molding Simulator".

Virtual X-ray imaging techniques in an immersive casting simulation environment

A computer code was developed to simulate radiograph of complex casting products in a CAVE TM-like environment. The simulation is based on the deterministic algorithms and ray tracing techniques. The aim of this study is to examine CAD/CAE/CAM models at the design stage, to optimize the design and inspect predicted defective regions with fast speed, good accuracy and small numerical expense. The present work discusses the algorithms for the radiography simulation of CAD/CAM model and proposes algorithmic solutions adapted from ray-box intersection algorithm and octree data structure specifically for radiographic simulation of CAE model. The stereoscopic visualization of full-size of product in the immersive casting simulation environment as well as the virtual X-ray images of castings provides an effective tool for design and evaluation of foundry processes by engineers and metallurgists.

Some effect of trim and body panels on the low-frequency interior noise in vehicles

Structure borne noise dominates the interior noise in vehicles at low frequencies. One of the basic vinroacoustic characteristics of the trimmed body is the noise transfer function, i.e., the acoustic response at a selected position in the passenger compartment, e.g., driver’s ear due to a mechanical excitation at a selected body mount. Detailed CAE models based on the FE method are today available for calculating this characteristic at low frequencies, corresponding to the engine idling and road excitation. However, the accuracy of CAE predictions of interior noise is still considered insufficient for the so-called analytical sign off, i.e., zero-prototypes vision. The current paper describes some investigations into the contribution of individual body panels to the overall interior noise. Also, the effect of selected interior trim items on the area investigated. Relative errors of prediction at different trim levels and different frequency ranges are discussed. Both experimental and CAE results are provided. The aim is to better understand the way the interior noise in vehicles is created, and how it can be controlled.

Stochastic design using cross-validated nonparametric meta-modelling techniques

This study adopts the quantile performance measures that address stochastic uncertainties in CAE modelling and simulations to support design decision-making. Two nonparametric meta-modelling techniques are introduced in conjunction with a uniform sampling scheme to approximate nonlinear CAE model input/output relationships. An integrated stochastic design framework that facilitates practical applications of time-consuming CAE simulations is described. A vehicle restraint system example is used to demonstrate the effectiveness of the proposed framework and the enabling techniques.

DFSS for shift quality using full-vehicle ADAMS model

Automatic transmission shift quality is a high-leverage attribute for customer satisfaction. Full-vehicle CAE models have been developed to enable prediction of shift quality before the availability of physical prototypes. The four phases of the Design for Six Sigma (DFSS) process: Define, Characterise, Optimise and Verify (DCOV) are used in conjunction with ADAMS full-vehicle models. Two candidate meta-models are developed, each of which represents a transfer function between automatic transmission torque output and a customer-correlated engineering metric, Vibration Dose Value (VDV).

A CAD–CAE integration approach using feature-based multi-resolution and multi-abstraction modelling techniques

In spite of the widespread use of CAD systems for design and CAE systems for analysis, the two processes are not well integrated because CAD and CAE models inherently use different types of geometric models and there currently exists no generic, unified model that allows both design and analysis information to be specified and shared. In this paper, a new approach called the CAD/CAE-integrated approach is proposed and implemented by a feature-based non-manifold modelling system. The system creates and manipulates a single master model containing different types of all of the geometric models required for CAD and CAE. Both a solid model (for CAD) and a non-manifold model (for CAE) are immediately extracted from the master model through a selection process. If a design change is required, the master model is modified by the feature modelling capabilities of the system. As a result, the design and analysis models are modified simultaneously and maintained consistently. This system also supports feature-based multi-resolution and multi-abstraction modelling capabilities providing the CAD model at different levels of detail and the CAE model at various levels of abstraction.

Reverse Engineering and CAE

Existing CAE is based on CAD data and is mainly applied to design and development. Product-based CAE to acquire data from actual products and implement CAE based on the derived data is being actively studied now. The present paper describes the important points in using reverse engineering that acquires data using noncontact 3D measuring instruments and generates CAD and CAE models based on the derived data. The present paper furthermore introduces the uniquely developed automatic surfacing tool, Clay Galaxy, for use in reverse engineering. The effectiveness of reverse engineering and Product-based CAE is also explained.