I-DEAS and ADINA in non-linear structural Finite Element and CFD-analysis Presented by Dr. Ulrich Heck

1. Dr. Heck Consulting and Engineering Dr. Heck Consulting and Engineering and Adam Hodgson Engineering: I-DEAS and ADINA in non-linear structural Finite Element and CFD-analysis Presented by Dr. Ulrich Heck Dr. Ulrich Heck

2. Dr. Heck Consulting and Engineering Presentation UG-User 2004 Background The FE-solver program ADINA will be embedded into NX NASTRAN to become the non-linear solver for structural analysis Our business Our needs Our tools Our experience Dr. Ulrich Heck

3. Dr. Heck Consulting and Engineering Structural Analysis CFD (Computational Fluid Dynamics) O-Ring Compression Karman vortex street Heat Transfer FSI (Fluid-Structure-Interaction) Frictional Heating (Brake) Vortex induced vibrations Our business: Engineering services Dr. Ulrich Heck

4. Dr. Heck Consulting and Engineering Our needs – customer’s demands Our mission : Quickly achieve high quality results for very complex problems 1. Initial task: Calculate effort for meshing and solving the problem • Meshing Needs • Time for meshing ->more a craft than an art • Generating high quality meshes from poor CAD-data (imported models) • Various options to achieve the result: • Optimise/repair the CAD data or mesh on existing CAD data • Manual meshing, merging models etc. • Reliable and robust • Solver Needs: • One CAE-Solvers for a wide range of complex problems • Reliable and robust • Universally applicable methods • Solving in reasonable time without super computer Dr. Ulrich Heck

5. Dr. Heck Consulting and Engineering Flow with conduction Flow with radiation Thermo-mechanical coupling • Heat transfer • Conduction • Radiation • Convection ADINA (FEM) Finite Volume CFD-Solver Fluent Our tools-Solver • CFD • Complex turbulent • Highly compressible (shocks) • Turbulent heat transfer • Multiphase • Large problems (turbulent 2 Mio Cells) • Non-lin structural • Contact • Nonlinear Material • (plastics, rubber) • Large (plastic) strain large displacement • CFD • laminar • turbulent • Transient/ steady state • moving meshes • moderate size • FSI • Transient, highly • coupled • Static flow induced large deformation or strains Dr. Ulrich Heck

6. Dr. Heck Consulting and Engineering • I-deas is used for: • All CAD-Modelling including geometry import and repairing poor CAD models • Meshing capabilities of I-deas • Mapped/Free Meshing • Section Meshing • Manual Meshing • All meshes for ADINA (structural, CFD, heat-transfer, FSI) • Special CFD mesh features are • used for complex CFD (Fluent) -> • TGrid: • Use I-deas hexahedral or surface mesh (triangular), • Merge mesh regions for hybrid “viscous” meshing • Mesh tetrahedral volume in TGrid Our meshing tools Dr. Ulrich Heck

7. Dr. Heck Consulting and Engineering Tools conclusion • Quickly achieve high quality results for very complex problems • I-deas • Focal tool for CAD-modelling and meshing • Covers our over all needs for meshing • Only high level CFD modelling demands other grid generators • ADINA • Covers our needs for a wide spectrum of problems • One system to solve this wide range of problems ADINA/I-deas in combination are the core tools for our daily work Dr. Ulrich Heck

8. Dr. Heck Consulting and Engineering • Present system: • TRANSOR is ADINA/I-deas interface • Is based on universal files • Runs ADINA in background • Imports results files via universal file translator ADINA/I-deas/NX-Nastran Our experience: 6 Years with ADINA/I-deas • needed improvements in NX-NASTRAN: • Simplified transfer of geometry information (e.g. element orientation contact surfaces, 2d models…) • Post processing: direct display results • Ease of use • Long term desirables: • Easier adaptive meshing • Topology optimisation -> • new CAD Model Dr. Ulrich Heck

9. Dr. Heck Consulting and Engineering Examples • Some examples similar to customer projects, pre-studies, own verification problems • Even if ADINA is a reliable, robust tool, setting up test cases is a must when working with new types of problems • Collect experience with the problem types • Check the feasibility (available models, hardware power etc.) • Check influence of modelling parameters (grid, time stepping etc.) • improve quality of results: Compare numerical results with experimental data • Advantages of ADINA System: • Universally applicable methods • ADINA suggest the correct solving method, element formulation etc. (e.g. automatically switches to u/p-formulation in case of incompressible material) • Gives hints if no solution is reached • ADINA user support • Excellent support • Works while you sleep • Never been disappointed by the results ADINA give us • Very satisfied customers ! Dr. Ulrich Heck

10. Dr. Heck Consulting and Engineering Contact Pressure load Several Tests: Pressure Test Drop Test Symmetry Typical project time: 3-4 days Including meshing, variants simulation, report Structural example I Technical problem: Plastic tank under pressure Dr. Ulrich Heck

11. Dr. Heck Consulting and Engineering Structural example I Tank problem: plastic strain caused by increasing pressure (100 bar) Dr. Ulrich Heck

12. Dr. Heck Consulting and Engineering Structural example I Machine: Dual Xeon 2.8 GHz, 4 GB-RAM, Linux, Dell Precision 650 Dr. Ulrich Heck

13. Dr. Heck Consulting and Engineering Structural example II Tank problem: Drop test Conditions: 3m high, steel sphere of 500 gr Fully dynamic analysis Dr. Ulrich Heck

14. Dr. Heck Consulting and Engineering Structural example II Machine: Dual Xeon 2.8 GHz, 4 GB-RAM, Linux, Dell Precision 650 Dr. Ulrich Heck

15. Dr. Heck Consulting and Engineering Rigid Wall O-Ring Hyperelastic, incompressible Structural example III Plastic body (elasto-plastic) Dr. Ulrich Heck

16. Dr. Heck Consulting and Engineering Structural example III Dr. Ulrich Heck

17. Dr. Heck Consulting and Engineering inflow outflow Slip wall Flexible Structure Rigid body Slip wall FSI-Benchmark • FSI-Benchmark: • Vortex induced vibrations, • Target: • tip displacement Dr. Ulrich Heck

18. Dr. Heck Consulting and Engineering • Result: Exactly the same tip displacement referred in literature • Modelling time: 1 day for such a complex problem (FSI, large displacement, grid movement) Ref: J. Steindorf "Partitionierte Verfahren für Probleme der Fluid-Struktur Wechselwirkungen", Thesis, Braunschweig, 2002, Germany FSI-Benchmark Dr. Ulrich Heck

19. Dr. Heck Consulting and Engineering Rubber Wall: Mooney Rivilin (non-linear incompressible) Fluidchamber Highly viscous oil r =45 mm, h= 70 mm FSI: Hydromount Pre-Study Hydromounts used in automotives to damp vibrations caused by the engine mount • axissymmetric (2d) • Model: Highly nonlinear, • transient FSI, strong coupling • boundary condition • load: • - Sinusoidal displacement • - Amp.= 0.05 mm • Force F(t) ? Dr. Ulrich Heck

20. Dr. Heck Consulting and Engineering FSI: Hydromount Pre-Study Resonance: here 650 Hz Low-frequency displacement Disp Mag=10 Dr. Ulrich Heck

21. Dr. Heck Consulting and Engineering Frequencies 200-500 hz Force [N] t/T [-] 200 Hz 350 Hz 500 Hz FSI: Hydromount Pre-Study Time history Dr. Ulrich Heck

22. Dr. Heck Consulting and Engineering All Frequencies Frequencies 200-500 hz Max Force [N] Max Force [N] Frequency [hz] Frequency [hz] 200 Hz 350 Hz 500 Hz FSI: Hydromount Pre-Study • Physical effects have been proven • Good agreement of numerical and experimental distribution • max. Force =f (Frequency) • Results of the study will be published soon Dr. Ulrich Heck

23. Dr. Heck Consulting and Engineering FSI: Hydromount Pre-Study • 3d FSI: Transient, non-linear Material Fluid model Total model Solid model Dr. Ulrich Heck

24. Dr. Heck Consulting and Engineering FSI: Hydromount Pre-Study 3d Dr. Ulrich Heck

25. Dr. Heck Consulting and Engineering Dr. Heck Consulting and Engineering Conclusion • ADINA is a very powerful tool to solve nonlinear problems in • structural analysis, • heat transfer • CFD and • Multi physics • I-deas offers state of the art capabilities for an efficient • CAD-Modelling, • poor geometry repair of imported models • Meshing • ADINA/I-deas in combination are the core tools for our daily work • ADINA/I-deas cover our needs • Quickly achieve high quality results for very complex problems www.dhcae.de www.c-a-e.com Dr. Ulrich Heck