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Russell.Peak@marc.gatech itimes.marc.gatech/ eislab.gatech/projects/

2003 Aerospace Product Data Exchange (APDE) Workshop April 7-9, 2003 NIST • Gaithersburg, Maryland . Characterizing Fine-Grained Associativity Gaps: A Preliminary Study of CAD-CAE Model Interoperability. Russell.Peak@marc.gatech.edu http://itimes.marc.gatech.edu/

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Russell.Peak@marc.gatech itimes.marc.gatech/ eislab.gatech/projects/

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  1. 2003 Aerospace Product Data Exchange (APDE) Workshop April 7-9, 2003 NIST • Gaithersburg, Maryland Characterizing Fine-Grained Associativity Gaps:A Preliminary Study of CAD-CAE Model Interoperability Russell.Peak@marc.gatech.eduhttp://itimes.marc.gatech.edu/ http://eislab.gatech.edu/projects/ A full report version is available here: http://eislab.gatech.edu/pubs/reports/EL004/

  2. AbstractConference Series Archive: http://step.nasa.gov/ Characterizing Fine-Grained Associativity Gaps:A Preliminary Study of CAD-CAE Model Interoperability This presentation describes an initial study towards characterizing model associativity gaps and other engineering interoperability problems. Drawing on over a decade of X-analysis integration (XAI) research and development, it uses the XAI multi-representation architecture (MRA) as a means to decompose the problem and guide identification of potential key metrics. A few such metrics are highlighted from the aerospace industry. These include number of structural analysis users, number of analysis templates, and identification of computing environment components (e.g., number of CAD and CAE tools used in an example aerospace electronics design environment). One problem, denoted the fine-grained associativity gap, is highlighted in particular. Today such a gap in the CAD-CAE arena typically requires manual effort to connect an attribute in a design model (CAD) with attributes in one of its analysis models (CAE). This study estimates that 1 million such gaps exist in the structural analysis of a complex product like an airframe. The labor cost alone to manually maintain such gaps likely runs in the tens of millions of dollars. Other associativity gap costs have yet to be estimated, including over- and under-design, lack of knowledge capture, and inconsistencies. Narrowing in on fundamental gaps like fine-grained associativity helps both to characterize the cost of today’s problems and to identify basic solution needs. Other studies are recommended to explore such facets further. A full report version is available here: http://eislab.gatech.edu/pubs/reports/EL004/ X = design, mfg., sustainment, and other lifecycle phases.

  3. Model Interoperability Challenges: Heterogeneous Transformations STEP AP210 Mentor Graphics Cadence STEP AP210 STEP AP209 ?? Mentor Graphics Ansys • Homogeneous Transformation • Heterogeneous Transformation Design Model A Design Model B Design Model A Analysis Model A

  4. Analogy: Bottom-Up Budget Estimation Goal: Conceptual Framework for Complex Model Interoperability Characterization & Solutions

  5. Contents • Background • Example Airframe Structural Analysis Needs (Boeing) • Example CAD/E/X Toolset (JPL) • Multi-Representation Architecture • Conceptual framework for complex model interoperability • Quantity estimates by representation type • Characterization of CAD-CAE Associativity Gaps • Summary

  6. Example Industrial Needs:Common Structures Workstation (CSW) Request for Information Publicly available document (see http://eislab.gatech.edu/projects/boeing-psi/2000-06-csw-rfi/ )

  7. Current Typical Airframe Structural Analysis Process From: Request for Information (RFI): Common Structures Workstation (CSW). June 14, 2000. The Boeing Company. Available at http://eislab.gatech.edu/projects/boeing-psi/2000-06-csw-rfi/

  8. Common Structures Workstation (CSW) Design Requirements and Objectives: Contents

  9. Example Part-based Analysis Template

  10. Connection with CAD-based Geometric Parameters

  11. Contents • Background • Example Airframe Structural Analysis Needs (Boeing) • Example CAD/E/X Toolset (JPL) • Multi-Representation Architecture • Conceptual framework for complex model interoperability • Quantity estimates by representation type • Characterization of CAD-CAE Associativity Gaps • Summary

  12. Example CAD/E/X Toolset (JPL) Design, Build, Assembly, Test (DBAT) Process Management and Administration Robin Moncada RF & EM CAE Software CAE Mechanical CAE Optical CAE Electronics CAE System CAE DIVISION 34 DIVISION 35 DIVISION 31 DIVISION 36 DIVISION 38 DIVISION 33 Customers JPL Projects and Technical Divisions SoapSat Took Kit SDKDoorsApGenFast Flight Ansoft HPEE SofSonnet Mentor GraphicsCadenceMathworks MatlabSynopsysSynplicityIlogix StatemateOrcad AutoCad RelexAvant! Place & Route- Actel- Xilinx - Atmel (and many more) PTC Computer VisionPTC Pro-ESDRC IdeasSDRC FemapSolid WorksCosmosNASTRANAdamsSinda/Fluent PDMS - EDMGSDRC MetaphaseSherpa Visual ToolSetsCool JexPercepsRational RoseRuifyHarlequin LISPI-Logix Rhapsody Code VLensViewTraceProZemax Software Tools ~100 tools CAE Cost Centers Holding Account Billing & Payable M-CAE Toolsmithsand Workstations Toolsmiths Workstations E-CAE Toolsmiths and Workstations Servers & Sys Admin M-CAE Servers& Sys Admin TMOD Severs Servers & SA DNP Operations * Not DNP Operations Adapted from “Computer Aided Engineering Tool Service at JPL” - 2001-07-22 - Mike Dickerson -NASA-JPL

  13. Contents • Background • Example Airframe Structural Analysis Needs (Boeing) • Example CAD/E/X Toolset (JPL) • Multi-Representation Architecture • Constrained object knowledge representation • Conceptual framework for complex model interoperability (e.g., between CAD-CAE models) • Quantity estimates by representation type • Characterization of CAD-CAE Associativity Gaps • Summary

  14. Example Chip Package Products Source: www.shinko.co.jp Quad Flat Packs (QFPs) Plastic Ball Grid Array (PBGA) Packages Wafer Level Package (WLP) Glass-to-Metal Seals System-in-Package (SIP)

  15. Flexible High Diversity Design-Analysis Integration Electronic Packaging Examples: Chip Packages/Mounting Shinko Electric Project: Phase 1 (production usage) Design Tools Modular, Reusable Template Libraries Analysis Modules (CBAMs) of Diverse Behavior & Fidelity Prelim/APM Design Tool Analysis Tools XaiTools ChipPackage XaiTools ChipPackage General Math Mathematica FEAAnsys Thermal Resistance Analyzable Product Model 3D XaiTools PWB DB Materials DB* ThermalStress EBGA, PBGA, QFP Basic 3D** Basic Documentation Automation AuthoringMS Excel ** = Demonstration module

  16. ProAM Design-Analysis IntegrationElectronic Packaging Examples: PWA/B Pro AM Design Tools Modular, Reusable Template Libraries Analysis Modules (CBAMs) of Diverse Mode & Fidelity ECAD Tools Mentor Graphics, Accel* Analysis Tools XaiTools PWA-B General Math Mathematica STEP AP210‡ GenCAM**, PDIF* 1D, 2D, 3D Solder Joint Deformation* FEAAnsys PWB Stackup Tool XaiTools PWA-B Analyzable Product Model PWB Warpage XaiToolsPWA-B 1D, 2D Laminates DB PTH Deformation & Fatigue** Materials DB 1D, 2D ‡ AP210 DIS WD1.7 * = Item not yet available in toolkit (all others have working examples) ** = Item available via U-Engineer.com

  17. Analysis Template Methodology & X-Analysis Integration Objectives (X=Design, Mfg., etc.) • Goal: Improve engineering processes via analysis templates with enhanced CAx-CAE interoperability • Challenges (Gaps): • Idealizations & Heterogeneous Transformations • Diversity: Information, Behaviors, Disciplines, Fidelity, Feature Levels, CAD/CAE Methods & Tools, … • Multi-Directional Associativity: DesignAnalysis, Analysis  Analysis • Focus: Capture analysis template knowledge for modular, regular design usage • Approach: Multi-Representation Architecture (MRA)using Constrained Objects (COBs)

  18. X-Analysis Integration Techniquesfor CAD-CAE Interoperabilityhttp://eislab.gatech.edu/research/ a. Multi-Representation Architecture (MRA) b. Explicit Design-Analysis Associativity c. Analysis Module Creation Methodology

  19. An Introduction to X-Analysis Integration (XAI)Short Course Outline Part 1: Constrained Objects (COBs) Primer • Nomenclature Part 2: Multi-Representation Architecture (MRA) Primer • Analysis Integration Challenges • Overview of COB-based XAI • Ubiquitization Methodology Part 3: Example Applications • Airframe Structural Analysis (Boeing) • Circuit Board Thermomechanical Analysis (DoD: ProAM; JPL/NASA) • Chip Package Thermal Analysis (Shinko) • Summary Part 4: Advanced Topics & Current Research

  20. Multi-Representation Architecture for Design-Analysis Integration O(100) tools

  21. Analyzable Product Models (APMs) Provide advanced access to design data needed by diverse analyses. Design Applications Analysis Applications Add reusable multifidelity idealizations Combine information Solid Modeler FEA-Based Analysis ... Materials Database Formula- Based Analysis Fasteners Database Analyzable Product Model (APM) Support multi-directionality

  22. Multi-Fidelity IdealizationsSame Behavior; Idealized Geometries of Varying Dimension Design Model (MCAD) Analysis Models (MCAE) Behavior = Deformation 1D Beam/Stick Model flap support assembly inboard beam 3D Continuum/Brick Model

  23. Flap Link Geometric Model(with idealizations) 28b

  24. Flap Linkage ExampleManufacturable Product Model (MPM) = Design Description Product Attribute Ri Product Relation Extended Constraint Graph Constrained Object (COB) Structure (template)

  25. Flap Linkage ExampleAnalyzable Product Model (APM) = MPM Subset + Idealizations Product Attribute Ri Product Relation Idealized Attribute Ri effective_length flap_link Idealization Relation w sleeve_1 t r x w sleeve_2 R 1 t R r 1 R 2 x R 3 shaft cross_section wf R tw 4 R t1f R 6 5 t2f critical_section critical_detailed wf tw R hw 11 rib_1 b R7 t1f h t2f R t R 8 2 area rib_2 b R critical_simple wf 10 R h 9 tw R t 3 E hw R 12 name material n tf area stress_strain_model linear_elastic cte Extended Constraint Graph effective_length, Leff == inter_axis_length - (sleeve1.hole.cross_section.radius + sleeve2.hole.cross_section.radius) Partial COB Structure (COS)

  26. Concurrent Multi-FidelityCross-Section Representations MULTI_LEVEL_COB cross_section; design : filleted_tapered_I_section; tapered : tapered_I_section; basic : basic_I_section; RELATIONS PRODUCT_IDEALIZATION_RELATIONS pir8 : "<basic.total_height> == <design.total_height>"; pir9 : "<basic.flange_width> == <design.flange_width>"; pir10 : "<basic.flange_thickness> == <design.flange_base_thickness>"; pir11 : "<basic.web_thickness> == <design.web_thickness>"; pir12 : "<tapered.total_height> == <design.total_height>"; pir13 : "<tapered.flange_width> == <design.flange_width>"; pir14 : "<tapered.flange_base_thickness> == <design.flange_base_thickness>"; pir15 : "<tapered.flange_taper_thickness> == <design.flange_taper_thickness>"; pir16 : "<tapered.flange_taper_angle> == <design.flange_taper_angle>"; pir17 : "<tapered.web_thickness> == <design.web_thickness>"; END_MULTI_LEVEL_COB; Detailed Design Cross-Section Idealized Cross-Sections Associativity Relations between Cross-Section Fidelities

  27. Flap Link APMImplementation in CATIA v5 Design-Idealization Relation Design Model Idealized Model

  28. Multi-Representation Architecture for Design-Analysis Integration O(100) types

  29. Analysis Building Blocks (ABBs) s s De N e e y Distributed Load q(x) Rigid x Support Beam body 2 body 1 q(x) Object representation of product-independent analytical engineering concepts Analysis Primitives Analysis Systems - Primitive building blocks - Containers of ABB "assemblies" Material Models Continua Specialized - Predefined templates Beam Linear- Bilinear Low Cycle Plane Strain Body Plate Elastic Plastic Fatigue Geometry Interconnections Cantilever Beam System Rigid No-Slip Support Discrete Elements Analysis Variables General - User-defined systems T Temperature, Stress, s Mass Spring Damper Distributed Load Strain, e

  30. Common Structures Workstation (CSW) Request for Information June 2000, The Boeing Company. Appendix B: Required Standard Analysis Methods ~110 generic template groupings Available at http://eislab.gatech.edu/projects/boeing-psi/2000-06-csw-rfi/

  31. Appendix B: Required Standard Analysis Methods (continued)

  32. COB-based Libraries of Analysis Building Blocks (ABBs)Material Model and Continuum ABBs - Constraint Schematic-S Continuum ABBs Extensional Rod Material Model ABB 1D Linear Elastic Model modular re-usage Torsional Rod

  33. COB-based Libraries of Analysis Building Blocks (ABBs)Material Model and Continuum ABBs - COB Structure-S COB one_D_linear_elastic_model SUBTYPE_OF elastic_model; youngs_modulus, E : REAL; poissons_ratio,  : REAL; cte,  : REAL; shear_modulus, G : REAL; strain,  : REAL; stress,  : REAL; shear_stress,  : REAL; shear_strain,  : REAL; thermal_strain, t : REAL; elastic_strain, e : REAL; temperature_change, T : REAL; RELATIONS r1 : "<shear_modulus> * ( 2 * (1 + <poissons_ratio> ) ) == <youngs_modulus> "; r2 : "<strain> == <elastic_strain> + <thermal_strain>"; r3 : "<elastic_strain> == <stress> / <youngs_modulus>"; r4 : "<thermal_strain> == <cte> * <temperature_change>"; r5 : "<shear_strain> == <shear_stress> / <shear_modulus>"; END_COB; COB one_D_linear_elastic_model_isothermal SUBTYPE_OF one_D_linear_elastic_model; RELATIONS r6 : "<temperature_change> == 0"; END_COB; COB slender_body SUBTYPE_OF deformable_body; undeformed_length, L0 : REAL; reference_temperature, T0 : REAL; temperature, T : REAL; RELATIONS sb1 : "<material_model.temperature_change> == <temperature> - <reference_temperature>"; END_COB; COB extensional_rod SUBTYPE_OF slender_body; start, x1 : REAL; end, x2 : REAL; length, L : REAL; total_elongation, &Delta;L : REAL; force, F : REAL; area, A : REAL; material_model : one_D_linear_elastic_model_noShear; RELATIONS er1 : "<length> == <end> - <start>"; er2 : "<total_elongation> == <length> - <undeformed_length>"; er3 : "<material_model.strain> == <total_elongation> / <undeformed_length>"; er4 : "<material_model.stress> == <force> / <area>"; END_COB;

  34. Appendix B: Required Standard Analysis Methods (continued)

  35. Multi-Representation Architecture for Design-Analysis Integration O(10,000)

  36. COB-based Constraint Schematic for Multi-Fidelity CAD-CAE InteroperabilityFlap Link Benchmark Example

  37. Tutorial Example:Flap Link Analysis Template (CBAM) CBAM CAD-CAE Associativity (idealization usage) APM ABB Geometry Material Models SMM ABB Boundary Condition Objects (links to other analyses)* Solution Tool Interaction Requirements & Objectives (1a) Analysis Template: Flap Link Extensional Model

  38. FEA-based Analysis Subsystem Used in Linkage Plane Stress Model (2D Analysis Problem) Higher fidelity version vs. Linkage Extensional Model ABBSMM SMM Template

  39. Flap Link Extensional Model (CBAM)Example COB Instance in XaiTools (object-oriented spreadsheet) example 1, state 1 Library data for materials Detailed CAD data from CATIA Idealized analysis features in APM Modular generic analysis templates (ABBs) Focus Point of CAD-CAE Integration Explicit multi-directional associativity between design & analysis

  40. Contents • Background • Example Airframe Structural Analysis Needs (Boeing) • Example CAD/E/X Toolset (JPL) • Multi-Representation Architecture • Conceptual framework for complex model interoperability • Quantity estimates by representation type • Characterization of CAD-CAE Associativity Gaps • Summary

  41. Quantity estimates by MRA representation type O(10,000) O(100) types O(100) tools

  42. Contents • Background • Example Airframe Structural Analysis Needs (Boeing) • Example CAD/E/X Toolset (JPL) • Multi-Representation Architecture • Conceptual framework for complex model interoperability • Quantity estimates by representation type • Characterization of CAD-CAE Associativity Gaps • Summary

  43. CAD-CAE associativity relations are represented as APM-ABB relations (in CBAMs) O(1,000,000) relations An associativity gapis a computer-insensible relation

  44. Associativity Gapsbetween CAD and CAE Models G1 : b = cavity3.inner_width + rib8.thickness/2 + rib9.thickness/2 ... No explicit fine-grained CAD-CAE associativity G Idealizations “It is no secret that CAD models are driving more of today’s product development processes ... With the growing number of design tools on the market, however, the interoperability gap with downstream applications, such as finite element analysis, is a very real problem. As a result, CAD models are being recreated at unprecedented levels.” Ansys/ITI press Release, July 6 1999 http://www.ansys.com/webdocs/VisitAnsys/CorpInfo/PR/pr-060799.html = K f ( r , b , h ) 3 1 P P = f C = f be 1 2 ht se p 2 r t e 0 e Detailed Design Model Analysis Model (with Idealized Features) Channel Fitting Analysis

  45. Flexible High Diversity Design-Analysis Integration Phases 1-3 Airframe Examples:“Bike Frame” / Flap Support Inboard Beam Design Tools Modular, Reusable Template Libraries Analysis Modules (CBAMs) of Diverse Feature:Mode, & Fidelity MCAD Tools CATIA v4, v5 XaiTools Analysis Tools 1.5D General Math Mathematica In-HouseCodes Lug:Axial/Oblique; Ultimate/Shear Image API (CATGEO); VBScript Analyzable Product Model XaiTools 1.5D Fitting:Bending/Shear Materials DB FEA Elfini* MATDB-like 3D Assembly: Ultimate/FailSafe/Fatigue* Fasteners DB FASTDB-like * = Item not yet available in toolkit (all others have working examples)

  46. “Bike Frame” Bulkhead Fitting Analysis TemplateUsing Constrained Object (COB) Knowledge/Info Representation = K f ( r , b , h ) 3 1 P P = f C = f be 1 2 ht se p 2 r t e 0 e 18 CAD-CAE associativity relations

  47. Cost of Associativity GapsReference: http://eislab.gatech.edu/pubs/reports/EL004/ Initial Cost Estimate per Complex Product(only for manual maintenance costs of structural analysis problems) • Categories of Gap Costs • Associativity time & labor • - Manual maintenance • - Little re-use • - Lost knowledge • Inconsistencies • Limited analysis usage • - Fewer parts analyzed • - Fewer iterations per part • “Wrong” values • - Too conservative: Extra part costs and performance inefficiencies • - Too loose: Re-work, failures, law suits

  48. Cost Estimate per Complex Product p.1/2Manual Maintenance of Associativity Gaps in Structural Analysis Problems Reference: http://eislab.gatech.edu/pubs/reports/EL004/

  49. Cost Estimate per Complex Product p.2/2Manual Maintenance of Associativity Gaps in Structural Analysis Problems Reference: http://eislab.gatech.edu/pubs/reports/EL004/

  50. “Bike Frame” Bulkhead Fitting Analysis TemplateUsing Constrained Object (COB) Knowledge/Info Representation = K f ( r , b , h ) 3 1 P P = f C = f be 1 2 ht se p 2 r t e 0 e 18 associativity relations

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