Process Automation With ANSA Data Management and Task Manager
Contents
1. Table 1 Types of BiW connections Model Assembly Realization of Connector Entities The Connector Entities are applied during the execution of the Model assembly group of items Some characteristic features of the connector entities realization are 1 The Connector Entities are defined using mesh density independent patterns for the identification of the connected entities Thus a connector can be applied on a hole circular feature a certain number of nodes or elements in a pre defined search domain 2 Connector Entities that connect a rigid with a deformable component with rigid interface automatically detect the case and create CONTRAINED_EXTRA_NODE instead of CONSTRAINED_NODAL_RIGID_BODY entities 3 Connector Entities that connect rigid components together with rigid interface automatically detect the case and create CONSTRAINED_RIGID_ BODY entities 4 The Connector Entities can use the built in representations i e revolute and spherical joints or custom made ones retrieved as templates from ANSA DM libraries LS_DYNA deck card values of the library items can also be parameterized so that they can be editable during the set up of the connector 10 9 Pre Post and Data Management 10 International LS DYNA Users Conference Table 2 below summarizes the custom templates used for the representation of Connector entities Template in ANSA DM ELEMENT BEAM ELFORM_1 Parameters diameter length and orientation a2. Users Conference Pre Post and Data Management Tasks View gt Bl T amp Root E E Common Model W LSDyna FrontImpact Common Model O QLs pyNA FrontImpact offset barrier uspyna control FE Model E Manual Items M Rigid Road amp Barrier slobal Contact oravity 2 El K Model Checks Fixes o cput O g run solver Figure 20 LS DYNA Front impact 40 offset 64 km h complete model Conclusion and Remarks The data organization and process standardization necessary for the demanding task of crash test simulation models build up can be achieved with the use of ANSA Task Manager in combination with ANSA Data Management With the aid of ANSA Task Manager OEMs can safeguard the model quality and promote knowledge transfer capturing the best proven practices for the analysis model build up as a sequence of modeling actions ANSA Data Management assures the organization of all data storing them in a structured form under a common location enabling their easy retrieval by Task Manager ANSA DM libraries carry custom template definitions for connectors output requests and boundary conditions assuring that model entities are defined with the proper parameters Multi parametric solver cards e g contact definitions initial velocity acceleration field solver controls are incorporated in ANSA Task Manager with parameter values set by the CAE analysis expert eliminating error prone procedures and promoting the model r
3. 10 International LS DYNA Users Conference Pre Post and Data Management LS DYNA Impact Model Build up Process Automation With ANSA Data Management and Task Manager I Makropoulou Y Kolokythas L Rorris BETA CAE Systems S A Thessaloniki Greece Abstract In the presently CAE driven vehicle design process a great number of discipline models must be built and analyzed for the validation of a new vehicle model design The increasing number of vehicle model variants further increases the number of the load cases that must be studied This process introduces a great amount of disparate data that need to be handled by the CAE teams However due to the multiple sources and the diversity of the CAE data the current level of organization and data management deployed does not account for them Setting as a target the reduction of the CAE turnaround cycle and cost the pre processing tools are required to streamline all input data and at the same time the simulation model build up process itself this paper will present the means provided by BETA CAE Systems S A towards the development of realistic repeatable and robust crash simulation models for LS DYNA ANSA Task Manager using template processes supervises the generation of the simulation models while ANSA Data Management in the background facilitates the components management ensuring that the engineering teams will always work with the most up to date data The simulation model
4. E sub assemblies or include files BiW Connections The connection information is read from an xml vip vip2 any ASCII file and many more formats Model Assembly Data Generic Connectors This Data contain information regarding the connection between sub assemblies i e the doors and the body Collecting the data that construct the Model ANSA has the ability to group the individual parts per sub assembly The parts hierarchy can be created though a VPM tree xml output Figure 4 VPM tree to ANSA Parts The example case of this paper consists of six sub models which are BiW assembly closures sub systems Plastic parts and trimming front seats and third raw seats Figure 5 ANSA Parts Manager 10 4 10 International LS DYNA Users Conference Pre Post and Data Management Through the ANSA Data Management a suitable mesh representation can be called for the front crash analysis In addition the system will notify the user for any part updates that will be available for to be incorporated in the model During the execution of the Common Model Task the task manager verifies that there are no parts missing from the referenced sub models BiW Connections Welding The BiW connections come next in the order of the common model task The data that can be retrieved from the ANSA DM 1s of the form of connection points and connection lines The TM runs through every connection and verifies its realization The connections are gr
5. addition the connector and trim item entities must also be applied with the required built in or custom made representations In the following paragraphs the transformation of the common model is explored following the task sequence Sub model items Fe representation With the LS DYNA Common Model task in the Task Manager the common model sub models will not get checked validated unless all the macro area or volumes are meshed For each sub model a proper representation needs to be retrieved from the ANSA DM with the assistance of the Part Representation Manager Available r Supported New MESH Type Alternatives rear_impact side_impact front_impact front_impactl new_frontal new_side NVH rear imnart ES Delete Cancel Figure 8 Retrieval of the front impact mesh representation through the Part Representation manager 10 7 Pre Post and Data Management 10 International LS DYNA Users Conference The Part Representation Manager will look into the ANSA DM to find available representations In the case where representations are not available for a sub model or parts of a sub model the manager calls the batch mesher to mesh the parts and create the missing representations Name Color Parts Mesh Parameters Quality Criteria Status t M Meshing Scena 19 v Draw Sessions ne Default Session C TZ 10mm 10mm for Crash and Durablit
6. ccording to application Ce CONSTRAINED_JOINT_SPHERICAL Parameters Value of added mass on both ends CONSTRAINED_JOINT_ REVOLUTE Parameters Value of added mass on both ends orientation according to application RLEMENT_DISCRETE for 6 dofs Predefined DEFINE SD ORIENTATION vectors SECTION_ DISCRETE Parameters Value of added mass on both ends CONSTRAINED_JOINT UNIVERSAL Parameters Value of added mass on central nodes orientation according to application CONSTRAINED_JOINT_ CYLINDRICAL Parameters Value of added mass on both ends orientation according to application Table 2 Parameterized templates for connectors retrieved from the ANSA DM library Figure 11 below shows an example of Connector Entities realization Figure 11 Connector Entities before and after their realization of revolute joints 10 10 10 International LS DYNA Users Conference Pre Post and Data Management Model Assembly Realization of Connector Entities With the LS DYNA Common Model present during the execution of the Mass Trimming group of items ANSA Task Manger applies the Mass Trim items FE representation The FE representations of Mass Trim items for LS DYNA can be 1 Pre defined amount of added mass distributed over pre defined components in the form of ELEMENT_MASS 2 Pre defined amount of added mass attached on pre defined components at specified locations in the form of lumped mass 3 Pre defined amount of mass a
7. dded as non structural mass in the component s SECTION_SHELL MAREA field The mass per area is automatically calculated so as to result to the desired total weight 4 The substitution of the detailed FE representation of a component by an equivalent amount of mass distributed over the nearby components After the realization of Mass Trim items with the pattern dictated by the LS DYNA Common Model the Common Model has adopted a form suitable for the front impact analysis Front Impact Related Items As previously discussed the LS DYNA Common Model task items are common to all front impact load cases that may follow Additional components may enter in the model at this stage 1 Dummies Dummies can be inputted positioned and restrained El K Driver_h350 ADummy Positioner El Retractor _Slipring B la Shoulder Belt El m Lap Belt El Dummy Contacts Figure 12 Dummy positioning and restraining 2 Instrumentation mass This mass of pre defined value is added in the trunk in the form of lumped mass and is attached to pre defined parts via a Mass Trim Items ie Be LsDyna FrontImpact Common Model O Added components amp Reduced Represe 0 Bf Model Triming rE K Instrumentation E O K output Requests O Model Checks Fixes Figure 13 Instrumentation trim mass attached with nodal rigid bodies to the vehicle 10 11 Pre Post and Data Management 10 International LS DYNA Users Conference 3 Closures inte
8. e specific simulation model In addition all the dependencies between the related actions are taken into account by the task manager The Common Model It contains all the non analysis specific common tasks These tasks include the creation of mesh representations assembly of the sub models mass trimming The LS DYNA Common model This group of task contains modeling actions that are common for the load cases that will follow These tasks can be addition of parts creation of common output requests such as cross sections and accelerometers positioning and restraining of dummies etc The LS DYNA load case This group of tasks contains all the load case specifics that are needed to complete and run the model These actions are definition of initial velocity global contact barrier and road positioning and output of the model In addition checks of the integrity of the model can also be performed The Common Model in ANSA Task Manager The common model is the starting point for the creation of solution specific model The Common Model includes all the modeling actions that are common between multiple CAE disciplines such as Crash NVH Durability etc A Common Model is composed of the following entities 10 3 Pre Post and Data Management 10 International LS DYNA Users Conference Figure 3 The Common Model Task Sub models They are grouped parts inside ANSA that make up sub assemblies They can include geometry complete F
9. er is retrieved from the ANSA DM data pool and is automatically positioned and de penetrated according to the load case specifications 4 Rigid road The attributes of the rigid wall used as the boundary road are saved along with the Task 5 Initial velocity and acceleration field The solver cards parameters are defined once by the CAE analysis expert There is no need for user intervention during the Task execution since Task Manager automatically fills the sets referenced in these cards with the appropriate entities 6 Model checks The model is checked prior to the output with respect to load case specific entities definition All the aforementioned Solver Load case attributes find application in the front impact load case Additionally in this LS DYNA Load case nodal time history is requested at pre defined locations with the aid of Output Request Generic Entities These output requests are retrieved from the ANSA DM library in the form of DATABASE_HISTORY_NODE_SET entities Figures 17 18 show the items added sequentially by the LS DYNA Load case 10 13 Pre Post and Data Management 10 International LS DYNA Users Conference Finally the global contact definition and gravity are added and the model is checked with respect to load case specific definitions After the execution of model checks the analysis model is ready for output The complete model is shown in figure 20 10 14 10 International LS DYNA
10. hat reside inside the DM are Model assembly components Parts geometry sub assemblies Mesh representations Auxiliary components Dummies barriers etc Engineering Data material databases connection files etc Library items Custom made entities such as connector entities mass trim items boundary conditions output requests Task Manager Processes Task manager processes created by the CAE expert who outlines the actions needed to be performed to set up the simulation load case Post processing results ANSA DM is capable of indentifying any change that has taken place and automatically updates the users Such change maybe a new CAD version of a part or a new modification of an existing part version performed by another member of the CAE group Once a new part has been identified the user can select to bring the updated version into the working ANSA database A recently added capability is a comparison tool that compares the part or a sub assembly with the updated version in the ANSA DM The tool lists the differences in the geometry visualization of the geometry differences is possible Part amp Section properties and in material properties Thus the user can make an informed decision if the new version needs to be included in the model or not ANSA Task Manager The ANSA Task Manager is a tool that organizes in hierarchical form all the different modeling actions that need to take place in order to build a disciplin
11. obustness During the execution of pre defined Tasks ANSA Task Manager makes sure that all task items are properly executed considering at the same time possible dependencies between them The validity of model entities definitions is checked prior to the output with the aid of various built in check algorithms The model quality is safeguarded and the build up of crash test simulation models becomes fast and efficient 10 15 Pre Post and Data Management 10 International LS DYNA Users Conference 10 16 References Makropoulou I Template Driven LS DYNA Model Build up with ANSA Task Manager 6 LS DYNA Anwenderforum Frankenthal 2007 Nikolaidis G Zafeiropoulos D Ntamagkas K Building Discipline Specific FE Models with the Common Model Concept 2 ANSA amp META International Congress Halkidiki Greece 2007 Pavlidids V Trifonidis M Automated Built up and Analysis of NVH Models with ANSA META Package 2 ANSA amp META International Congress Halkidiki Greece 2007 BETA CAE Systems SA ANSA Data Management Users Guide ANSA v12 1 3 Documentation Thessaloniki Greece 2007 BETA CAE Systems SA ANSA User s Guide ANSA v12 1 3 Documentation Thessaloniki Greece 2007 Halquist J O LsS DYNA Keywords User s manual Version 971 Livermore Software Technology Corporation Livermore 2007
12. or example RBE2 a l RBE3 e FE Representation It can be any type of point or built in mass repesentation or a custom made representation that can be called in through the ANSA DM as a library item 10 5 Pre Post and Data Management 10 International LS DYNA Users Conference During the execution of the model trim group of items the task manager validates every single trim item with respect to availability of the part or properties that are referenced in the connectivity information With the completion of the Common Model task the assembly of model has a reached a level that is described below 1 There are no parts missing among the sub models that would compromise the model assembly 2 The welding information exists in the form of connection entities connection points and connection curves and it is verified with respect to connectivity information 3 The locations were kinematic constrains exist between sub assemblies are marked with connector entities These entities are verified with respect to the connectivity information 4 The locations where mass trimming takes place for all discipline models are marked with Mass Trim items These are verified with respect to their connectivity information Tasks View o amp Root oH Ee Common Model K BiwW assembly M m Sub systems K Plastic parts K Front seats M m 3rd row seats H BIW Connec tions K Model Assembly K Model Triming Figu
13. ouped per type such as spotwelds spotlines gumdrops adhesive lines seamwelds adhesive faces hemming and bolts The connection entities are solution independent and their FE representation will be applied during the built up of the solution specific loadcase Model Assembly The Connector Entity Connectors are ANSA entities that are used to connect sub models Connectors can model any type of kinematic constrain that exists in the particular location A connector entity 1s created with the following information e The x y z location in space e Connectivity information A connector can connect up to four different parts In addition search type information needs to be given in order to find the parts in space e FE Interface of the connector with the parts For example RBE2 RBE3 e FE Representation It can be any type of built in kinematic element or a custom made item called in through the ANSA DM as a library item The FE interface and representation are solution specific and they will be applied when the discipline common model in this case DYNA common model is created Model Trimming The Mass Trim Item Mass trim items are entities that are used to add extra mass in on specific parts The information needed for the application of the trim item id shown below e The x y z location in space e Connectivity information Parts for the mass trim to be applied i e FE Interface for mass elements F
14. r does not proceed until all checks are successfully implemented The model built up to this stage can be used for the creation of any LS DYNA front impact load case Tasks View Te Root Common Model QBiw assembly Gy Closures E gy sub systems M Plastic parts GQ Front seats GQ 3rd row seats BIW Connections E m Model Assembly K Model Triming QLsbyna FrontImpact Common Model m Added Components amp Reduced Repr a K output Requests Figure 16 LS DYNA front impact Common Model completed The LS DYNA Load case All the entities that differentiate the front impact load cases from each other are added by the Solver Load case group of items This Task is again invoked from the ANSA DM data pool The most important aspects of the LS DYNA Load case Task are outlined below 1 Solver controls The solver controls are set up once for each load case by the CAE analysis expert and are safeguarded in the Task 2 Contact interface cards The contact interface cards along with their parameters are set up once during the Task build up During the Task execution Task Manager automatically fills the contact sets and there is no need for user intervention in the contact definition 3 Barrier file definition and positioning The barrier file to be used in each load case is pre defined in the Barrier Positioning item of ANSA Task Manager along with information for the positioning procedure During the Task execution the barri
15. re 6 A completed Common Model The LS DYNA Common Model The LS DYNA Common Model is the group of items that tie together the common model and the LS DYNA load case The LS DYNA common model dictates the conversion of the common model to solver specific model As soon as the LS DYNA common model gets called the task manager switches the Common Model tasks to be adapted to entities that are suitable for an LS DYNA analysis All the common model items will be affected by this conversion resulting to all of them getting unchecked The common model needs to be re run to adapt to the LS DYNA requirements 10 6 10 International LS DYNA Users Conference Pre Post and Data Management Tasks View T Root O e Common Model O K BiW assembly O m Closures O m Sub systems O m Plastice parts O Ge Front seats O m 3rd row seats O BIW Connections O Model Assembly O Model Triming m Ge LSDyna FrontImpact Common Model Figure 7 Task Manager with the new LS DYNA common task The LS DYNA common model is a group of tasks that are common to all the LS DYNA load cases that will follow Transforming the Common Model to a form suitable for frontal crash analysis During the re run of the Common Model the parts referenced by the sub models items need to get a meshed representation based on the front impact analysis mesh requirements and BiW connections must be applied to connect the referenced parts with the required LS DYNA entities In
16. riors plastic components The detailed FE representation of these components is substituted by a Trim representation spreading mass elements of an equivalent total weight over the nearby inner panel components Figure 14 Trim representation created to replace plastic geometry The creation of section forces using the Output Request Generic Entities The positions cutting planes and the components cut are pre defined in the Output Request Generic Once defined they can be applied during the Task execution with no extra input Output Request Generic Entities are also used for the positioning and assembly of accelerometer sensors at pre defined locations The representation of accelerometer sensors again pre defined by the CAE analysis expert 1s stored as custom template in ANSA DM library Table 3 Template in ANSA DM RELEMENT_SEATBELT_ACCELEROMETER Each accelerometer is attached on a 10x10x10 rigid hexa element A mass element is attached to the accelerometer reference node Table 3 Custom template for accelerometer sensor retrievd from the ANSA DM library Figures 15 Accelerometers and sections created by Generic Entities After the addition of output requests the model integrity is checked Apart from the various available checks the CAE analysis expert is flexible to add custom checks with the aid of user 10 12 10 International LS DYNA Users Conference Pre Post and Data Management scripts ANSA Task Manage
17. set up becomes a repeatable and user independent procedure safeguarding the model quality and fidelity Introduction The preparation and built up of a crash simulation is a technically demanding and time consuming process This makes the process susceptible to error and vulnerable to model parameter changes The week points of the links in the process chain of building a crash test simulation can be roughly outlined as follows Organization The required data need to be retrieved from multiple locations and in various formats Flexibility It is very difficult to incorporate and manage updates at a later design stage of the model build up such as part version updates study versions etc In addition there is a further difficulty monitoring and resolving the affects these updates will have to the whole model Repeatability The simulation model construction requires high level of expertise from the engineering team This makes the success of the simulation dependant to the individual In addition the load case may need to be applied in many variants of the same or similar model Robustness Changes in the model may lead to undetected errors that will impact the validity of the simulation results Model Validation Models go to the solver for solution incomplete and with errors 10 1 Pre Post and Data Management 10 International LS DYNA Users Conference In this paper the capabilities of the ANSA pre processor are presented
18. targeting the elimination of the above drawbacks that arise during crash simulation model built up ANSA Data Management ANSA DM collects and organizes all the engineering data under one common location while that ANSA Task Manager ANSA TM is used to organize the build up of simulation load cases accounting for the load case hierarchy dependency between task actions and safeguarding the best practices provided by the technical expert Common Model A J Batch Meshing ae K n E a spe eh N ANSA DM vim Side Impact Rear Impact Durability NVH i Common Model Common Medel Front Impact Common Model Common Model c Common Model L 0 A D Cc A S E Figure 1 ANSA Task Manager and ANSA Data Management working together concept As an example a full vehicle will be used to set up a front impact 40 offset analysis at 40mph 64km h based on the HHS standards Figure 2 Full vehicle model ANSA Data Manager ANSA DM is a structured and centralized data management system It assures that all engineering data which are used for the creation of the model are stored securely and are organized in a way that can be easily retrievable by all CAE engineers working on various CAE 10 2 10 International LS DYNA Users Conference Pre Post and Data Management disciplines ANSA DM in cooperation with ANSA s batch mesher creates the different mesh representations for the every part Typical data t
19. y Add Scenario Read Scenario Save Scenario Add Session Delete OK Run Stop Cancel Figure 9 Batch Mesh Manager After the retrieval of all the required representations the ANSA Task Manager verifies their definition with respect to unmeshed areas and volumes and checks the items as valid Tasks View T Root O m Common Model H Biw assembly GY Closures Wy Sub systems GY Plastic parts K Front seats 3rd row seats O BIW Connections O m Model Assembly m We Model Triming o K LSDyna FrontImpact Common Model Figure 10 Front Impact Mesh representation of the model BiW Connections Realization of welding information The Task Manager will validate all the connections entities that are correctly realized per connectivity information and per LS DYNA entities The table below shows connection entities that are supported per LS DYNA modeling requirements 10 8 10 International LS DYNA Users Conference Pre Post and Data Management BiW Connection type LS DYNA Spotweld They can be PBEAM or PSOLID with 1 3 8 and16 HEXA elements patent DEFINE_ HEX _SPOWELD_ASSEMBL Y card can automatically be created for all or selected spotwelds Adhesive Line Created from connection line data The type of the connection 1s HEXA CONTACT both the interface and the body It this model the interface and the body are rigid bodies E do Bolt connections Options are available for
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