CADFEM & ANSYS • Simulation Conference - …...M. Schimmelpfennig, CADFEM ANSYS Simulation...

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1 Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders mit ANSYS optiSLang M. Schimmelpfennig R. Kallmeyer Dynardo GmbH CADFEM ANSYS Simulation Conference Winterthur, 2017

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  • 1

    Kalibrierung, Optimierung und

    Robustheitsbewertung eines

    Steckverbinders mit

    ANSYS optiSLang

    M. Schimmelpfennig

    R. Kallmeyer

    Dynardo GmbH

    CADFEM ANSYS Simulation Conference

    Winterthur, 2017

  • 2

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Outline

    • Overview

    • Theoretical background

    • Example 1: connector – material calibration

    • Example 2: connector – system calibration

    • Material Calibration

    • 5 material parameters

    • System Calibration

    • 15 geometry parameters

    calibrated material for load simulation

  • 3

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Overview

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    • is a general purpose tool for variation analysis

    using CAE-based design sets (and/or data sets)

    for the purpose of

    • sensitivity analysis

    • design/data exploration

    • calibration of virtual models to tests

    • optimization of product performance

    • quantification of product robustness and product reliability

    • Robust Design Optimization (RDO) and Design for Six Sigma (DFSS)

    serves arbitrary CAX tools with

    optiSLang

    support of process integration

    process automation

    workflow generation

    © Dynardo GmbH

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    SPDM

    Input

    1

    Input 2

    Input n

    Output 1

    with Process Integration

    and for Automatization

    Workflow-Management

    ANSYS optiSLang

    Postprocessing

    Excel Add-In other Solver

    Output 2

    Output m

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    Midas Edyson

    Adams

    TurboOpt

    © Dynardo GmbH

    optiSLang v6: Integrations

    Win-Batch MATLAB Linux-Shell

    Plug-in and WB node

    LMS Amesim

    Octave LS-DYNA

    Python

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    optiSLang as an ANSYS Workbench plugin

    • optiSLang modules

    Sensitivity + MOP,

    Optimization and

    Robustness are directly

    available in ANSYS Workbench

    Signal Processing module to work with curves inside ANSYS Workbench

    © Dynardo GmbH

  • 8

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    Model Calibration Identify important model parameters

    for the best fit between simulation

    and measurement

    Model Calibration Identify important model parameters

    for the best fit between simulation

    and measurement

    Design Improvement Optimize design performance

    Design Quality Ensure design robustness

    and reliability

    Design Quality Ensure design robustness

    and reliability

    Design Understanding Investigate parameter sensitivities,

    reduce complexity and

    generate best possible meta models

    Design Understanding Investigate parameter sensitivities,

    reduce complexity and

    generate best possible meta models

    © Dynardo GmbH

    CAE-Data

    Measurement

    Data

    Robust Design

    Design Improvement Optimize design performance

  • 9

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    Model Calibration Identify important model parameters

    for the best fit between simulation

    and measurement

    Model Calibration Identify important model parameters

    for the best fit between simulation

    and measurement

    Design Improvement Optimize design performance

    Design Quality Ensure design robustness

    and reliability

    Design Quality Ensure design robustness

    and reliability

    Design Understanding Investigate parameter sensitivities,

    reduce complexity and

    generate best possible meta models

    Design Understanding Investigate parameter sensitivities,

    reduce complexity and

    generate best possible meta models

    © Dynardo GmbH

    CAE-Data

    Measurement

    Data

    Robust Design

    Design Improvement Optimize design performance

  • 10

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    • use scalar values or signals inside ANSYS Workbench

    • identify which parameters have influence and

    can be calibrated

    • match experimental data with simulation

    Model Calibration Model update to increase your simulation quality!

  • 11

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Theoretical Background

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    The Forward Simulation

    • For given set of model parameters p the model responses y can be calculated with a given simulation model

    • Deviation of model responses and measurements y* can be evaluated

    • For which parameter set popt model responses and measurement agree sufficiently well?

    Model parameters Simulation model Model responses

    Measurements

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Signals in optiSLang • Signals are vector outputs having an abscissa (e.g. time axis)

    and several output channels (e.g. displacements, velocities)

    • Signal functions enables the user to extract local and statistical

    quantities and to analyze differences between several signals

    • Match signal data (curves) with Signal Processing

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Example 1: Connector – material calibration

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Simulation of a connector

    • Material Calibration

    • Curve Fit between Simulation

    and Tensile-Experiment

    • 5 material parameters

    • System Calibration

    • Curve Fit between Simulation

    and desired behavour

    • 15 geometry parameters

    calibrated material for load simulation

  • 16

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Tension Test – material definition

    • Identification of the material parameters to optimally fit the

    force-displacement curve to the measurements

    • Unknown material parameters for

    nonlinear isotropic hardening (nliso):

    • Young´s modulus

    • Yield stress σ0

    • Linear hardening coefficient R0

    • Exponential hardening coefficient R∞

    • Exponential saturation parameter b

    • Objective function is the sum of squared errors

    between the reference and the calculated

    force-displacement function values

    σ = σ0 + R0εpl + R∞ (1-e-b εpl)

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Tension Test – signal functions

    15. 1.

    • The displacement is divided in 15 equally spaced steps (1-15) to get more

    detailed information about the influence of the 5 material parameters

    • At these steps the forces will be extracted these 15 steps have unique MOP´s

    • These 15 MOP´s will be used for optimization on MOP

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Tension Test – sensitivity results

    • Only Linear hardening coefficient R0 is unimportant for all responses

    • Single values can be explained

    very well

    • force_steps_sim values:

    The influence of the Young´s modulus

    decreases meanwhile the influence of

    the exponential hardening coefficient

    and yield stress increases

    force_steps_sim[0]

    force_steps_sim[14] …

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Tension Test – sensitivity results, F-CoP with SoS

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Tension Test – optimization with direct optimizer

    • For excellent agreement use the direct optimizer, with results from

    optimization on MOP

    - Design Variation - Reference Curve - Best Design (Optimization)

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Example 2: Connector – system calibration

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Simulation of a connector

    • Material Calibration

    • Curve Fit between Simulation

    and Tensile-Experiment

    • 5 material parameters

    • System Calibration

    • Curve Fit between Simulation

    and desired behavour

    • 15 geometry parameters

    calibrated material for load simulation

  • 23

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Load simulation of a connector

    component 1

    component 2

    possible design variation

    possible design variation

    • Insertion and Pull-Out

    • Component 1: 13 geometry parameter

    • Component 2: 2 geometry parameter

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Load simulation – task description

    • No curve fit with reference specification of a desired behavour:

    desired curve or desired points

    desired behavour - points

    insertion_force_gradient

    insertion_force

    pull_out_force

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Optimization – desired behavour curve

    • Objective:

    sum_of_squared_errors_insertion + sum_of_squared_errors_pull_out MIN

    • insertion from 0 ≤ x ≥ 15 and pull-out from 60 ≤ x ≥ 75

    - Design Variation - Reference Curve - Best Design (Optimization)

    insertion process

    pull out process

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Optimization – desired behavour curve

    Input Parameter

    Ou

    tpu

    t P

    aram

    ete

    r

    insertion process

    pull out process

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Optimization – desired behavour curve

    • Objective:

    sum_of_squared_errors_insertion + sum_of_squared_errors_pull_out MIN

    • insertion 0 ≤ x ≥ 15 and pull-out 60 ≤ x ≥ 75

    Best Design Detail View

  • 28

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    Model Calibration Identify important model parameters

    for the best fit between simulation

    and measurement

    Model Calibration Identify important model parameters

    for the best fit between simulation

    and measurement

    Design Improvement Optimize design performance

    Design Quality Ensure design robustness

    and reliability

    Design Quality Ensure design robustness

    and reliability

    Design Understanding Investigate parameter sensitivities,

    reduce complexity and

    generate best possible meta models

    Design Understanding Investigate parameter sensitivities,

    reduce complexity and

    generate best possible meta models

    © Dynardo GmbH

    CAE-Data

    Measurement

    Data

    Robust Design

    Design Improvement Optimize design performance

  • 29

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    Robustness Evaluation Ensure your product quality!

    Output parameter variation

    © Dynardo GmbH

    Powerful procedure to check design quality:

    • Latin Hypercube Sampling representing

    scattering variables optimally

    • check variation interval limits and critical responses

    • Identify the most important scattering variables

    and check the solver noise

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH © Dynardo GmbH

    Variance-Based Robustness Analysis (Overview)

    1) Define the robustness space using scatter range, distribution and correlation

    2) Scan the robustness space by producing and evaluating n designs

    3) Check the variation 4) Check the

    explainability of the model

    5) Identify the most important scattering variables

  • 31

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Tolerance viewing – optimized design

    • 5% scattering with normal distribution for all 15 geometry parameters

  • 32

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Tolerance viewing – optimized design

    Optimization Tolerance

    Optimization Tolerance

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    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Input Parameter

    Ou

    tpu

    t P

    aram

    ete

    r

    insertion process

    pull out process

    Tolerance viewing – optimized design

  • 34

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    © Dynardo GmbH

    Summary

    • Model Calibration

    • Identification of material parameters for material calibration

    • Identification of geometry parameters for system calibration

    • no curve fit with measurement

    • specification of a desired behavior

    • different possibilities for objective

    • Easy to use

    • in ANSYS Workbench and

    • in ANSYS optiSLang

  • 35

    Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders

    mit ANSYS optiSLang

    M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur

    Thank you for your attention!

    For more information

    please visit

    our booth and homepage:

    www.dynardo.com

    © Dynardo GmbH