Aerospace Product Development NX CAE A Modern Simulation ... · Embedded in NX CAD Simulation wizards Part validation Stress & vibration Guided process NX Nastran solver Design Engineer

Unrestricted © Siemens AG 2013 All rights reserved. Smarter decisions, better products.

NX CAE

A Modern Simulation Environment

Aerospace Product Development

Unrestricted © Siemens AG 2013 All rights reserved.

Siemens PLM Software

Simulation in Aerospace

Where is it going?

Earlier and faster iterations

More complex phenomena

Larger models, systems

Increasing amounts of data



Simulation Challenges Today

Complex Workflows and Numerous Data Transfers

Engine Clearance Analysis

3D Master Model

External

Aero Analysis

Aero Mechanics

Analysis

Engine Dynamics

Analysis

Modal Analysis

Transient Heat Transfer Analysis

Geometry

Analysis Data Internal Aero

Analysis

Life Analysis

Analysis



People

• Expert analysts

Simulation

Data

• Work in progress

• Variants

Simulation Today

Lack of a Cohesive Environment

Simulation

Processes

• Capture

• Re-use

Simulation

Software

• Various pre/post tools

• Many solvers



Evolution of the Role of CAE

Modern Simulation Environments

“CAE is evolving from being a set of

‘black box tools’ for highly

specialized individuals toward a

group productivity environment

that delivers strategic competitive

advantages to the business by

supporting simulation-driven design.”



People:

• Expert analysts

Simulation

Data


• Variants

Modern CAE Environment

Delivering Competitive Advantages

Simulation

Processes

• Capture

• Re-use

Modern

Simulation

Environment

People

• Expert analysts

• Designers /

Design

Engineers



People

• Expert analysts

• Designers /

Design

Engineers

Simulation

Data


• Variants

Modern CAE Environment

Delivering Competitive Advantages

Simulation

Processes

• Capture

• Re-use

SPM

KBE

Modern

Simulation

Environment

Smarter

Decisions

Training

Support

SDM



Elements of a Modern Simulation Environment

Integrated Modeling and Solutions

Multi-Discipline Simulation and Optimization

System Level Modeling and Simulation

Simulation Data and Process Management



Simulation in Aerospace

Where is it going?

Earlier and faster iterations

More complex phenomena

Larger models, systems

Increasing amounts of data







NX CAE


Data Management & Automation Simulation Driven Design

Simulation Modeling Thermal

Motion Multiphysics

Structural

Flow

Optimization



Designer

Embedded in NX CAD

Simulation wizards

Part validation

Stress & vibration

Guided process

NX Nastran solver

Design Engineer

Embedded in NX CAD

Part / assembly validation

Statics / modal / thermal

Motion analysis

Clearance & interference

NX Nastran solver

Expert Analyst

Works with Non-NX geometry

Modern, role-based interface

Superior geometry editing

Powerful FE modeling tools

Linear, dynamics, non-linear,

thermal, flow, motion,

optimization, multiphysics

NX Nastran + Multiple solver

environments

Problem Complexity

User

Scalable Simulation Capabilities

For all User Levels



Aerojet ATK (Thiokol) Arianespace Avio

BAE Systems Ball Aerospace Boeing Space

Canadian Space

Agency

DLR (German Aerospace) EADS Astrium

European Space

Agency Honeywell

IHI Space Development ISRO Satellite Centre

Japan Aerospace

Exploration Agency

Korea Aerospace

Research Inst.

L-3 Communications

LM Missiles & Fire

Control

Lockheed Martin

Space MDA Space Missions

MHI Space NASA – Ames NASA – Glenn NASA - Goddard

NASA - Jet Propulsion Lab NASA - Johnson NASA – Kennedy NASA - Langley

NASA - Marshall

Northrop Grumman

(TRW) Oerlikon Space Orbital Sciences

Pratt & Whitney (Rocketdyne) Raytheon RUAG Aerospace Saab Bofors Dynamics

Space Exploration SpaceDev

Thales Alenia

Space United Launch Alliance

United Space Alliance Volvo Aero

Global NX CAE Examples

““...our analysts are very

excited about being able

to use synchronous

technology to de-feature

models and get the

geometry down to what

they need to build a finite

element model, a CFD

model or a thermal

model.”

Nathan ChristensenSr Manager, Engineering

Tools & Analysis

ATK

“NX most reliable mesher”Source: GE, PLM World

“NX fastest mesher”Source: GE, PLM World

“NX best mesh

(fewest elements)”Source: GE, PLM World

“NX is a world-class

environment for CAE:

• Full support of solver

features and solutions

• Batch capability for

parametric FEA models

• Globally managed

• Powerful geometry

manipulation”

Steven Mueller Team lead for Gas Turbines

Siemens Energy










NX CAE


Fast, easy-to-use geometry tools

Automatic clean up of CAD models

Quick creation of fluid domain

Associativity to design geometry

Rapid updates when designs change

Leveraging geometry for CAE analysis



The Traditional CAE Process

Find &

Import Data Repair & Edit Geometry Mesh

Loads &

BCs

Part

DesignAnalysis Modeling Solve Evaluate



Traditional CAE Process

NX CAE vs. Traditional CAE

Faster initial iteration

Rapid update for later

iterations



Simulation Modeling

Demo

Modeling Demo.avi



ATA Engineering

Case Study

Business challenge:

Increase productivity and efficiency

Adapt to changes in specifications or

requirements

Keys to Success:

Exploit NX integrated design and analysis

modeling approaches, including ST

Results:

100 times faster than the manual process

3 times faster for meshing of the updated

model

“Real-world structures have complex

design definitions and challenging

analysis requirements – and both are

constantly changing. NX helps you

cope with changes very efficiently

and productively.”

Allison Hutchings

Engineer

ATA Engineering, Inc.










Design Requirements

Deformation, clearance

Stress

Strength

Stiffness

Natural frequencies

Useful life

Temperatures

Pressures

Weight

Thermal

Random Vibration Tests

Aerospace

Typical Requirements & Analyses

Analysis Types

Stress

Stiffness

Modal

Frequency response

Transient response

Durability

Thermal

Fluid flow

Optimization

Test correlation



NX CAE


Broad range of solutions

Single environment

Coupled solutions for structural,

thermal, flow, and motion

Scalable performance on HPC

Streamlined workflows for combined physics solutions



NX CAE

Multi-Discipline CAE in One Environment

Motion Multiphysics

Structural Thermal Flow

Optimization

Linear

Nonlinear

Dynamics

Rotor Dynamics

Durability

Composites

Geometry

FE Parameter

Thermal Stress

Thermal Fluid

Fluid Structure

Interaction

Motion Structural

Acoustic

Structural

Conduction

Convection

Conjugate Heat

Transfer

Radiation

Compressible

Incompressible

1-D Fluid

Networks

Non-Newtonian

CFD Modeling

Rigid Body

Contacts

Flexible Bodies

Co-simulation &

Control Systems

Packaging

Studies



Structural Analysis

Composite Materials

Weight reduction

Easier manufacturing of complex

shapes

Parts consolidation

No corrosion

Freedom to design the material

Composite materials increasingly important in Aerospace

Airliner composites

content



Structural Analysis

Challenges to Analyzing Composites

Challenges

Access to composite design data

Need faster and more frequent iteration

cycles

Data accuracy of composites analysis

models

Optimization of product performance

Lack of analysis driving design

Closing the loop with manufacturing

Need to validate the as-manufactured design



Structural Analysis

An Integrated Solution for Composites

Siemens PLM Acquired Vistagy in 2011

Fibersim now part of Siemens’ product

family



Structural Analysis

Composites Demo

Composites Demo.avi



Thermal Analysis

Demo

aeroengine_thermal_final.avi

Thermal Demo.avi



Motion Analysis with Flexible Bodies

Demo

FlexibleBodies.avi

FlexibleBodies.avi



ATK

Case Study

Business challenge:

Redesign Arming Switch for improved

reliability and ease of fabrication

Validate system thermal loads using

analysis in lieu of full scale system testing

Keys to Success:

NX Thermal

Results:

System Thermal Simulation successful

without full system testing

High fidelity can be achieved with detailed

modeling/analysis

High confidence in redesigned switch

gained thru simulation



NASA Jet Propulsion Laboratory (JPL)

Case Study

Business challenge:

Tighter schedules

Large daily temperature swings during the

life of the mission

Keys to Success:

Single software platform (NX) from design

through manufacturing

Multi-discipline simulation with NX CAE

Results:

Faster design-analysis redesign iterations

More confidence in the hardware

modeling, the design implementation, and

mission simulations

NX was able to evaluate the thermal

control system’s performance under

conditions that JPL could not

simulate with physical testing.










NX CAE


Analogous to CAD assembly

Individual FE component models

Assembly model instances FE

components

Supports very large models

Distributed CAE Assembly Model

x 4



Assembly FEM

Demo

Assembly Fem - Final2 - voice.avi

Assembly Fem - Final2 - voice.avi



Case Study

NASA - Kennedy

Challenges:

Building assemblies

Property management

NX CAE Benefit:

Assembly FEM allows separate

development of component models

Used for Stabilizer, Damper, and Vehicle

Support Posts

Collectors make it fast to assign properties

“Drag and Drop”

Change on the fly

Run “what-if” scenarios quickly

Color by metadata (properties, etc.)

Toggling entities on and off by

groups or layers

Color by physical property

Stabilizer component

connecting with tower

2010



NX CAE

Test-Model Correlation

Correlate analysis with physical test

Correlate analysis with analysis

Ensure accuracy of reduced DOF

models

Pre-test planning to optimize sensor

locations

Optimize analysis model to better

reflect reality

Quantitatively and qualitatively compare simulation with physical test











Out of the box integration with

Teamcenter

Synchronize models with design

Knowledge capture and process

automation

Intelligent integration between design & simulation processes



The Need:

Central, Global, Secure,

Relational Data Management

System

Case Study

Honeywell

Challenges:

Form of analysis data has changed over the last

20 years

Management of this data has not kept pace

Key to Success:

Introduced PLM to Analysis World at Honeywell

Rolled out Teamcenter Simulation Process

Management data model

Benefit: (Difficult to quantify all the savings)

Centralized - Know where to find analysis data

Global - Sharing data is more efficient. Enables

collaboration and reuse

Secure - Sensitive data remains sensitive, ITAR

controlled

Relational -Traceable, Locate all data related to a part.

2012

The Problem




Automation tools that can drive complex

analysis

Common architecture allowing plug-ins

Managed environment to distribute

process automation to enterprise

Guide designers through basic

simulation tasks

Automate simulation processes for analysts and designers



Dead mesh imported

Region of nodes selected

Displacement specified

Mesh morphed

Case Study

GE Aircraft Engines

Challenges:

Modifying mesh of legacy models without

geometry

Key to Success:

Developed utility in NX Open to morph

node locations

Benefit:

Automates a routine process to save time

2012










Why Siemens?

Major Investments in CAE for Product Development

“The integration of product development, simulation and

validation is now at the top of our agenda.”

Anton Huber, CEO

Siemens Industry Automation

“We are investing heavily in CAE … for multi-disciplinary

analysis throughout the product definition cycle.”

Chuck Grindstaff, CEO




Siemens acquires LMS International

Based on system simulation and test

Enabling mission-critical applications

and best practices

Embracing open strategies

Supported by world-class engineering

services

Providing unprecedented value to

customers

Providing a closed-loop, systems-driven product development solution



LMS – A Siemens Business

Simulation software, hardware and test solutions

Services – problem solving, process optimization

and co-development

3D Simulation – finite element and multi-body

modeling software to simulate and optimize

mechanical systems

Mechatronic system simulation – modeling

and analysis of multi-domain intelligent systems

to predict performance in physical domains

Test – physical prototype testing and analysis

solutions for durability, noise and vibration

engineering



Collaborative and Robust Engineering using Simulation

Capability Enabling Next Design Optimisation

What is it?

EU co-funded R&T project led by Airbus

59 organizations including Siemens PLM

Objectives:

10% reduction of development lifecycle

duration and cost

50% reduction in rework

20% reduction in the cost of physical tests

Learn More:

Webinar available at:

www.siemens.com/plm/nxcaewebinars

http://www.crescendo-fp7.eu

http://www.siemens.com/plm/nxcaewebinars




for Aerospace Development

Smarter decisions, better products

Documents

Aerospace Product Development NX CAE A Modern Simulation ... · Embedded in NX CAD Simulation wizards Part validation Stress & vibration Guided process NX Nastran solver Design Engineer