AUTOMATION OF MULTI-DISCIPLINARY ANALYSIS PROCESSES …

NAFEMS

AUTOMATION OF MULTI-DISCIPLINARY ANALYSIS PROCESSES WITH ANSA/META AND OPTISLANG

Dr.-Ing. Lars Gräning,[email protected] GmbH

2L. Gräning, AUTOMATION OF MULTI-DISCIPLINARY ANALYSIS PROCESSES WITH ANSA/META AND OPTISLANG

Beta CAE, 8th BEFORE REALITY Conference, May, 20.-22., Munich, Germany

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• Assumption: optimal design is superior to the

optimization of all disciplines in a sequence by

exploiting interaction between disciplines and groups

• Identification of trade-offs and conflicts early in the

design process

• Including multiple disciplines simultaneously increases

complexity of the optimization task

• Connection of different engineers and teams

Introduction MDO (Multi-disciplinary optimization)

Car

Safety

NVH

Durability



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1. Process automation and customization

2. Efficient algorithms: meta-modeling, sensitivities,

optimization, robustness analysis and opt. …

3. Simulation and Process Data Management (SPDM)

4. Knowledge and data exchange

5. Re-use of models, workflows and scripts

Concepts and tools for an efficient and successful MDO:

Car

Safety

NVH

Durability



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• Founded: 2001

• More than 60 employees, offices at Weimar, Viennaand San Francisco

• Leading technology companies Daimler, Bosch, ZF/TRW, Siemens rely on our products

Software Development

Dynardo is engineering specialist for CAE-based sensitivity analysis, optimization, robustness evaluationand robust design optimization

• Mechanical engineering• Civil engineering &

Geomechanics• Automotive industry• Consumer goods industry• Power generation

CAE-Consulting

Dynardo GmbH



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optiSLang and virtual product development

• Create testing plans (DoE) for measurements

• For the evaluation of measurement data

• Can control measuring stations automatically

(Hardware in the Loop, e.g. with LabView)

• For tolerance evaluation based on CAD

• Comparison: Measurement & Simulation

• Speed up your virtual product development

• Identify optimization potentials

• Robust products in face of manufacturing

and material scattering

• Data based Reduced Order Models (ROM)

• Interface between simulation and database (PLM)



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Automated Workflows

„Best Practice Workflow“

for the virtual product development:

• Connect all numerical solvers to an automated

design run

• Automate CAE processes

• Connects to PLM database to get the newest

CAD data and write all necessary data back to

the database

• Integrate conditional execution for different

paths in workflow

• Run nested loops for:

– Robustness in optimization

– Performance maps

– Different load cases

– Operating windows

• Generate customized reports

Simulation Workflow



ANSA / META Integration

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Define Design variables Define evaluation criteria



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Reduced Crash Box modelCrash can

Traverse

Front bumperMounting points

• ANSA: LS-Dyna Tutorial example

• Beams are connected with a

cylindric traverse

• Front connected with double

traverse

• Evaluation of NVH: static stiffness &

Safety: front crash

• Crumble zones to control

buggling



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Vertical offset 1...4

Vertical Width 1...4

Width_Extend_Front_Sym

Width_Extend_Base_Sym

Height_Extend_Front_Sym

Height_Extend_Base_Sym

Design variables (Shape morphing with ANSA)

• ANSA morphing to parameterize

double beam geometry

• Compact representation to generate

geometric variations

• Elongation of front and rear can be

controled independently

• Direct morphing is used to vary

crumble zones

• Morphing techniques facilitate a

smooth deformation of the surface –

suited for design optimization tasks



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ANSA integration into optiSLang



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I. NVH: Stiffness

2:Fz = -10.0 kN1:Fy = 10.0 kN

II. Safety: Front Crash

Objective: minimize mass

Constraints:

• dy < 1.5 mm

• dz < 2.5 mm

Simulation: MSC Nastran

Vx=12m/s

Objective: minimize mass

Constraints:

• Fmax < 100 kN

• dmax < 340 mm

Simulation: LS Dyna



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META integration into optiSLang



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ANSA Solver META post

wall

crash box structure

Signed von Mises

Process automation for direct MDO



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- Simulation results

- Pictures, movies, …

- Meta-model / ROMs

- Workflow + settings

- Meta-model

- …

- CAD geometry

- FE mesh

- Boundary conditions

- Material properties

- Meta-model

- …

SPDMProcess Execution & Data Management

Simulation process data management



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Results direct optimization with Evolutionary Algorithm

Resulting mass: 8.99 kg Computational costs: 282 simulations



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Process data /

information

Design data /

information

EKM



Automatic workflow with a minimum of solver runs to:

• identify the important parameters for each response

• understand and reduce the optimization task

• check solver and extraction noise

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Sensitivity Analysis: build Meta-model of optimal Prognosis (MoP) and identify most important design variables



Meta-model: Meta-model of Optimal Prognosis (MOP)

• Objective measure of prognosis quality

• Determination of relevant parameter subspace

• Competition of diverse Meta-Models like,Polynomials, Kriging, MLS, Neural Network, …

• Determination of optimal approximation model

• Approximation of solver output by fast surrogate model without over-fitting

• Evaluation of variable sensitivities

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Total CoP 82%



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SPDM

Discipline:

DurabilityDiscipline:

Crash (Car Safety)

Meta-model assisted MDO



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Front crash



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Stiffness



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SPDM

Meta-model

assisted

MDO

Discipline:

DurabilityDiscipline:

Crash (Car Safety)

Meta-model assisted MDO



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Results meta-model assisted optimization with Evolutionary Algorithm

Resulting mass: 8.68 kg (-3.7%) Computational costs: 161 simulations (Sensi + validation) (-75%)



© Dynardo GmbH

1. Process automation and customization

2. Efficient algorithms: meta-modeling, sensitivities,

optimization, robustness analysis and opt. …

3. Simulation and Process Data Management (SPDM)

4. Knowledge and data exchange

5. Re-use of models, workflows and scripts

Concepts for an efficient and successful MDO:

Car

Safety

NVH

Durability



© Dynardo GmbH

[email protected]

phone +49 (0) 3643 9008-32

Many thanks to Serafim Chatzimoisiadis and Vassilios Mazis from BETA CAE Systems for

there support regarding ANSA and META.

Acknowledgement:

Vielen Dank!



© Dynardo GmbH



© Dynardo GmbH

Re-use and version control of processing scripts



Tutorial optiSLang © Dynardo GmbH

…

Workflow management, re-use and exchange

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AUTOMATION OF MULTI-DISCIPLINARY ANALYSIS PROCESSES …