Refined Investigations and Data Manipulation for FE Post

Refined Investigations and Data Manipulation for FE Post Processing

2nd Workshop on Structural Analysis of Lightweight Structures Natters, May 30, 2012

B.Caillaud S.Müller

INTALES GmbH-Innsbrucker Str. 1 - A-6161 Natters - www.intales.com

Data Handling and Automation

• Increasing complexity of FE models

FEAInput data Output results

Sensitivity Studies, ...

Analysis Controls (NLA)

Refined Investigations


• Increasing complexity of FE models

• Diversity of post-processing methods (computation of

various failure criteria, refined 3D analyses, customer-oriented tools...)

• Necessity for adaptability to different environments

2

Creation of automated tools

Contents

Data Handling and Automation

1. Reduction of Computational Time (Load Case Selection)

2. Real-Time Analysis Support (NLA Manager)



3. Decision Makers for large Data Amount (Sensitivity Study)

4. Automated Failure Mode Investigation (Parametric 3D FEM)

Outline and Customer Interfaces

3

Load Case Selection

• Based on user / customer defined criteria

• Detection of similar LCs with comparable

impacts on the structural behaviour

• Final decision makers

Tool Description

INTALES GmbH-Innsbrucker Str. 1 - A-6161 Natters - www.intales.com4

Application

• 168 Static Load Cases

A350 XWB Winglet

• ~ 400.000 Finite Elements

• Decision based on >15 variables

Load Case Selection

Large quantity of

State VariablesBinary output

Key Points

• Upstream work to limit the quantity of computations


• Establish a ranking based on criteria importance level

Unitary LCs

+

Linear superposition

Statistical

approaches

Decision

matrix

• Upstream work to limit the quantity of computations

• Efficient selection process based on the State Variables of interest

Challenges of Automated Data Handling



6INTALES GmbH-Innsbrucker Str. 1 - A-6161 Natters - www.intales.com





Non-Linear Analysis Manager

ENERGY DENSITIES

674000

676000

678000

680000

682000

684000

686000

688000

690000

En

erg

y

TPENER

Tool Description

• Based on the “Branching Analysis 1”

to detect the correct equilibrium path

• Real-time treatment of state variables

during the analysis run


• Applicable especially for structures that are sensitive to buckling and a

non-linear potential

• Fully automated NLA of deterministic load scenarios

• Deeper insight of various state variables with a special emphasize on non-

linear behaviour

670000

672000

3 4 5 6 7 8

StepTime

7

Application

Non-Linear Analysis Manager

• Abstract data handling required to be free in the

choice of the criterion to judge the equilibrium path

• Object oriented coding shall be preferred (Python,

C++,...)

Key Points


C++,...)

• User interface to set job and criterion parameters









Sensitivity Study

• Determine the correlation between FEM input

and output variables

• How sensitive is the structure to perturbations?

• Filter and rank the results of interest

Tool Description


Application

Rocket Nozzle

• 2.000.000 DOFs

• NLA of entire flight scenario ~ 20 h (RAM 20Gb)

• Sensitivity Study (60 samples) ~ 2 months (~3000Gb of data created)

Sensitivity Study

z

Enormous quantity of

computed correlations

Selection of

meaningful results

Key Points

• Uniform DB containers


• Uniform DB containers

• Modular environment

Random fields application on Nozzle Extension

• Results filtering strategy

Storage of

input parameters and

output resultsIndependence to

the FE Code used









Failure Mode Failure Mode

Failure Mode Investigation

FE-Solver

( Abaqus, Nastran, Ansys, ... )

Failure Mode Analysis

Failure Mode Analysis


Results Container

( ODB, XDB, DB, ... )

Standard Post Processors

( CAE, PATRAN,

Workbench, ... )

Determination of Reserve

Factors. PP-Programs are

used for visualization only

13

• Manipulation of state variables for refined

RF / MS calculation

Failure Mode Investigation

Tool Description

Application

Ramped Areas of Sandwich Parts

• Advanced and automated generation of


Radius Bending Analysis of Spar Corners

• Advanced and automated generation of

parametric 3D model for detailed failure

mode investigation

Key Points

• Results from 3D analysis are highly

sensitive to the parameters

• Partly high geometrical efforts to be taken

for the mesh generation

Outline

Minimize the computational effort

Real-time treatment of information


Structured and uniformed data containers

Modular environment

Automated parametric studies

15

Customer Interfaces

• Relieve the engineer from repetitive and failure intense tasks

• Avoid time consuming manual GUI interaction

• Interface tools enables us to satisfy every customer Interface


• Interface tools enables us to satisfy every customer Interface– Fast generation of Input for FM analyses

– Reproducible input with variable agreed input generation methods (load calculations,...)

– Comparable results in projects with decentralised co operations

• Latest Example:– ISAMI interface for AIRBUS UK for various Failure Modes for

composite structures for the A350 XWB Winglet

– Used by INTALES, FACC, Assystem UK, Atkins UK

16

Documents

Refined Investigations and Data Manipulation for FE Post