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Victor Remmers Holland Engineering Consultants BV

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1 Victor Remmers Holland Engineering Consultants BV
Pro/ENGINEER Advanced Mechanica Robust capabilities to support your product development needs Victor Remmers Holland Engineering Consultants BV

2 Pro/ENGINEER Advanced Mechanica
Agenda- State of PTC Simulation Solutions PTC Structural and Thermal Analysis Solutions Pro/ENGINEER Mechanica Pro/ENGINEER Advanced Mechanica Advanced Mechanica Capabilities Supported Solutions Types Additional Modeling Entities FEM Modeling Capabilities © 2006 PTC

3 PTC as a Simulation Solutions Partner
Developing innovative simulation solutions for over a decade Significant ongoing investments in computer aided engineering (CAE) Supports a healthy ecosystem of more than 200 software development partners Over 8000 customers in diverse industry verticals Leading respected companies such as... When companies think PTC they think Pro/E and Windchill. What they often underestimate is our level of commitment to simulation and CAE as an integral part of the overall PLM strategy…. If you aren’t looking to PTC for CAE solutions, perhaps you should… © 2006 PTC

4 PTC as a Simulation Solutions Partner
PTC continue to invest heavily in simulation solutions – The proof is in the results... Wildfire 1.0 The biggest release of Structural and Thermal Simulation ever (even pre-dating the RASNA acquisition) -Over 130 individual projects Wildfire 2.0 Redesigned user interface – leveraging the Wildfire user model Many new functionality features such as bolt fasteners Wildfire 3.0 User customizable simulation process guides Continuing usability and functionality enhancements Much more... PTC is not resting on past accomplishments, but continues to lead with innovative simulation solutions © 2006 PTC

5 Pro/ENGINEER Mechanica
Using Pro/ENGINEER Mechanica in the design process serves to reduce risk- Concept Design Detailed Design Drawing / Detailing Prototype Mfg. Prototype Testing Are you spending Money? $ $ $ $ $ Do you know if the design works? No No No No Yes Risk Simulation early in the design process reduces risk, reducing time and improves quality © 2006 PTC

6 Pro/ENGINEER Mechanica
Pro/ENGINEER Mechanica satisfies the need to evaluate product performance during design by satisfying the following four key points- Integration Accuracy Affordability Scalability “I was amazed at how fast I was able to produce accurate stress results…” - Derrick Rogers, Lead Technical Engineer Miss Budweiser Racing; also a Loads and Dynamics Engineer at Boeing Commercial Aircraft Integration A native Pro/E module, no external files, associativty, leverages other modules such as MDO, etc… Accuracy Unique PTC MECHANICA technology ensures accuracy for non-expert users Value The basic package supports optimization, idealizations such as beams and shells Scalability Users are not locked into a dead-end solution Structural and Thermal Simulation is the BEST solution for functional simulation early in the design process if you use Pro/ENGINEER © 2006 PTC

7 Pro/ENGINEER Mechanica
Pro/ENGINEER Mechanica satisfies the needs of design level analysis Intended for everyday use as a design based simulation tool Functionality addresses more common use scenarios However, the complexity of the products and problems engineers face is increasing... More nonlinear capabilities are required More solution types necessary More exotic properties and modeling entities required Pro/ENGINEER Advanced Mechanica has the capabilities to address the broader range of problems posed by complex product design requirements © 2006 PTC

8 Why Advanced Mechanica from PTC?
Advanced Mechanica addresses the greater needs of dedicated and expert users while maintaining the basic benefits of Mechanica- Leverage your existing skills and investment in Mechanica infrastructure Unique solution technology for not just any answer, but the right answer A broad set of capabilities that build on the base package making simulation accessible from engineers through analysts The power to get the job done, without compromise Integration A native Pro/E module, no external files, associativty, leverages other modules such as MDO, etc… Accuracy Unique PTC MECHANICA technology ensures accuracy for non-expert users Value The basic package supports optimization, idealizations such as beams and shells Scalability Users are not locked into a dead-end solution The Scalability to address the needs of designers through experts © 2006 PTC

9 The bottom line... Advanced Mechanica expands the types of problems you can simulate- Validate product performance to improve quality and reduce cost Understand product performance in real world conditions before money is committed for physical prototypes A prototype should validate your decisions, not be used for design Use simulation to drive the design, not validate it late in the process Without Mechanica, you won’t leverage the power of Pro/ENGINEER. Without Advanced, you can’t leverage the full power of Mechanica © 2006 PTC

10 Pro/ENGINEER Advanced Mechanica
Advanced Mechanica extends the capabilities of Mechanica in the following areas- Supported Analysis/Solution Types Support for Advanced Materials Properties Advanced Modeling Entities Sophisticated FEM modeling tools Advanced Mechanica provides the depth of capability to simulate to today’s complex requirements © 2006 PTC

11 Advanced Tools for Model Simplification
2D Model simplification enables you to dramatically reduce the time to solution for applicable models Supported 2D Model types include- Plane Strain – Unit Thickness Plane Stress – Thin Plate Axisymmetric Benefits include- Extremely fast solution speed Fast non-linear solutions, including large deformation or contact Even models with contact defined solve in seconds! Ideal for design studies Very simple to set up Solve complex problems in a fraction of the time needed for full 3D models! © 2006 PTC

12 Advanced Solution Types
“How long will my design take to reach steady state?” Steady state thermal analysis can tell you how hot or cold a component will get – Transient Thermal will tell you how long it will take to get there Transient Thermal Analysis Setup is straightforward - Time dependant heat loads Time dependant convection coefficients Analysis definition is similar to that of steady state Available results include – Graphs of Measures vs. Time Full results at user selected intervals Temperatures to apply to structural models at user selected intervals © 2006 PTC

13 Advanced Solution Types
Large Deformation Nonlinearity The ability to perform analysis on components which undergo large deformations yet small strains (once the load is removed there is no permanent set) Common Applications include the design of- Snap Fits Springs Output can include – Graphs of displacement vs. force Full fringe result Linear static solution Unique adaptive nonlinear and solution algorithms are tailored for non-specialist users In Nonlinear Large Deformation analysis stresses are 11% lower © 2006 PTC

14 Advanced Solution Types
In certain structures the stiffness is dependant on an applied load For example, a sheet of paper is flexible and cannot support much, if any weight; however if I pull along the edges, the paper can support considerable weight Advanced Mechanica supports the analysis of such models in both static and dynamic analyses Prestress Static Analysis Static analysis which takes loading into account for stiffness Prestress Modal Analysis Modal (natural frequency) analysis which takes loading into account or stiffness Prestress Modal also includes additional physical effects including- Spin Softening Stress Stiffening © 2006 PTC

15 Advanced Solution Types
Advanced Mechanica supports a broad range of dynamic analyses Many products operate in environments where vibration plays a key factor in the performance of the design. The physical test equivalent for dynamic would be “shaker table” testing of components. Vibration analysis capabilities include- Dynamic Time Used for evaluating the behavior of systems where the input is a time history of load; common applications include transient or shock loadings For example the design of an aftermarket exhaust pipe for an off-road motorcycle where a requirement is the ability to withstand a 10 ms, 20g half-sine shock load Dynamic Frequency Used in evaluating the response of a structure to an input of loading vs. frequency; common applications include rotating machinery and engines - where the loading is highly periodic in nature For instance in the above example we may have test data of the accelerations vs. frequency form the engine, and we may need to evaluate the maximum displacements of the muffler assembly during a range of operating conditions. © 2006 PTC

16 Advanced Solution Types
Vibration analysis capabilities include (Cont’d)- Dynamic Random Some vibration environments are characterized as random; for example a plane flying through turbulent air or a truck driving on pavement. In both of these examples another plane flying the same path or truck driving the same road would experience similar, but not the exact, same accelerations. The input to random vibration analysis is a PSD (Power Spectral Density); basically the “probability” of encountering a level of acceleration for a given frequency. For example, we may be designing a control unit for an engine in a vehicle for which we have a PSD of the mount locations. The PSD will include the effects of the engine, the road, etc.. And Dynamic Random analysis can show us how the component will behave in this environment. Dynamic Shock Used for simulating seismic loads For example an equipment rack which must be able to withstand an earthquake of a given magnitude © 2006 PTC

17 Advanced Mechanica Capabilities
Laminates and Non-Isotropic Materials Not all materials behave the same in all directions. Once only used in aerospace, but now common in everything from sporting goods to automobiles, Advanced Mechanica enables you to define and use Anisotropic and Orthotropic materials with ease in your models Additional Capabilities Include: Advanced tools for modeling composite structures Ply editing for building up laminates Layup stiffness review Results by ply Support for common failure criteria such as Tsai-Wu Evaluate the performance of your designs with exotic materials © 2006 PTC

18 Advanced Mechanica Capabilities
More sophisticated Idealizations Advanced Mechanica builds on the robust set of idealizations provided in the basic package. Additional capabilities include- Advanced Mass Idealizations The ability to enter in the full mass matrix including inertial terms, not just the mass value The ability to define mass idealizations “from component” where the mass matrix and orientation are taken from another component. Advanced Springs Idealizations The ability to define springs by specifying the full stiffness matrix including the coupling terms Control over automatic coupling between bending and tensile loads Advanced Shell Idealizations The ability to easily model composite structure © 2006 PTC

19 Advanced Mechanica Capabilities
More sophisticated Connection Capabilities Advanced Bolt Fasteners Build off of the capabilities in Basic Mechanica Additional Functionality Includes.... The ability to easily define preload Greater control over specifying bolt stiffness Control over the degrees of freedom in the bolt connection Weighted Link Connections The ability to couple a point to move as the average displacement of a set of geometry Powerful tool for attaching point loads and masses and distributing these over a model © 2006 PTC

20 Advanced Mechanica Capabilities
Advanced FEM Mode Modeling tools Sophisticated capabilities for interfacing between Pro/ENGINEER and 3rd party solvers such as NASTRAN or ANSYS Additional capabilities include- Hierarchical FEM modeling The ability to “Assemble” FEM meshes to build system level models Support for Rigid and Weighted Links NASTRAN RBE3 and RBAR support. ANSYS rigid like export Access in FEM Mode to other Advanced Capabilities Access to advanced shells, masses, distributed mass, etc... Scalability to pass your models to 3rd party solvers for performing systems level analyses © 2006 PTC

21 Why Advanced Mechanica from PTC?
Leverage your existing skills and investment in Mechanica solution technology Greater Solution Flexibility Greater Solution Capability Expand the breadth of your simulation coverage Integration A native Pro/E module, no external files, associativty, leverages other modules such as MDO, etc… Accuracy Unique PTC MECHANICA technology ensures accuracy for non-expert users Value The basic package supports optimization, idealizations such as beams and shells Scalability Users are not locked into a dead-end solution Advanced Mechanica is the ONLY solution for sophisticated simulation inside of Pro/ENGINEER © 2006 PTC

22 What is new in MECHANICA Wildfire 3.0?
A Quick overview…. © 2006 PTC

23 Structural and Thermal Usability Improvements
Remaining “Mechanica” objects merged into Pro/E Including... Spot welds Rigid connections Contact regions Enhanced capabilities include… Improved UI Object-Action interaction (direct editing) Layers support Model tree support Improved display and controls Much, much more... Automatic Contact Definition Select components and separation tolerance Contacts are automatically created Spot weld capabilities have been dramatically improved.  Some of the enhancements include- Model tree support Improved definition UI Layers support Direct editing (Object-Action) Improved display and control Much more... The new spot weld definition UI has been merged into the existing weld (end and perimeter) definition dialog. Definition and editing of rigid connections is improved over previous releases.  Rigid connections now appear in the model tree and can be edited directly by selecting them on the model.  Also, display improvements now allow users to control visibilities and place the connections onto layers. Contact regions have been enhanced to make definition and editing much easier.  Some of these improvements include... Improved display New definition UI Contact regions can now be automatically created between a set of selected parts in an assembly.  Once selected, a maximum seperation and angle between the parts may be specified.  Once created, the contact regions may be edited/deleted individally as though they were created manually. © 2006 PTC

24 Structural and Thermal Usability Improvements
New design study UI The last of the “Old Style” UI to be removed Usability improvements to... Optimization definition Sensitivity study definition Design Studies No more design variable definition Use dimensions and parameters directly Greater control of optimization settings Feasibility studies added The last of the "old style" interface from Mechanica has been re-implemented in Wildfire 3.0.  The dialogs for defining design studies, sensitivity studies, and optimizations are greatly enhanced.  In addition to improvements to the dialogs, the workflow is simplified as well.  Users no longer need to create design parameters to vary dimensions and parameters.  These can now be selected directly from the model. Other enhancements include the ability to access more optimization settings, as well as the ability to define feasibility studies. © 2006 PTC

25 Structural and Thermal Usability Improvements
Many smaller improvements.... Selection/Copy enhancements Copy and Paste of simulation modeling objects Multi-selection for delete Hide/Unhide for simulation objects in model tree Exploded views supported in modeling Contact definition is much simpler Define connections in exploded state Results improvements Dynamic query labels don’t erase when spinning model Spin center control allows rotations about a user selected location Legend settings don’t reset when window is edited Simulation modeling objects such as fasteners and loads can now be easily copied.  Once the object is selected from either the graphics window or model tree, the copy command is activated from the menus or right mouse button.  When the object is pasted, it may be edited and new references can be selected. Multiple simulation modeling objects may now be selected and deleted in one simple operation. Simulation modeling object visibility can now be controlled using the Hide/Unhide functionality.  Once an object is selected, it may be hidden by selecting the Hide menu in the right mouse button pop-up or top level menus.  This allows you to more effectively control the visual clutter on complex models. You can now work with exploded views when defining your simulation model.  This greatly simplifies the creation of connections such as contacts or free interfaces on complex assembly models. When dynamic query labels are placed on a model, if the model is rotated or resized the labels will stay attached.  This is an improvement over past releases where rotating the model erased the labels. It is now possible to toggle the model spin center in results.  If the spin center is toggled off, the model will rotate about the user selected point.  If the spin center is toggled on, the model will rotate about the spin center. In past releases editing a results window resulted in the loss of any legend customization.  In Wildfire 3.0, only changing the results quantity will reset the legend to the defaults.  This makes editing the appearance of results windows much easier. © 2006 PTC

26 Structural and Thermal Functionality Improvements
Volumetric assignment Ability to assign materials by volume Volume regions in a part can have different properties Ability to assign heat loads by volume Inertial relief This is the ability to run static analyses on “unconstrained” or “under constrained” models Users simply select a checkbox on the analysis definition dialog Externally applied loads are balanced in the solver by equal and opposite body forces (accelerations) Users may now assign heat loads to volume regions in parts or assemblies.  In past releases, heat loads could be assigned to components, surfaces, edges and points only. Inertial relief is now supported as an analysis option in Mechanica.  Inertial relief allows users to run under-constrained models in static analysis.  When solving a model with this option set, the externally applied loads/moments are balanced by equal and opposite body forces/accelerations.  This capability is especially useful for the definition of models where it may be difficult to constrain the model without artificially stiffening it, such as when components of a dynamic linkage are analyzed. Inertial relief is activated by selecting the checkbox in the analysis definition dialog. © 2006 PTC

27 Structural and Thermal Functionality Improvements
“Weighted” links in Mechanica Similar in functionality to NASTRAN RBE3 A point is tied to move the average of the displacements of selected geometry A great tool for “smearing out” singular effects over more of a model such as point loads Advanced springs Now advanced spring definition is supported inside of Pro/ENGINEER Full stiffness and coupling matrix may be defined Users also have the option to disable the “auto coupling” of simple springs Users may now define weighted links in Mechanica.  Weighted links allow you to select independent geometry including points, curves/edges, and surfaces and a dependant point.  The weighted link ties the dependant point to move the average of the displacements of the independent geometry. Weighted links provide a good means of "smearing" out local, singular effects over larger areas of the model.  For example, a point load can be applied at the dependant point and this point load will be applied to all of the independent geometry. Advanced spring properties have been enhanced to allow users greater control.  Users can now turn off the automatic computation of coupling terms.  If automatic coupling is turned off, the individual coupling terms may be manually entered. © 2006 PTC

28 Structural and Thermal FEM Improvements
FEM mode specific enhancements Spot weld connections supported for ANSYS and NASTRAN Rigid links enhancements (one to many) New modeling entities output to ANSYS Rigid links Beam releases Display only mode in Run dialog Allows preview of output without writing the model to file Supported solvers include... ANSYS 9.0 MSC.NASTRAN 2005 r1 Spot welds defined in Mechanica native or FEM mode are now supported and output to the FEM solvers. When defining rigid and weighted links, in past releases users could only define these between 2 surfaces or between two points.  The capability of defining these modeling entities between a point and a distribution along an edge or surface has now been added.  When point-edge or point-surface references are selected the option to distribute of project is provided.   This new functionality allows users to more easily build complex FEM models. More modeling entities are now supported for output to the ANSYS solver in FEM mode.  Rigid links and beam releases now defined in the model will be output to ANSYS at run time. Users can now display a preview of how the model will be output to FEM solvers.  On the FEM Solution dialog, selecting the Display option allows you to preview the model before selecting to output it to file. © 2006 PTC

29 Structural and Thermal Robustness Improvements
Meshing robustness Very large model AutoGEM robustness (200K+ solids) FEM solid and tri surface meshing robustness “Assembly modeling methodology” in FEM Mid-surface compressed models “joined” with rigid links Tolerance report Performance Improvements Removal of the 8 Gb memory limit on 64 bit operating systems Mechanica running on Linux Windows XP 64-bit support Intel Xeon 64 AMD Opteron 64 Both the AutoGEM and FEM meshers see improvements in robustness in the Wildfire 3.0 release.  AutoGEM has been enhanced in the area of large model meshing robustness, ensuring success when modeling large, complex structures. The FEM mesher sees a continuation of the robustness projects that started development last release. When midsurface compressed assemblies are modeled, in past releases users had to connect the parts that were compressed using welds, connections, beams, springs, etc... Now in FEM mode Mechanica detects where the parts were touching before they were compressed and rigid links are created between the corresponding nodes.  If a user defined connection is detected between the parts, this automatic linking does not take place. This new functionality makes the modeling of midsurface compressed assemblies in FEM mode easier and faster than ever.  The tolerance report has been enhanced to display not only the model tolerance, but the current accuracy setting as well.  The tolerance report allows users to easily see the current model tolerance.  This is important when attempting to mesh assembly models where if the tolerance of the components is similar the robustness of the mesher improves. The 8 Gb limit in the Mechanica solver has been removed for 64 bit operating systems.  In past releases the 8 Gb limit constrained the solver to models of up to 4-5 million degrees of freedom.  With the limit removed, the model size that can be run is practically unlimited. Mechanica will be supported on Redhat Linux in Wildfire 3.0. All of Pro/E Wildfire 3.0 (including Mechanica) will support Windows XP 64 running on Xeon 64 and AMD Opteron processor powered machines. This will allow Windows XP 64 users to run models well beyond the 32 bit operating limit of 2 Gb. © 2006 PTC

30 New Materials Definition UI/Database
Materials in Pro/E are completely overhauled Materials in Pro/E are being enhanced to support Simulation requirements Database will be open and extendable Including the ability to add user defined parameters to materials Each materials property has units associated Part materials will be “seen” at assembly level in Mechanica New functionality includes... User defined material parameters Assign materials in family tables Assign appearance by material Materials assignment has been overhauled in Wildfire 3.0.  In 3.0, if materials are assigned to models in Pro/ENGINEER, these assignments are seen in the parts and assemblies in Mechanica.  Additionally, users can also define materials assignment in Mechanica that override those inherited form Pro/ENGINEER.  The new materials assignments can be assigned to parts, assemblies, as well as volume regions. Assigning materials to volume regions allows for multiple materials to be assigned to separate volumes in a single part. Materials in Pro/ENGINEER have been enhanced to support simulation requirements.  All materials definition and assignment can be done in standard mode, and these assignments and properties will be seen when the models are used in Mechanica. The new materials definition interface improves usability, as well as adding new functionality such as the ability to define user parameters and save these with materials definitions. This new materials capability will make simulating designs created in Pro/ENGINEER much faster and easier by removing the necessity of re-applying materials solely for analysis. © 2006 PTC

31 Process Guide for Structural Simulation
A user customizable “wizard” that can be used alongside the standard user interface Defined by a user specified xml file Each “process” consists of one or more tasks Users simply follow the steps listed in the tasks What problem does Process Guide address? Some Product Development activities are very “process oriented”, such as manufacturing or analysis It is not uncommon for an engineer to perform analysis only a few weeks a year If a design cycle is 9-12 months, only a few weeks of that time may be simulating the design... Some analysis tasks consist of repeatable processes These may be dictated by expert users or analysts Pro/E’s simulation tools are robust and easy to use, but for infrequent users the difficulty is not in the “clicks and picks” but in the sequence of events Process Guide is a user customizable wizard that can be used alongside the standard user interface.  Expert s or consultants can create an xml file that will populate the process guide.  The Guide lists a set of tasks, or steps, that need to be completed for a given process.  The steps in the process consist of either actions, such as create a load, or information, such as a link to online help or an intranet page. As the steps in the process are completed, they are marked as such.  If a step is invalidated, such as a load created in the Guide is deleted from the model tree, te step will be marked as invalidated.  If a Guide is left in mid session, the steps completed to that point can be saved with the model. The Process Guide can be used to guide infrequent users through the steps of common analyses; or provide guidance for more sophisticated users in tasks they are not familiar with. © 2006 PTC

32 Process Guide for Structural Simulation
The process is made up of discrete tasks “Experts” or consultants can define process templates These are an xml file with the data that will populate Process Guide 37 different actions and may be defined, including... Info links – links to online help, company intranets, etc... Action links – loads, constraints, idealizations, etc... The resulting process file has some intelligence If created entity is deleted, task is invalidated Sub-steps may be created Some tasks are order dependant Analysis must be run before results may be viewed Each task may contain Text One action and multiple informational links Embedded images © 2006 PTC

33 Thank You! © 2006 PTC

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