1. Robust Design: The Future of Engineering Analysis in Design
Gene Allen and Brett Malone

2. Future of Engineering Analysis
COMPUTATION IS A COMMODITY
GIVEN:
IMPROVING COMPUTATIONAL CAPABILITIES
BETTER COMMUNICATIONS CAPABILITIES
HIGHER CUTOMER EXPECTATIONS
HOW DO YOU DO BETTER ENGINEERING?
IS PRODUCT UNDER-ENGINEERED?
OVER-ENGINEERED?

3. Future of Engineering Analysis
OBJECTIVE – DESIGN A ROBUST PRODUCT
MINIMIZE THE IMPACT VARIABILITY IN DESIGN
PARAMETERS HAS ON PRODUCT PERFORMANCE
ATTRIBUTES:
Reduced performance sensitivity to product and use variability
Performance repeatability
Designed-in product reliability, durability and operability
Safety even under malfunctions

4. INTEGRATED CALCULATION OF
Robust Design
Variability Management Attacks Fundamental Causes of Failure
INTEGRATED CALCULATION OF
Predicted
to occur
Capability
MANUFACTURING
• RISK • RELIABILITY
• ROBUSTNESS • LIFE
Frequency
Performance Parameter
Assembly Models
HARDWARE ASSEMBLY
AND MATERIALS
CHARACTERIZATION
HARDWARE
ENVIRONMENT
CHARACTERIZATION
Risk Measure
Process Models
LIFE CYCLE LOADS,
TEMPS, ETC
OPERATIONS
QUALITY ASSURANCE
MATERIALS
Probability of
detection
(e.g., flaws)
Loads . . . . . . .
Alt
Strain .
... . . . . . . . . . . . . . . . . . . .. . . .
... .
... . .
Cycles
Material Models
Inspection Models
Historical data and models
Operating conditions

5. ROBUST DESIGN Future of Engineering Analysis
PROVIDES ENGINEERS THE ABILITY TO:
Anticipate and Prevent Design Problems
Improve product and process Quality
Reduce time to market and number of
prototypes
REPLACES TRIAL and ERROR WITH DESIGN DISCIPLINES
Provides a structured method for engineering
decision making.

6. Future of Engineering Analysis
HOW DO YOU DO BETTER ENGINEERING TO
GET A ROBUST DESIGN?
FOLLOW METHODOLOGICAL ENGINEERING PROCESSES that provide:
COHERENT DESIGN EXPLORATION
QUICK RESULTS
EASY TO USE

7. Future of Engineering Analysis
PROCESS:
CAPTURE A DESIGN ANALYSIS PROCESS
RUN HUNDREDS OF INSTANCES OF THAT PROCESS
FOLLOW COHERENT METHODS FOR
EXPLORING DESIGN OPTIONS
DO QUICKLY WITH COMPUTE CAPABILITIES AVAILABLE
INTRANET NOW
INTERNET TOMORROW

8. Future of Engineering Analysis
DESIGN ANALYSIS PROCESS MODEL (MATH MODEL)
A NETWORK OF ONE OR MORE INDEPENDENT SOFTWARE APPLICATIONS (FUNCTIONAL MODELS)
REPRESENTS ONE INSTANCE OF THE DESIGN ANALYSIS PROCESS
USED TO DETERMINE ONE POINT IN THE DESIGN SPACE.
ONE OR MORE DESIGN EXPLORATIONS METHODS WILL BE USED TO RUN HUNDREDS OF INSTANCES OF THE DESIGN ANALYSIS MODEL
BY METHODOLOGICALLY VARYING THE INPUT VARIABLES

9. Design Analysis Model (Math Model)
Input Variables (X’s)
Geometry
Variables
Heat Transfer
Variables
Mechanical Load
Variables
Material Property
Variables
Thermal
Analyzer
Geometry
Engine
Thermal Stress +
Mechanical Stress
Life (F.S.)
Analyzer
Mechanical
Stress
Analyzer
Rapid Developed Links
Response Variables (R’s)
Mass Max.Temperature Max.Combined Stress F.S.
Green boxes represent
independent software applications
called FUNCTIONAL MODELS 14

10. MSC.RD Design Analysis Model
Service
Pallet
Connector
Customizable Service Pallet; Click and Drop Services

11. ModelCenter Process Integration

12. Future of Engineering Analysis
DESIGN EXPLORATION METHODS
TYPICAL/EXTREME DETERMINISTIC ANALYSIS
DESIGN SCANS
SENSITIVITY ANALYSIS
DETERMINISTIC OPTIMIZATION
PROBABILISTIC (STOCHASTIC) SIMULATION
TAGUCHI ANALYSIS

13. VIEW RESULTS TAGUCHI ANALYSIS RESULTS RESPONSE SURFACES Local Minimum
Global Minimum

14. MSC.ROBUST DESIGN ENABLES RAPID DESIGN EXPLORATION BY LINKING
Design Exploration with
Methods
Taguchi
Monte Carlo
Design Scans
Sensitivity Analysis
Optimization
Single point
Engineering Simulation with Distributed Computing
Mechanical Design
Manufacturing
Stress
Dynamics
Risk
Support
Intranet
Web

15. MSC.Robust Design Service Process
Work with Users to establish design-analysis process input
Integrate MSC.Software RD with the User’s IT infrastructure
Ensure integration of functional models
After services complete, User left with:
Software and process that provides capability to conduct Robust Design for a family of products/parts with significant increase in use of installed software tools and hardware

16. ESTABLISH PROCESS PARTNERSHIP
MSC HAS:
WORLD CLASS MULTI-DISCIPLINE ENGINEERS WHO KNOW SOFTWARE AND ENGINEERING
ANALYSES
CUSTOMER HAS:
WORLD CLASS
EXPERTISE IN
MAKING WHATEVER
BOTH ARE NEEDED
TO PROVIDE A ROBUST DESIGN CAPABILITY
THAT CUSTOMER’S PEOPLE CAN USE TO
IMPROVE THEIR PRODUCTS

17. MSC.Software - Phoenix Partnership
Has BEST NT-based process capture tools:
Easy to use
Easy to install
Easy to learn
CATIA V5 Development Environment
MSC.Software
Has BEST process analysis capability:
Selection of design exploration methods
Parallel analysis through distributed computing
Structural analysis applications
Dassault Strategic Partnership