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1
Kalibrierung, Optimierung und
Robustheitsbewertung eines
Steckverbinders mit
ANSYS optiSLang
M. Schimmelpfennig
R. Kallmeyer
Dynardo GmbH
CADFEM ANSYS Simulation Conference
Winterthur, 2017
2
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Outline
• Overview
• Theoretical background
• Example 1: connector – material calibration
• Example 2: connector – system calibration
• Material Calibration
• 5 material parameters
• System Calibration
• 15 geometry parameters
calibrated material for load simulation
3
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Overview
4
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
• is a general purpose tool for variation analysis
using CAE-based design sets (and/or data sets)
for the purpose of
• sensitivity analysis
• design/data exploration
• calibration of virtual models to tests
• optimization of product performance
• quantification of product robustness and product reliability
• Robust Design Optimization (RDO) and Design for Six Sigma (DFSS)
serves arbitrary CAX tools with
optiSLang
support of process integration
process automation
workflow generation
© Dynardo GmbH
5
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
SPDM
Input
1
Input 2
Input n
Output 1
with Process Integration
and for Automatization
Workflow-Management
ANSYS optiSLang
Postprocessing
Excel Add-In other Solver
Output 2
Output m
6
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
Midas Edyson
Adams
TurboOpt
© Dynardo GmbH
optiSLang v6: Integrations
Win-Batch MATLAB Linux-Shell
Plug-in and WB node
LMS Amesim
Octave LS-DYNA
Python
7
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
optiSLang as an ANSYS Workbench plugin
• optiSLang modules
Sensitivity + MOP,
Optimization and
Robustness are directly
available in ANSYS Workbench
Signal Processing module to work with curves inside ANSYS Workbench
© Dynardo GmbH
8
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
Model Calibration Identify important model parameters
for the best fit between simulation
and measurement
Model Calibration Identify important model parameters
for the best fit between simulation
and measurement
Design Improvement Optimize design performance
Design Quality Ensure design robustness
and reliability
Design Quality Ensure design robustness
and reliability
Design Understanding Investigate parameter sensitivities,
reduce complexity and
generate best possible meta models
Design Understanding Investigate parameter sensitivities,
reduce complexity and
generate best possible meta models
© Dynardo GmbH
CAE-Data
Measurement
Data
Robust Design
Design Improvement Optimize design performance
9
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
Model Calibration Identify important model parameters
for the best fit between simulation
and measurement
Model Calibration Identify important model parameters
for the best fit between simulation
and measurement
Design Improvement Optimize design performance
Design Quality Ensure design robustness
and reliability
Design Quality Ensure design robustness
and reliability
Design Understanding Investigate parameter sensitivities,
reduce complexity and
generate best possible meta models
Design Understanding Investigate parameter sensitivities,
reduce complexity and
generate best possible meta models
© Dynardo GmbH
CAE-Data
Measurement
Data
Robust Design
Design Improvement Optimize design performance
10
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
• use scalar values or signals inside ANSYS Workbench
• identify which parameters have influence and
can be calibrated
• match experimental data with simulation
Model Calibration Model update to increase your simulation quality!
11
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Theoretical Background
12
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
The Forward Simulation
• For given set of model parameters p the model responses y can be calculated with a given simulation model
• Deviation of model responses and measurements y* can be evaluated
• For which parameter set popt model responses and measurement agree sufficiently well?
Model parameters Simulation model Model responses
Measurements
13
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Signals in optiSLang • Signals are vector outputs having an abscissa (e.g. time axis)
and several output channels (e.g. displacements, velocities)
• Signal functions enables the user to extract local and statistical
quantities and to analyze differences between several signals
• Match signal data (curves) with Signal Processing
14
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Example 1: Connector – material calibration
15
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Simulation of a connector
• Material Calibration
• Curve Fit between Simulation
and Tensile-Experiment
• 5 material parameters
• System Calibration
• Curve Fit between Simulation
and desired behavour
• 15 geometry parameters
calibrated material for load simulation
16
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Tension Test – material definition
• Identification of the material parameters to optimally fit the
force-displacement curve to the measurements
• Unknown material parameters for
nonlinear isotropic hardening (nliso):
• Young´s modulus
• Yield stress σ0
• Linear hardening coefficient R0
• Exponential hardening coefficient R∞
• Exponential saturation parameter b
• Objective function is the sum of squared errors
between the reference and the calculated
force-displacement function values
σ = σ0 + R0εpl + R∞ (1-e-b εpl)
17
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Tension Test – signal functions
15. 1.
• The displacement is divided in 15 equally spaced steps (1-15) to get more
detailed information about the influence of the 5 material parameters
• At these steps the forces will be extracted these 15 steps have unique MOP´s
• These 15 MOP´s will be used for optimization on MOP
…
18
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Tension Test – sensitivity results
• Only Linear hardening coefficient R0
is unimportant for all responses
• Single values can be explained
very well
• force_steps_sim values:
The influence of the Young´s modulus
decreases meanwhile the influence of
the exponential hardening coefficient
and yield stress increases
force_steps_sim[0]
force_steps_sim[14] …
19
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Tension Test – sensitivity results, F-CoP with SoS
20
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Tension Test – optimization with direct optimizer
• For excellent agreement use the direct optimizer, with results from
optimization on MOP
- Design Variation - Reference Curve - Best Design (Optimization)
21
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Example 2: Connector – system calibration
22
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Simulation of a connector
• Material Calibration
• Curve Fit between Simulation
and Tensile-Experiment
• 5 material parameters
• System Calibration
• Curve Fit between Simulation
and desired behavour
• 15 geometry parameters
calibrated material for load simulation
23
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Load simulation of a connector
component 1
component 2
possible design variation
possible design variation
• Insertion and Pull-Out
• Component 1: 13 geometry parameter
• Component 2: 2 geometry parameter
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Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Load simulation – task description
• No curve fit with reference specification of a desired behavour:
desired curve or desired points
desired behavour - points
insertion_force_gradient
insertion_force
pull_out_force
25
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Optimization – desired behavour curve
• Objective:
sum_of_squared_errors_insertion + sum_of_squared_errors_pull_out MIN
• insertion from 0 ≤ x ≥ 15 and pull-out from 60 ≤ x ≥ 75
- Design Variation - Reference Curve - Best Design (Optimization)
insertion process
pull out process
26
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Optimization – desired behavour curve
Input Parameter
Ou
tpu
t P
aram
ete
r
insertion process
pull out process
27
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Optimization – desired behavour curve
• Objective:
sum_of_squared_errors_insertion + sum_of_squared_errors_pull_out MIN
• insertion 0 ≤ x ≥ 15 and pull-out 60 ≤ x ≥ 75
Best Design Detail View
28
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
Model Calibration Identify important model parameters
for the best fit between simulation
and measurement
Model Calibration Identify important model parameters
for the best fit between simulation
and measurement
Design Improvement Optimize design performance
Design Quality Ensure design robustness
and reliability
Design Quality Ensure design robustness
and reliability
Design Understanding Investigate parameter sensitivities,
reduce complexity and
generate best possible meta models
Design Understanding Investigate parameter sensitivities,
reduce complexity and
generate best possible meta models
© Dynardo GmbH
CAE-Data
Measurement
Data
Robust Design
Design Improvement Optimize design performance
29
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
Robustness Evaluation Ensure your product quality!
Output parameter variation
© Dynardo GmbH
Powerful procedure to check design quality:
• Latin Hypercube Sampling representing
scattering variables optimally
• check variation interval limits and critical responses
• Identify the most important scattering variables
and check the solver noise
30
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH © Dynardo GmbH
Variance-Based Robustness Analysis (Overview)
1) Define the robustness space using scatter range, distribution and correlation
2) Scan the robustness space by producing and evaluating n designs
3) Check the variation 4) Check the
explainability of the model
5) Identify the most important scattering variables
31
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Tolerance viewing – optimized design
• 5% scattering with normal distribution for all 15 geometry parameters
32
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Tolerance viewing – optimized design
Optimization Tolerance
Optimization Tolerance
33
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Input Parameter
Ou
tpu
t P
aram
ete
r
insertion process
pull out process
Tolerance viewing – optimized design
34
Kalibrierung, Optimierung und Robustheitsbewertung eines Steckverbinders
mit ANSYS optiSLang
M. Schimmelpfennig, CADFEM ANSYS Simulation Conference, 2017, Winterthur
© Dynardo GmbH
Summary
• Model Calibration
• Identification of material parameters for material calibration
• Identification of geometry parameters for system calibration
• no curve fit with measurement
• specification of a desired behavior
• different possibilities for objective
• Easy to use
• in ANSYS Workbench and
• in ANSYS optiSLang
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