cadfem & ansys • simulation conference - …...m. schimmelpfennig, cadfem ansys simulation...

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Kalibrierung, Optimierung und

Robustheitsbewertung eines

Steckverbinders mit

ANSYS optiSLang

M. Schimmelpfennig

R. Kallmeyer

Dynardo GmbH

CADFEM ANSYS Simulation Conference

Winterthur, 2017

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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

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mit ANSYS optiSLang


© Dynardo GmbH

Overview

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• 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

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© 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

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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

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mit ANSYS optiSLang


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

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Model Calibration Identify important model parameters

for the best fit between simulation

and measurement



and measurement

Design Improvement Optimize design performance

Design Quality Ensure design robustness

and reliability


and reliability

Design Understanding Investigate parameter sensitivities,

reduce complexity and

generate best possible meta models




© Dynardo GmbH

CAE-Data

Measurement

Data

Robust Design


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mit ANSYS optiSLang




and measurement



and measurement



and reliability


and reliability







© Dynardo GmbH

CAE-Data

Measurement

Data

Robust Design


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mit ANSYS optiSLang


© 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!

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© Dynardo GmbH

Theoretical Background

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© 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

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© 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

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© Dynardo GmbH

Example 1: Connector – material calibration

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© Dynardo GmbH

Simulation of a connector


• Curve Fit between Simulation

and Tensile-Experiment




and desired behavour



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© 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)

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mit ANSYS optiSLang


© 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

…

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© 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] …

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mit ANSYS optiSLang


© Dynardo GmbH

Tension Test – sensitivity results, F-CoP with SoS

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© 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)

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© Dynardo GmbH

Example 2: Connector – system calibration

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© Dynardo GmbH

Simulation of a connector



and Tensile-Experiment




and desired behavour



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mit ANSYS optiSLang


© 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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© 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

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© 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

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© Dynardo GmbH


Input Parameter

Ou

tpu

t P

aram

ete

r

insertion process

pull out process

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© Dynardo GmbH


• 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

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mit ANSYS optiSLang




and measurement



and measurement



and reliability


and reliability







© Dynardo GmbH

CAE-Data

Measurement

Data

Robust Design


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mit ANSYS optiSLang


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

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© 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

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© Dynardo GmbH

Tolerance viewing – optimized design

• 5% scattering with normal distribution for all 15 geometry parameters

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© Dynardo GmbH

Input Parameter

Ou

tpu

t P

aram

ete

r

insertion process

pull out process


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© 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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Thank you for your attention!

For more information

please visit

our booth and homepage:

www.dynardo.com

© Dynardo GmbH

cadfem & ansys • simulation conference - …...m. schimmelpfennig, cadfem ansys simulation...

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