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3DCS Compliant Modeler, add FEA to your Tolerance Analysis

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3DCS Compliant Modeler is the easy way to add Finite Element Analysis to your Tolerance Analysis.

This add-on accounts for deformation in parts and assemblies from force, gravity, heat, clamping, welding, springback and other effects.

Working with FEA Mesh, a simple output from any FEA Solver, 3DCS Compliant Modeler makes it easy to add greater depth to your analysis.

Use simulation to resolve issues upfront in the design phase, and reduce the rework and flexible problems caused by many new materials.

Let us show you how you can reduce variation and avoid a major headache from working with flexible materials.

Email DCS today at sales@3dcs.com for a free demonstration.

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3DCS Compliant Modeler, add FEA to your Tolerance Analysis

  1. 1. Advanced Compliant Variation Analysis FEA Compliant Modeler for 3DCS Variation Analyst Suite
  2. 2. Clamp/Weld Clamp/Weld Agenda • Rigid Body Modeling • Compliant Modeling • 3 Compliant Cases –Aircraft Wing –Car Hood –Rail Assembly • FEA Interfaces • Q & A Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  3. 3. Rigid Body Tolerance Analysis Inputs • Assembly Strategy • Part Tolerances (GD&T) • Desired Measurements Outputs • Datum Locating Scheme • Tolerance Sensitivity • 6sigma Variation *Assumption: Parts do not bend or morph to meet over-constraining targets Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  4. 4. Compliant (Flexible) Parts What Parts are Compliant? • Structures • Interiors • Power Train • Suspension Why? • Size & Thickness • Gravity • Heat • Force Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  5. 5. 4/15/2014 © Dimensional Control Systems Inc. 2008 5 Compliant Tolerance Analysis Uses Finite Element Methods to simulate variation with deformable parts Additional Model Inputs • FEA Data o Mesh o Material Properties o Stiffness o Mass o Thermal • Compliant Processes o Clamping o Welding o Bending o Springback o Etc. Compliant FEA Data Compliant Processes
  6. 6. Analysis Results3DCS Model Rigid Body Assembly Method Part GD&T Measurements Compliant FEA Data Compliant Processes Compliant Tolerance Analysis Uses Finite Element Methods to simulate variation with deformable parts Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  7. 7. Methods for Modeling Compliant Parts User Experience Difficulty Level Relative # of Moves Locating Points in Example Relative Timing / Part Software Rigid-Body 3DCS® training Beginner 1 5 1.0 3DCS® Analyst Bend Routine 3DCS® Advanced 1 17 2.0 3DCS® Analyst + User DLLs Compliant Modeler 3DCS®, FEA Intermediate 3 18 1.5 3DCS® Analyst + 3DCS® FEA CM AddIn +FEA Software Accuracy 1.Rigid-Body Traditional Moves - part does not deform 2.Bend Routines User DLLs - part deforms about defined bend lines 3.Compliant Modeler using Finite Element Analysis (FEA) - part deforms to target points Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  8. 8. Compliant Modeling Benefits • More Accurate Analysis • Faster to build Model • Limited FEA interaction • Analyze Assembly Sequence • Optimize Clamp, Fasten, Weld,… Sequence • Analyze Gravity and Thermal effects Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  9. 9. AIRCRAFT: Ground Clearance AUTOMOBILE: Hood to Fender Flushness Rail Model Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  10. 10. Examples of Very Low Ground Clearance Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  11. 11. Gravity acting on Wing and Engine Effect of Gravity On Distance (mm) Wing Tip 29.17 Ground Clearance 5.97 Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  12. 12. *min & max position measurements are relative to nominal position Effect of Engine Position On Min Position (mm) Max Position (mm) Tip Displacement - 0.30 + 0.36 Ground Clearance - 70.17 + 68.76 Engine moved from min to max position Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  13. 13. Tolerances were added to simulate imperfect parts
  14. 14. Measurement Nominal Range with Variation Wing Tip 29.18 264.48 Ground Clearance 5.97 57.62 1st Tolerance Scenario: • Engine at nominal • Fuselage Tol- 5mm 5 mm
  15. 15. 2nd Tolerance Scenario: • Engine at nominal • Fuselage Tol- 3mm Measurement 1st Scenario 2nd Scenario % Change Tip Displacement 264.48 158.71 40 Ground Clearance 57.62 35.12 39 3 mm
  16. 16. Hood Fender Hood is under-flush to Fender with high variation
  17. 17. Add a pair of bumpers to contour the Hood to the Fender and reduce flush variation… but where?
  18. 18. 1. Front 2. Mid 3. Mid2 4. Upper Determine the location of lowest flush variation between Hood and Fender. Simulate the placement of Bumpers at (4) locations:
  19. 19. Flush variation measured at these locations
  20. 20. 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3 3.2 1 2 3 4 5 6 7 8 Est.RangeVariation(mm) Rear - Mid - Front No Front Mid Mid2 Upper Avg Hood to Fender Flush
  21. 21. 2.7 2.8 2.9 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 1 2 3 Est.RangeVariation(mm) Front - Mid - Rear No Front Mid Mid2 Upper Hood to Fender Gap Hood to Fender Gap is Independent of Bumper Location
  22. 22. 1. Front 2. Mid 3. Mid2 4. Upper 2.173 mm 2.172 mm 2.305 mm 2.328 mm 2.483 mm0. None Mid2 bumper location is best for Hood to Fender flushness. Avg. Est. Range at Bumper Locations
  23. 23. Pushing the Envelope… • Real Time Diagnosis of Manufacturing issues • Mechanical System Analysis – Analysis through a range of motion – Effects of Rubber Bushings on Variation • Fuel Efficiency Impacts – Tolerances on Mass – Number of Shims on Mass – Surface Quality on Wind Drag • Plant Layout Cycle Times – Clamps and welds required per station – Machining stations required • Design & Manufacturing Optimization – Fit and Finish based on Perceived Quality – Design Interfaces, Cut Lines & Locators – Tolerances – Number of parts and Sequence of Assembly and Fastening • Non Linear Sensitivity Analysis Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  24. 24. Confidential – Please do not distribute.4/15/2014 © Dimensional Control Systems Inc. 2008
  25. 25. 4/15/2014 © Dimensional Control Systems Inc. 2008 27 How is the model Created? 2. Using the 3DCS FEA CM Modeler create clamp, weld, unclamp operations. 1. Create Model utilizing the standard DCS Moves, Measures, and DCS Tolerances and/or FTA 3. Generate FEA Input Deck and Stiffness Matrix using your FEA Pre & Processor and Solver. 4. Link 3DCS FEA CM to Input Deck and Stiffness Matrix and run Visual and Statistical Study.
  26. 26. © Dimensional Control Systems Inc. 2008 How does it work? The 3DCS FEA Compliant Modeler deforms the parts during simulation based on the part stiffness matrix for each compliant part that has been imported into the 3DCS model. The FEA Mesh and stiffness matrix is acquired from software like Abaqus, Hypermesh and NASTRAN. The part stiffness matrix defines how a deformation at one point will affect other areas of the part – where, and how severely. Clamp/Weld Clamp/Weld Confidential – Please do not distribute.4/15/2014
  27. 27. Causes Moves method Sequence Rigid moves Compliant moves Clamping method Joining type N° clamping points FEA files Input data Type and size elements Pre-processor and solver SOFT 1DOF vs HARD 3DOF CM Model Influences
  28. 28. Product Mesh File Extension Stiffness Matrix Extension Abaqus .inp .mtx Nastran .bdf, .blk, .dat, .nas .bdf Optistruct .fem, .parm .dmig MSC Nastran .dat .pch *DCS is constantly adding new features and functions, making this list subject to change
  29. 29. 4/15/2014 © Dimensional Control Systems Inc. 2008 31 What Process are Supported? • Clamping • Spot Welding • Unclamping • Spring Back • Bolting • Riveting • Joining • Clipping • Heat Staking • Compliant to Rigid • Compliant to Compliant • Single Stage Assemblies • Multi Stage Assemblies • Force Application • Gravity • Thermal Expansion Shrinkage • Distortion • Load Sequence • Clamp, Weld and Un-Clamp Sequence • 3+ thickness welding • Nearly anything supported by the state of the art FEA tools.

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