Category "Dassault Systemes"

A Virtual Journey in 3DEXPERIENCE

Today’s manufacturers are confronting a rapidly changing business environment. The new reality and relentless competition are having companies re-examine their business models. On Shoring, Near Shoring and diversified Supply Chains are just some of the topics that companies and leaders want to know about.

Tata Technologies has extensive knowledge and expertise in implementing manufacturing technology that will help meet these challenges. We partner with Dassault Systemes to bring world class solutions to our customers.

Launching on July 29th, 3DEXPERIENCE: A Virtual Journey, is an online series designed to help companies transform their business with episodes focusing on industry leading strategy and insight – ready to stream anytime, anywhere. Discover how to bring together all aspects of business to increase collaboration, improve execution and accelerate the transformation to full digital continuity. Learn how to make your business accessible from anywhere with real-time collaboration for your entire team

Register now and join us July 29th for the live plenary session at 1:00 EDT. This will be followed by release of episode 1 –
3DEXPERIENCE: A Virtual Journey

Analysts are analysts and they have an analytical mindset. So whenever a traditional Abaqus user is exposed to a radically different application such as 3D Experience platform, he looks at it with intricacy. The level of inquiry is high and meshing is always one concern that cannot be skipped. Quite often this discussion ends up in a comparison between 3DX meshing and Abaqus CAE or between 3DX meshing and third party meshing applications. This blog is around comparison between the Abaqus CAE and 3DX meshing capabilities. I have tried to make as many apples with apples comparison as possible by taking same part as reference in both the environments.

Take a look at the frame structure. It’s a thin solid part that has been meshed in Abaqus CAE as well as in 3DX. The frame has been partitioned at many sections to get maximum hexahedral elements. When this frame is taken in Abaqus CAE mesh module, it looks like this: The green region is structural mesh domain and yellow regions is sweep mesh domain. However, both of these approaches give a hexahedral mesh.

When the same part is taken in 3D Experience platform, there are bunch of meshing tools in the meshing app. However, the one most straightforward for use without as many partitions as used in CAE is the partition hex mesh approach. The technique shows the following color code.

Its worth mentioning here that in 3DX the yellow represents the sweep mesh region and orange represents the free mesh regions. This is different coding from CAE where orange represents region that cannot be meshed. The mesh looks as below with 75 percent hexahedral and 25 percent tetrahedral elements.

Conclusion: Using very similar meshing techniques of partition, we get different kinds of meshes in the two applications. At the same time, using a different design method with no partitions, it is possible to get all hexahedral elements in 3DX.

Its also worth to show here all the meshing methods in 3DX meshing app. While few of these are available in CAE as well, other such as partition hex mesh and hex dominant mesh do not. At the same time, CAE offers bottom’s up meshing method that does not exist in 3DX. So meshing comparison between 3DX and Abaqus CAE is indeed an apple with orange comparison.

To find out more or schedule a demonstration, contact us or visit our website at www.tatatechnologies.com

One thing common between SIMULIA roles of 3DExperience platform and the standalone Abaqus products is that both require an Abaqus solver to perform computations. It further means that both solutions require Abaqus tokens to complete or speed up the computation part of the simulation. For standalone abaqus product, we know that the calculation is straight forward. Abaqus requires a minimum of five tokens to execute a single core non-linear job. Large models require more number of cores to solve in real time and more number of cores require more tokens as follows:

The computation capacity of 3D Experience platform, however, cannot be defined by a single equation. Unlike Abaqus solver, that is available as an integrated all-in-one license for all types of simulations such as standard, CFD, explicit etc., 3D Experience offerings are in form of roles. Each role is a sellable license that includes either some or all Abaqus solver capabilities. Offers are made further flexible by on premise vs. on cloud offerings. Let’s have a look at solver offerings in different configurations and roles.

    Designer role vs. Analyst role

While most of design engineer roles have embedded Abaqus tokens, most of the analyst roles do not have any compute capacity at all. The number of tokens embedded in designer role depends on the level of simulation complexity a role can accommodate. For example

                     Structural designer role has 8 embedded tokens to accommodate up-to 4 cores job

      Structural professional engineer role has 12 embedded tokens to accommodate up-to 8 cores job

It is possible to submit jobs on more number of cores than what embedded solver permits but in that situation external tokens need to be utilized and embedded solver takes no credit at all.

                Tokens vs. Hours

In case of analyst roles such as stress analyst, fluid mechanics analyst etc., the role itself does not have any compute capacity which should be procured either in the form of tokens or credits. Tokens are renewable form of compute capacity which means they can be used over and over. 3D Experience uses tokens in a very similar fashion as does standalone Abaqus. The token consumption with respect to number of cores is the same for Abaqus as for 3D Experience platform. On the contrary compute hours are a non-renewable form of compute power. It means that hours, just like the talk time over phone, can be consumed only once.

       Why compute hours at all!!!

In general compute hours is an expensive preposition for customer but there are exceptions. Compute hours are utilized to meet unexpected and rare increase in peak usage. This is somewhat more common in engineering consulting firms that can face high demand of simulation capacity due to influx of many short duration simulation projects at any time. To meet this sudden spike in demand, one-time compute hours bundle offering makes more sense than increase in perpetual tokens. Once peak demand is over and credits are consumed, simulation capacity is returned to normal levels. 

On premise vs. on cloud

Design engineer as well as analyst roles are available in on premise as well as on cloud formats. There are three ways of utilizing cloud resources: store the models on cloud, stores the results on cloud and solve on cloud. The first two offerings require only cloud storage and are available at no additional charge with cloud based license. However, the third offering requires cloud compute resources that consumes compute hours in addition to cloud based license.

Need to know more about SIMULIA 3D Experience platform compute capacity! Please visit our website at www.tatatechnologies.com

Best in class stamping die design tool

Stamping Die design is complicated. Designers must juggle complex requirements such as draw direction, parting surface, folded features and progressive steps. Stamping simulation results must be incorporated. And lead times keep reducing

CATIA Stamping Die Designer, increases productivity by guiding users from the conceptual planning through to detailed tooling design of complex stamped sheet metal parts

Early concept method planning allows designers to anticipate manufacturing constraints and facilitate collaboration between design, tooling and the supply chain organizations. Easy to use specialist features and wizards guide the user in best practices, helping the tool designer work with and extend complex surfaces without having to be a surfacing expert

CATIA has a discipline-specific set of functions for the optimization of stamping direction, creation of addenda surfaces, trim lines and spring-back compensation, all with full associativity to the original part geometry. This ensures high quality die geometry and right-first –time tooling

Benefits

  • High productivity with specialized wizard and features
  • Intuitive and process oriented
  • Facilitate design for manufacturing with early process engineering
  • Die face method planning
  • Conceptual die surface design to enable quick validation
  • Simplify and automate the tool compensation from simulation inputs
  • High quality surfaces for manufacturing

Highlights

  • Best stamping direction selection with optimization
  • Quick (KPI) analysis of draft, depth and cutout
  • Define and easily modify the concept method planning (stamp process flow)
  • Specialized and global deformation features to manage spring-back & structural tool compensation process from simulation results
  • Unfold flange as trimline or surface
  • Addenda surface based on high quality surface extensions and profiles
  • Trim Line cut analysis with key indicators
  • Efficient assembly design with reusable mechanical components

What’s New

  • Concept wizard to design complete method plan.
  • Embedded draft/depth/cutting angle analysis in process wizard
  • Press Line positioning of geometries on custom press line.
  • In Car positioning of parts in design
  • Wall surface creation based on sketch of lines
  • High quality surface extensions G1, G2 or Hybrid G1/G2
  • Wizard for generative hole filling with solution selection and embedded quality checker
  • Trim line concept with automatic split of input part boundary

Return on Investment

  • Achieved time savings of 20% across the initial die design process.
  • Improved whole design process time by 50%
  • Reduced the time to incorporate changes from DAYS to hours

To find out more or schedule a demonstration, contact us or visit our website at www.tatatechnologies.com

Previous few blog articles primarily addressed Abaqus 2020x enhancements. Let’s have a look at the extended products enhancements that include ISight, Tosca and FeSafe.

ISight Enhancements

  • Export of Approximations: Till 2019x release, the export of approximation models was limited to coefficient data or excel spreadsheet format. In 2020x release, the RBF and RSM approximation models can be exported to FMU as well.
  • New components: Functional Mock Up (FMU) and Computer Simulation Technology (CST) components are now available in ISight workflows.

Tosca Enhancements

  • Sensitivities support: Though not essentially an enhancement in 2020x, it is worth mentioning that all four modules of Tosca now accept Abaqus sensitivities for all types of non-linearities. However, supported analysis steps are Static and Frequency only. Inertia relief included.
  • New Response: Plastic strain PEMAG now supported for shape, size and bead optimization.
  • Algorithm stabilized: Higher volume fractions eventually lead to convergence and stability concerns. While convergence is an Abaqus issue, stability of optimization has been improved in topology module with large volume fractions.

Fe-Safe Enhancements in 3DX:

  • App enhancement: While the role is still a separate license called as durability engineer role, the mechanical and structural scenario have been enhanced to include the fatigue interface.

Simultaneous execution: Though it is well understood that any fe-safe analysis requires stress results from a stress analysis, user now has an option to simulate both structural and durability cases at the same time. The backend data management architecture takes care of sequencing and linking.

  • Material enhancement: The entire Fe-safe material database can now be imported in the 3DEXPERIENCE Platform. Surface finish factors supported as well.
  • Element nodal outputs: This is perhaps a KEY enhancement. The fatigue is a surface phenomenon so averaged stresses at the nodes on surface are most appropriate for fatigue analysis. In prior releases of 3DX, only integration point stresses were supported. Starting 2019x FD06, element nodal stresses are available for fatigue.
  • Loading enhancements: Loading blocks now include residual stresses as well as implicit dynamics step. All Fe-Safe algorithms with and without mean stress correction are now supported. Both SN curve as well as EN curve algorithms are now supported in 3DX.
  • Coming Soon!! Linux and COS execution on cloud.

Visit www.tatatechnologies.com to learn more about our PLM offerings and how we can help customers use the best technology for their needs.

This is a relatively bigger blog compared to previous ones because of an obvious reason; it covers a broad spectrum of non-linear enhancements which is Abaqus core technology. The blog covers four sections: additive manufacturing, element technology, material enhancements and fracture mechanics along with few other minor enhancements

Additive manufacturing:

  • Pattern based thermo-mechanical analysis: While in many cases laser scan paths are available to simulation users it is not always true. For those situations in which machine users do not wish to share their machine IP’s, a pattern based approach has been introduced which uses a raster scan path instead of a trajectory scan path. Material orientation and Anisotropic behavior are supported but not suitable for detailed microstructure simulation. This application is different from eigen strain simulation.
  • Event series enhancement: 2GB data size limit of event series was removed in 2019xGA and now event series can include up-to 420 million events.
  • Free surface evolution enhancements: In case of tie constraints, algorithm has been enhanced to include ties that are not activated until the underlying element becomes active.
  • Output enhancements: MAXPSCRT has been introduced to include maximum principal stress crack initiation criterion. It is available for both field and history outputs. BLADEINTERFERER has been introduced to predict clash between recoater and printed part. This will be available in 2020xFD01.

Element Technology:

  • Shear panel element update: SHEAR4 was introduced in 209xFD01 to model thin reinforced plates. It supports buckling. Equivalent shear flow output called SQEQ is supported.
  • Pyramid heat transfer element: DC3D5 has been introduced to manage transition between tetrahedral and hexahedral elements in thermal analysis.
  • Fluid pipe element enhancements: These elements now support following Non Newtonian flows as well:

Material enhancements:

  • VUMAT enhancement: A parameter has been added to define alternate bulk and shear modulus that can be used by explicit to find suitable time increment. It is called EFFMOD and visible in viewer. Abaqus CAE support is available from 2020xFD01.
  • Kinematic hardening enhancement: The material model has been enhanced to model stress relaxation behavior for metals subjected to step strain input. Suitable for metals that show viscoelastic like behavior during step inputs.

Creep Laws enhancement: Current creep models have A with dimensionality that creates ambiguity. The strain and time laws have been enhanced as follows to make A dimensionless. These enhancements are applicable to all the creep models.

Viscoelastic material enhancement: The prony series has now been enhanced to include frequency domain as well. Earlier prony series was valid in time domain only.

Yield surface enhancement: The non quadratic yield surface has been introduced in 2019xFD04. It is referred to as Barlat Plasticity. The stress component requires 18 coefficients and 1 exponent.

  • Metallurgical phase enhancement: In prior releases, the effect of additive manufacturing and other heat treatment processes on material properties at microstructural level required USDFLD subroutine. Effective 2020xFD01, this routine has been included on the material definition itself. Inservice performance of printed parts can now be more accurately simulated.

Injection Molding:

  • 3DX injection molding compatibility: The fiber orientation and residual stresses from third party simulation such as Moldflow can now be converted to a SIM file format. That means the 3DX structural simulation apps can now read moldflow results to predict in-service loads and warpage from third party plastic injection results.

Pre-tension enhancements

  • Non linear enhancement: In earlier releases, the direction of pre-tension section normal was not updated even in general step. Effective 2020xGA, the cut section normal direction can be updated in large displacement or large rotation analysis. It is activated as follows in the input file

*PRE-TENSION SECTION, FOLLOWER = (YES/NO)

Fracture Mechanics enhancements

  • Linear elastic fatigue enhancements: Linear elastic fatigue crack model was introduced recently in collaboration with NASA ACC team to model crack propagation for cyclic fatigue cycles. It allows for change in contact conditions as well as non-linear geometry effects. Several enhancements have been made in this model in recent FD’s. In 2019x FD03, an alternative method to smoothening of crack front was introduced. In 2019x FD04, mode dependent stiffness degradation was introduced.
  • Cohesive elements for Multiphysics: Couples temperature-displacement cohesive elements have been introduced to simulate debonding due to thermal expansion as well as hydraulic fracture. These elements are COH2D4T, COHAX4T, COH3D6T, COH3D8T. Coupled temperature-displacement-pore pressure elements available as well to include gap conductance effect. There is no change in the structural response of these elements.

Visit www.tatatechnologies.com to learn more about our PLM offerings and how we can help customers use the best technology for their needs.

Increase Competitiveness Through Integrated  Mold & Tool Design

The pressure on mold and tool-makers is relentless. Time is always of the essence, and as cycle times reduce, further demands are made. Mold & tool production that took 4 months last year is now demanded in 3 months this year.  And so it goes on. Even when a part design is delivered late, the completion target for the mold or tool often remains unchanged

With these ever decreasing design-to-manufacturing cycle times and increasing complexity of the parts to be produced, toolmakers need to maximize the efficiency of the complete mold and tool design process

To do this toolmakers need to be able to:

  • Accelerate the design of molds & tools and ensure that that can produce the most complex of parts, reliably and to the required cost and quality targets.
  • Simulate, early in the design process, and compensate for the effect of deformation introduced by the manufacturing process such as material shrinkage, warping or spring-back.
  • Respond quickly to change requests – whether through late changes to the design of the part to be produced, or the need to address problems found during the manufacturing process itself. 

To addresses these challenges, the CATIA Mold & Tool design solution from Dassault Systèmes provides comprehensive and fully integrated capabilities specifically developed to meet the needs of mold and tool designers. These capabilities include the following features:

  • Rapid design of molds and tools
  • Process specific mold & tool design capabilities such as semi-automatic creation of parting surfaces, mold cores, cavities, runners, lifters and inserts.
  • Faster and safer design of complex tool assemblies through ‘smart’ components and standardized resources that embed custom behavior.
  • Advanced simulation & validation: Simulate the part forming process in order to quickly and accurately compensate for material deformation.
  • Integrated change management – Quickly identify the impact of a part change on the mold or tool, with full associativity between the part the mold and tool forming surfaces so that design changes can be propagated to the mold & tool designs.

Many leading companies have gained significant competitive advantage through these capabilities, with typical benefits being:

• Improved the whole mold & tool design process time by 70%.
• Achieved time savings of 30% across the initial mold design process.
• Reduced the time for manufacturability analysis from DAYS to hours
• Accelerated mold core & cavity design by 70 %.

Tata Technologies can help you get set up with CATIA Mold and Tooling. Contact us for a demonstration or visit our website www.tatatechnologies.com

While few of the Abaqus explicit enhancements in 2020x have been discussed in previous blogs on contact, this particular blog article specifically focuses on many more enhancements in explicit, with or without contact.

  • DT based element deletion: While explicit jobs never exit with fatal errors due to lack of convergence, they can still give fatal errors because of severe element distortion. An element deletion criterion has been introduced that allows user to set a trigger for element deletions based on element area, element volume, stable time increment and characteristic length. These triggers can be defined either as absolute or as ratios.
  • Linear Kinematic conversion: This is yet another approach to avoid fatal errors because of severe element distortion. In this approach, the elements are transformed to linear elements based on certain trigger threshold on distortion. It is applicable to most of continuum tetrahedral and hexahedral elements.

Enhanced CEL approach: Conventional CEL approach is good for solids only. When applied to liquids and gases, it may cause leakage especially when fluids create high pressure gradient, when fluids have large tangential velocity or at the location of sharp corners. The enhanced CEL contact formulation fixes this problem and is applicable to both solid and shell meshes. However, this enhanced formulation is more expensive in memory and computation.

Hybrid message parsing (HMP): This is an enhancement in parallel processing that can combine MPI (DMP) based parallelization and Threads (SMP) based parallelization. The solution can utilize thread based parallelism within a node as well as MPI to communicate between the nodes. It results in fine grained dynamic load balancing because when a thread completes its own elements computation work, it helps other threads within the same MPI rank.

Visit www.tatatechnologies.com to learn more about our PLM offerings and how we can help customers use the best technology for their needs.

Subsequent to the blog article on few functionalities in Abaqus CAE 20202x, this particular blog article mentions enhancements in Abaqus solver 2020x contacts and constraints. The enhancements would be mentioned in reverse chronological order and few of these have been introduced in FP’s of 2019x as well.

  • Interference fit in Abaqus explicit: This feature has been in waiting list since long by users and its finally available now. Earlier releases of explicit had an option of strain free adjustment only for overclosures. From 2020x, if initial overclosure is “x” and interference is defined as “y”, then strain free adjustment is performed till “x-y” and rest is treated as interference being resolved through a smooth amplitude curve. That means a “two in one advantage” for explicit. Moreover, it is supported in Abaqus CAE.

Change in contact status legend: To make output more meaningful for the users, the contact status has been changed to bonded and “not in contact” as shown below. This is applicable to both standard and explicit.

Rate dependent cohesive damage: The damage initiation and damage evolution laws now have parameters to include rate dependency in cohesive contact for explicit. Earlier this feature was available in cohesive elements approach only. Effective since 2019xFD04.

  • Material based general contact property assignment: The conventional process of property assignment in general contact is a three-step process. First, define sets of elements. Second, use sets to define surfaces. Third, use surfaces in property definition. From 2020x, material can be directly called for surface assignment if that approach helps. This is true for both standard and explicit.

Thermal expansion of rigid bodies: The analytical and discrete rigid bodies have been existing in Abaqus since long. However, when it comes to combined structural and thermal steps, a body very rigid from structural perspective may expand well when heated. To incorporate this effect, thermal expansion of rigid bodies feature is now included in Abaqus standard. This is applicable to kinematic couplings as well as for bodies are not explicitly defined through a CAD geometry.

  • Small sliding in general contact: This is again a BIG enhancement based in users request. Small sliding substantially reduces the contact search time because it is based on flat surface approximation. When used correctly, it results in convergence improvement and less overall solution time. However, its absence in general contact was a bit bothersome. From 2020x, small sliding exists in general contact for standard.

General contact enhancement for Multiphysics: Beam elements have been introduced in general contact for thermal and thermal electrical procedures. This may be helpful in approximating some large size applications such as heat exchangers by modeling pipes as beam elements.

Visit www.tatatechnologies.com to learn more about our PLM offerings and how we can help customers use the best technology for their needs.

Computer aided engineering has always been a role of a specialist. This statement is very much evident from the fact that more than 50 percent of analysts today have a graduate degree; either an MS or a PhD. This is because these physics-based simulations are a lot more than collection of icons, toolbars and pull-down menus. Unless the user is well familiar with the core engineering aspect of the problem being solved as well as with the underlying governing equations that solve the problem, he is very likely to make an error in modeling that would lead to erroneous results. In such situations “a stress solver becomes a stress creator.”

If one dissects the subject of computer aided engineering, he would see several branches of it. The main ones are: finite element analysis, computational fluid dynamics, multi-physical simulation as well as multi body dynamics. Each of these branches have several sub-branches of it. For example, finite element analysis can be divided into structural analysis, thermal analysis, coupled analysis. The structural analysis can be further sub-divided into linear static structural, non linear static structural, linear dynamic, non linear dynamic etc. As one moves keeps digging inside, simulation becomes more niche and more specialized. This justifies the need of a specialist with many years of experience with advanced technical and academic credentials.

While we, at TATA Technologies do not provide work experience or academic credentials, we do transfer expertise in computer aided engineering and many other fields of engineering through dedicated technical trainings as well as on the job trainings. We offer software products specific trainings such as Dassault Systemes portfolio, Siemens PLM portfolio, Autodesk portfolio as well as several industry vertical trainings such as modeling of welds and connectors in automotive chassis, design for light weight etc. We do provide small sessions on best practices as well such as effective element selection in Abaqus, overcome convergence problems in non linear simulation etc.

We train people with various levels of experience and knowledge. The student may be a fresh designer out of college who has recently joined his first organization or may be a subject matter expert with years of design or simulation experience and trying to learn something new. As mentioned, we teach both software as well as methodologies and workflows.

If you have a high end engineering software in your organization that seems to be underutilized because of lack of human resource, please get in touch with us.

Visit www.tatatechnologies.com to learn more about our PLM offerings and how we can help customers use the best technology for their needs.

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