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11/5/2013

NX CAE

Symposium

2013

NX and LMS Test.Lab Integration at AAM

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Title

11/5/2013

NX CAE

Symposium

2013


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Introduction: About AAM

World Headquarters

Technical Center

North America

South America

Europe

Asia

Key Facts

• $2.93 Billion USD Sales (2012)

• 33 Locations in 13 Countries

• 11,000 Associates

• 20 Manufacturing Facilities

• 11 Business, Technical and

Engineering Centers

• 2 Joint Venture Operations

NX and LMS Test.Lab Integration at AAM Company Background

NX CAE

Symposium

2013

11/5/2013

NX CAE

Symposium

2013


Front Axle

Rear Beam Axle

Driveshafts

AAM’s products

Passenger Car & Crossover Vehicle

Commercial Vehicle

Light Truck and SUV

Multi-piece Propeller shaft

Power Transfer Unit

Rear Drive Module w/ Torque

Transfer Device

eAAM electric AWD

Front Axle (Independent & Steerable)

Front & Rear Propeller shafts

Transfer Case

Rear Beam Axle

55.8%

16.8%

6.3%

8.0%

11.5%

1.6%

Rear Axle Systems

(Includes Rear Drive Modules)

Front

Axles

Metal

Formed Products

Propeller

Shafts

Other

Chassis Components

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AAM’s Customers

Driveshafts

Light Truck / SUV

Front AxlesRear Axles

Transfer Cases

Passenger Car / Crossover

Independent Rear

Drive Axles (IRDAs)

Torque Transfer

Devices (TTDs)

Multi-Piece Driveshafts

Independent Front

Drive Axles (IFDAs)

Transmission

Differentials

Power Transfer Units (PTUs)

Bus Axles (Rear Engine)

Rear Axles

Commercial Vehicle

Front Axles

Tandem

Metal Formed Products

Transmission Components

Axle / Output ShaftsDifferential Gears

Ring / Pinion Gears


http://www.adamauto.lv/opel/images/opel_logo_mono.gif

http://www.sgmw.com.cn/

http://www.avia.cz/en/

http://www.optare.com/og_introduction.htm

11/5/2013

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Typical Automotive Driveline System NVH Problems • Gear Whine

• Driveshaft critical speed

• Engine torque fluctuation

• Gear Rattle

• Shudder / Moan / Chatter

• Clunk

NX and LMS Test.Lab Integration at AAM NVH Background

AAM NVH CAE Responsibilities 1. Early upfront analysis and optimization to minimize

NVH risks

2. Model correlation and physical validation during product development

1. Product behavior with different boundary conditions (Dyno vs Vehicle etc.)

2. Model methodology and database improvement

3. Problem troubleshooting and identification

3. Assist with Production and Field NVH Issues

• NVH CAE Team resides in NVH Product Engineering Department

• Test, Project Management, CAE

• Driveline 1st order (imbalance and pitch line run-out)

• Driveline 2nd order (Cardan joint kinematics)

• Propshaft instability

• Chain noise

• Wheel imbalance

• Engine idle shake

11/5/2013

NX CAE

Symposium

2013

NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM AAM Software History

• LMS Test.Lab

• No CAE functionality

• Very easy user interface

• Entire group has learned how to use the software effectively

• Used by CAE for Function Math and Plotting

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Timeline

1990s 2000 2001 2002 … 2010 2011 2012 2013

LMS Cada-X

Test

C

AE

I-DEAS

LMS Test.Lab

I-DEAS Siemens NX 8.5

Windows 7 Upgrade

Siemens LMS Acquisition

• LMS Cada-X

• No CAE functionality

• Few individuals could use the software efficiently

• I-DEAS

• Thoroughly integrated Test and CAE functionality

• Entire group used the software efficiently through use of scripts

I-DEAS

• Siemens NX

• Mature CAE Environment

• Easy transition from I-DEAS

• Entire CAE group is very capable within the software

11/5/2013

NX CAE

Symposium

2013

NX and LMS Test.Lab Integration at AAM NX and LMS Test.Lab Integration at AAM

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NX CAE

Symposium

2013 CAE Analysis Process

• Generating correlated CAE results involves a fairly standard iterative loop consisting of :

1. Model Construction

2. Model Solution

3. Calculating Responses

4. Comparison/Correlation to Test Data

5. Design Studies

• As with any iterative process, several repetitive software functions are used as each iteration requires a new calculation of results

• This is further complicated by the need to use Test.Lab for function math and powerful plotting tools

• NX 8.5 Journaling has saved significant effort as repetitive functions within NX can be replayed automatically

11/5/2013

NX CAE

Symposium

2013


800100 200 300 400 500 600 700150 250 350 450 550 650 750

Hz

100.0

100e-6

1.0e-3

10e-3

0.1

1.0

10.0

300e-6

3.0e-3

30e-3

0.3

3.0

30.0

Log (

...)

m/s

2


• Predictive Analysis is conducted in NX Advanced Simulation Module

• Models are solved using standard Sol 103 (Normal Modes)

• Response Simulation (FRF Calculator) is used to generate functions

• Iterative correlation activities occur often requiring the use of both Test.Lab and NX for analysis currently

• Test.Lab Functionality allows for more complex operations

• NX does not currently read Test.Lab data

• Test.Lab does read NX data

• Test.Lab has Advanced Function Math Tools

• Test.Lab plotting is very advanced

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NX CAE

Symposium

2013

Pinion Nose Vertical Response

Test CAE

Front Axle Model in NX

Test and CAE Data displayed in Test.Lab

CAE Analysis Process

11/5/2013

NX CAE

Symposium

2013


0.0100

100.00

0.1000

1.000

10.00

100 1000 200 400 600 800Frequnecy (Hz)


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NX CAE

Symposium

2013

Pinion Nose Vertical Response

Test CAE

Rear Drive Module Model in NX

Test and CAE Data displayed in Test.Lab

CAE Analysis Process

• While the process could be conducted within NX, efficiency is improved dramatically when post processing is carried out within Test.Lab for the following reasons:

• Advanced function math, data manipulation and calculation “scripting” capability

• Very advanced plotting capabilities that enhance ability to review data

• Convenient comparison of Test data and model data (overlays)

• For reporting purposes, calculated results are displayed in LMS Test.Lab

• NX data is in .afu format and is automatically saved externally

• LMS created a plugin for AAM that allows Test.Lab to read AFUs directly for comparison to Test data

11/5/2013

NX CAE

Symposium

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NX CAE

Symposium

2013 CAE Analysis Process - Correlation

Inputs - CAD Models - Nastran Models - Gear Contact Info - Boundary Conditions (Dyno, Vehicle, etc.)

NX 8.5 Advanced Simulation - FEM - Generate FEA Mesh (if necessary) - Auto-mesh most 2D and 3D components

Solve

NX 8.5 Response Simulation - Apply appropriate damping treatment - Generate functions

Test.Lab - Import calculated functions - Perform function math (scaling, multiplying, etc.) - Compare to Test Data - Evaluate Effectiveness

Yes Acceptable Correlation?

Report

No

Strain Energy Table

NX 8.5 Advanced Simulation - FEM - Manual Mesh 1D/0D components - Generate Gear Mesh Kinematics - Ensure proper connectivity between components (Springs, RBEs)

NX 8.5 Advanced Simulation - SIM - Connect to appropriate Boundary Conditions - Add appropriate constraints (MPCs, SPCs, etc.)

NX 8.5 Advanced Simulation - FEM - Design Studies / Optimization

NX 8.5 Advanced Simulation - FEM - Manual remesh of 2D and 3D components (if necessary)

11/5/2013

NX CAE

Symposium

2013


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NX CAE

Symposium

2013 CAE Analysis Process – Design Studies

Inputs - CAD Models - Nastran Models - Gear Contact Info - Boundary Conditions (Dyno, Vehicle, etc.)

NX 8.5 Advanced Simulation - FEM - Generate FEA Mesh (if necessary) - Auto-mesh most 2D and 3D components

Solve

NX 8.5 Response Simulation - Apply appropriate damping treatment - Generate functions

Test.Lab - Import calculated functions - Perform function math (scaling, multiplying, etc.) - Compare to Test Data - Evaluate Effectiveness

Yes Acceptable Correlation?

Report

No

Strain Energy Table

NX 8.5 Advanced Simulation - FEM - Manual Mesh 1D/0D components - Generate Gear Mesh Kinematics - Ensure proper connectivity between components (Springs, RBEs)

NX 8.5 Advanced Simulation - SIM - Connect to appropriate Boundary Conditions - Add appropriate constraints (MPCs, SPCs, etc.)

NX 8.5 Advanced Simulation - FEM - Design Studies / Optimization

NX 8.5 Advanced Simulation - FEM - Manual remesh of 2D and 3D components (if necessary)

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Symposium

2013


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NX CAE

Symposium


Rear Axle Single Piece Propshaft Example

Mode #8

Mode #9

• The Strain Energy Tabulation allows the primary contributor to each mode to be clearly identified so that appropriate modifications to the mesh can be easily made to achieve the desired dynamic changes

• The table shows clearly that Modes #7 and #8 are Propshaft Bending Modes

• The Prop 2D (Tube modeled as shells) group contains more than 90% of the Strain Energy

• Mode #9 is Propshaft/Transmission Interface Torsion as the Prop 2D and Prop Joint Groups are the highest contributors

• Animation of the mode in conjunction with the Strain Energy table clearly identifies the controlling components in each mode

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NX CAE

Symposium

2013


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NX CAE

Symposium


• A great improvement to the NX user experience has been the addition of the Journaling Tool

• Works like Macros in Microsoft products

• Can Record and Playback actions as needed

• Very useful for repetitive actions

Journal used to Calculate and Display Frequency Response Functions

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NX CAE

Symposium

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NX CAE

Symposium


• The calculated functions are easily read into Test.Lab by browsing to the files from the Navigator

• Functions are stored locally as .AFU files

• LMS created an AFU reader plugin to easily access the data

NX AFU files plotted within Test.Lab

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NX CAE

Symposium

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NX CAE

Symposium


• The functions are added to the Data Calculator and a previously used Formula Set is loaded

• For each iteration the FRFs and the necessary calculations are the same

Functions are easily loaded for calculation

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NX CAE

Symposium

2013


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NX CAE

Symposium


• The newly calculated Acceleration data is then displayed easily within Test.Lab

• The use of tabs in Test.Lab lets the user easily switch between the current plot window and a previously created plot

Previous Plot

Calculated CAE Surface Acceleration

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NX CAE

Symposium

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NX CAE

Symposium


• The plots within LMS can then be copied to the MS Office suite and manipulated as the user sees fit

• Plot editing from within PowerPoint includes:

• X and Y-Axis modification

• Addition of cursors

• Curve Color and Line Thickness editing

• Statistical calculations (Max, Mean, RMS, etc)

• And much more…

• CAE data is easily overlaid with Test Data for correlation

6000.000.00 1000 2000 3000 4000 5000500 1500 2500 3500 4500

Hz

1000.00

1.00

10

100

2

3

5

7

20

30

50

70

200

300

500

Log

m/s

2

1580.49

451.92

F FRF 60Y:+X/3000:+X 0 /

F FRF 61Y:+X/3000:+X 0 /

F FRF 62Y:+X/3000:+X 0 /

F FRF 63Y:+X/3000:+X 0 /

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Summary

• The NVH CAE team at AAM has been using NX for almost 18 months

• The transition from IDEAS was smooth as old IDEAS models were easily imported into NX

• NX provides a very powerful environment for analysis

• The primary shortcomings on NX are with Function Math and Data Plotting

• Test.Lab serves very well as a supplement to complete the required analyses

11/5/2013

NX CAE

Symposium

2013


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