MSC.Software Simulation Solutions Overview for...

Presented By: Daniele Catelani – MSC.Software

June 13, 2012

MSC.Software Simulation Solutions

Overview for Aerospace

MSC Software Confidential 6/13/20121

1999Addition of

Nonlinear

Simulation

1963MacNeal-

Schwendler

Corporation

founded

1965MSC & NASA:

Nastran is born

1973MSC goes

Global

2009STG Acquires

MSC

2002Addition of

Multibody

Simulation

2010Multidiscipline

Innovation in

MSC Nastran

Solver

1994Addition of

Pre/Post

Processing

1969First MSC

Nastran

Installation

2011Addition of

CFD and

Acoustics

49 years in Simulation for Engineering

MSC Software Confidential

MSC Software: A Global Team

Corporate talent assets

1200 people WW

Corporate Headquarters

Pune

Munich Tokyo Beijing Paris

Ann Arbor

6/13/2012 2


MSC Software: The Italian Team

• Italy talent assets

• 40 people + external

consultants / partners

• Offices Location

• Roma

• Torino

• Udine

• Genova


MSC.Software Customers

Trusted by over 10,000 Manufacturers

Worldwide

http://www.alenia.it/en/Default.asp

http://www.mbda-systems.com/mbda/site/FO/


MSC Simulation PortfolioBuild, Manage, Solve

56/13/2012

Broadest Range of CAE

Solutions for Engineers

Simulate range of structural and

multiphysics problems

Create, build and simulate

mechanical systems and controls

performance

Model and simulate acoustics

and CFD problems to optimize

designs

Study durability and design

life predictions to improve quality

Manage simulation process and

track pedigree of all data


Structures

& Multiphysics


MSC Software Simulation SolutionsStructural and Multiphysics Simulations

Simulate Advanced Linear,

Nonlinear, and Multiphysics

• Linear statics and dynamics

• Frequency domain analyses

• Nonlinear analysis capabilities through supported Marc solver

• Thermal

• Composites

• Optimization

• Superelement and parallelization

• Standard, scalable solution with widely recognized input file format

• Benefits

• Fewer physical prototypes

• Optimized Designs

• Faster results with better reliability


MSC NastranIntegrated CAE Solver

8

Linear statics•Connectors

•Contact

•Assemblies

Linear Dynamics•Eigen value•Real and complex

•Frequency response

Acoustics•Interior

•Exterior

•Structural-acoustic coupling

Optimization•Shape

•Size

•Topology

•Topometry

•Topography

•NonlinearNonlinear

Structures•Materials

•Large strain/deformation

•Contact

•Failure

•Composites

•Rotor dynamics

Thermal•Conduction

•Convection

•Radiation

•Advection

Coupling•Thermal-structural

•Structural-acoustic

•Fluid-structural

Nonlinear Dynamics•Explicit

•Nonlinear materials

•Contact

•Large deformation

Chaining•Thermal-structural

•Perturbation

•Implicit-explicit-implicit

•Explicit-explicit

High Performance•Shared memory parallel

•Distributed memory

parallel

•Massively parallel

•Iterative solvers


• Laminate effective material properties

are tailored to meet performance

requirements through the use of

lamination theory integrated in the

MSC.Software products.

• Used to accurately predict laminate

properties. These analysis methods

address:

• Stress-strain relationship for

membrane and bending response

• Thermal and moisture effects

• Inelastic behavior

• Strength and failure

• Interlaminar stresses

6/13/2012 9

= 0º, t=0.0125

= 45º, t=0.01

= 90º, t=0.01

= -45º, t=0.01

=0º, t=0.01

= -45º, t=0.0125

= 90º, t=0.0125

= 45º, t=0.0125

Classical Lamination Theory (CLT)


• Evaluate the load redistribution in a composite structure as the

plies fail progressively

10

CZM

Delamination

PFA

• Simulate delamination growth from initial flaw

• Study crack propagation to design for fail-safe

structures

VCCT

Going Beyond First-Ply-Failure


• SOL 200 used extensively for

airframe sizing at Boeing,

Lockheed, Fairchild-Dornier

and others

• Recent Examples

– Boeing Sonic Cruiser

– Boeing 7E7

– Lockeed F-35

– FD 728/928 series regional

aircraft

• Typically Multi-disciplinary

– Statics

– Flutter

– Performance/Control

Effectiveness (Static

Aeroelasticity)

Sizing optimization in aerospace structuresAirframe Sizing

• References

– Reference 1: Lockheed-Martin– Integration of External Design Criteria with MSC.Nastran Structural

Analysis and Optimization. Paper No. 2001-15, MSC.Software 2002 Worldwide Aerospace and Technology howcase,D.K. Barker, J.C. Johnson, E.H. Johnson, D.P. Layfield

– Reference 2: Fairchild-Dornier– Multidisciplinary Design Optimization Of A Regional Aircraft Wing Box.

G. Schuhmacher, I. Murra, L. Wang, A. Laxander, O.J. O’Leary. 9th AIAA Symposium on Multidisciplinary Analysis and Optimization, September, 2002. Paper: AIAA 2002 5406

ObjectiveWeight Minimization

Design VariablesThicknesses, areas, offsetsCROD-sections properties and dimensions

Typical constraintsStress and force (DRESP1)Panel Buckling (DRESP1)Design criteria calculations (DRESP1 or DRESP3)Manufacturability criteria (DRESP2 or DRESP3)Flutter damping values (DRESP1)Performance rates and effectiveness - e.g. roll

rate and roll effectiveness (DRESP1 or DRESP2)


• Fairchild Dornier FD 728 regional aircraft wing box (reference 2)

Sizing optimization in aerospace structuresAirframe Sizing - Example

Design Variable Summary

Design Criteria Summary

Conclusion

“The achieved sizing results of the wing box proved that is is very efficient to apply MDO in a real life aircraft design cycle. Once all the tools for pre- and post-processing were in place, it became clear that the sizing process could be completed in a much shorter time than that of a traditional means” (reference 2)

“Furthermore, the MDO sizing process produced the much desired minimum weight design with its economic and performance benefits” (reference 2)


• The main objective is to minimize the compliance of the front

mount beam of the engine

The areas highlighted in blue (relative to the constraints regions) should not be touched by the process of topology optimization

DESIGN SPACE

14 loading conditions relative to different load combinations acting in the holes of the connection in case of the most critical maneuvers

XYZ Displacement constraints at 5 selected Grids:

- 6. < Δu > + 6.

Topology optimization - Aircraft Engine Mount

Problem definition


Optimized Geometry ‘SMOOTHED’

• It shows the structure obtained as a result of topology

optimization


Analysis of the results – Patran Post-Processing


Optimized Geometry ‘SMOOTHED’


Analysis of the results (Patran) in case of casting constraint

• It shows the structure obtained as a result of topology

optimization


CAD Definition of Design Space

FE Model

Basic Topology Result

With Manufacturing Constraints

Smoothed and RemeshedFinal CAD Geometry

Topology optimization within the Design Process


Conventional Design

‒ Weight=11.39; F1 = 79.5Hz

Topograpy optimizationSpace Example

- 1 -

Objective: Max Freq

Constraint: none

F1=61.0 Hz

Wt = 10.91

13 cycles

Initial Design is Flat PanelR=90., Θ=28.6°, Z=30., t=.08, Wtinit=10.78, F1init=16.8Hz

- 2 -

Objective: Min Wt

Constraint: F1>35Hz

F1 = 36.0 Hz

Wt = 10.81

6 cycles

MSC Software Confidential Bolt Pre-Loading

Thermal-Structural

Coupling

Multiphysics – Fluid, Thermal, Structural, EM, EE

OpenFSI

Engine Bolts

Magnetostatic-

Structural

Fluid-Structure


Nonlinear, Thermal, and Multiphysics Analysis

• General large sliding contact– Deformable and rigid bodies

– Line contact

– 2D and 3D contact

• Nonlinear materials– Nonlinear material behavior of metals,

composites, plastics, elastomers

• Multiphysics– Coupled electrical-thermal-structural

– Joule heating

– Electromagnetics, electrostatics, magnetostatics

Benefits

• Easy nonlinear model setup

• Solves complex problems involving contact and nonlinear material effects

• Reduce time and cost of physical test

Industries

• Biomedical

• Wind Energy

• Oil & Gas

• Automotive

• Heavy Equipment

• Aerospace

Worm Gear

Contact Analysis


Business: Mechanical junctions

Challenge: Simulate the clamping process of a stratified pipe in order to eliminate expensive experimental tests

Solution: MSC.MARC to simulate complete clamping process

MSC.CaseStudy: ITR - Parker

http://www.parker.com/indexv4.asp


• Coupled thermal analysis in a brake

– Effects of the contact with friction between the pad and the rotating

disk

Multi-physics

Test Case - Effect of friction in heat generation

Movie in file: brake_thermal.avi Movie in file: disco1.avi


MultiphysicsElectromagnetic Analysis with Structural and Thermal Analysis

• Different coupling capabilities

• Electrostatic – Structural

• Magnetic – Structural• The Lorentz forces are calculated

and applied to the structure

Potential Magnetic Induction Temperature

• Magnetostatic – Thermal• The ferromagnetic lamination loss computation is done with magnetostatic

analysis and the heat generated due to these losses is used in the thermal

analysis

Magnetic Induction

Displacement


Systems

& Controls


MSC Software Simulation SolutionsFunctional Virtual Prototype Simulations

246/13/2012

Accurately simulate product

performance and optimize virtual

prototypes

Perform design of experiments to

examine more design variations

Predict performance of systems &

mechanisms with integrated

controls

Study the dynamics of moving

parts, how loads and forces are

distributed throughout mechanical

systems, and improve & optimize

product performance

Build Functional Virtual

Prototypes with Adams


MSC Software Simulation Solutions Powerful Schematic-based Modeling Simulations

• Broad & Powerful Analysis Capabilities:

– Steady-state tool

– System stability via linear analyses tools

– Control system analyses

– DOE

– And More!

• CAE Tool Integration:

– Multibody dynamics via Adams

– DOE, optimization via Adams/Insight

– Flexible bodies via Nastran

– 3rd Party codes

256/13/2012

Quickly create high-fidelity system models with pre-built,

ready-to-use blocks in several Application Libraries


Case Study : Landing Gear Extraction/Retraction

26

• Integration MBS/Hydraulic system

• Modelization of actuators

• Performance evaluation


Example: Business Jet

27


Example: Business Jet

28

From take-off …

… To landing .


CFD


XFlow


Acoustic


Noise radiation by a large truck powertrain

FE Model

Noise maps

Contribution

analysis

ACTRAN


Multidiscipline

Simulation


Multidiscipline Parts & SystemsControls-MBD-FE Integration + CFD + Fatigue + …..

MBS + Fatigue

MBS + CFD + Fatigue

MBS + CFD + Fatigue + EE + Controls

MSC Software Confidential MSC Software Confidential 35

MB+FEMFlexible Body

Stress&Strains

Loads

CAD MB

Assembly

Modeling

Geometry

MB KIN & DYN

Kinematics

Clearance

Verification

Actuator

Hydraulics

Co-simulation

MB + Controls CFD+FEM+MB

Aerodynamic Loads

Full System

Multi Discipline Value

IPCommon Framework

Common Data Model

OP


Purpose: simulate VIRTUALLY the condition that an helicopter could experience

on a ship deck

Reasons:

Increase number and combinations of Ship Trials simulated conditions

In Order to:

Reduce risk of damage during Ship Trials

Reduce duration of Ship Trials

Reduce Cost

Note: Ship deck environment is VERY DIFFERENT from Ground one, in terms of

wind and dynamic movement of the ship

Case Study: Ship Deck operation


Rotor Engage/Disengage: Blade Sailing

Aeroelastic Phenomenon:

• Involves Helicopter Rotor

• Characterized by Large Deflection and Loads

Risk: Tail Boom or Tunnel Strike

Occur: Low Rotational Speed during Rotor Engage and Disengage

Cause:

• Low Centrifugal Stiffening

• Non Uniform Aerodynamic Field (Beam Wind)

• Inertial Loads due to Ship Motions

• Flap Stop Impact


INTEGRATED ANALYSIS ENVIRONMENT

Multidisciplinary Problem

DOE

MULTIBODY

CFD

FEM

Blade Structure

Aerodynamic Environment

Controls Description

Ship Motions

Transient Manoeuvres

Conditions Simulations


Blade Structure: FEM / ADAMS Flex

MSC.Nastran Beams Model

Component Mode Synthesis

Inertia Structural Stiffness

Centrifugal

Stiffness

Elastic Deflection

Centre Mass


Aerodynamic Environment

Blade Aerodynamic Forces Complex Routine

•panel method

•steady/unsteady flow

•Inflow effect

•axial/hovering/forward flight

Rotor Aerodynamic Field

•CFD Based

•3D Interpolation

Wind Non Uniform Field


CFD Based Aerodynamic

CFD Analysis

Wind Components on Grid Points

3D Interpolation

Non Uniform Wind Velocity Field

Ship Motion

Rotor Motions

Wind Additional Components

Aerodynamic Forces


MultiBody

•Rotor Control Chain

•Blade Flap Stops

•Helicopter

Ship:

• Motions

• Helicopter Spot

Rotor Transient

Submodel


Doe Analysis

Customized Advanced Design of Experiment:•Single Blade Analysis

•Blade Starting Azimuth

•Wind Maps (CFD)

•Ship Motion Phases

Wind

1

n

Win

d

A1

A4

MSC Software Confidential 44

Helicopter Crash Analysis

• Testing area: Occupant Safety &

Crashworthiness.

• To guarantee FAA about helicopter standards

before it rolls out

• High cost and difficulties involved in real time

testing

• Accuracy of MSC.Dytran in predicting actual

crash events

• High speed computers available in the

market that solves a crash event within

hours/days

• Flexibility to setup the same model with

different crash scenarios (pitch, roll, yaw

angles and initial velocities)

==> Use MSC.ADAMS to initialize crash

events

4000 nodes

7000 elements


• Good Correlation with measured data

• Comparison with photographs and movies

• Accelerometers definition on physical and

virtual model

• Comparison btw numerical and experimental

plots

Helicopter Crash Analysis


Dimensions

Length 9.725 m

Span 9.937 m

Weights

MTOW 1200 kg

OEW 850 kg

Fuel 200 kg

Payload 150 kg

Performances

LOS Radius 50 nm

Range 500 nm

Altitude 25.000 ft

Endurance 12 h

Engine

1 Diesel 160 HP

Conceived as technology demonstrator for a MALE surveillance UAV. Its purpose is to develop enabling technologies that increase the aircraft’s autonomous flight and data collection and distribution capabilities.

Sky-Y has an all-composite structure, all-electric systems and a diesel engine of automotive derivation giving it up to 12 hours endurance.

UAV flight loads: a Multi-Disciplinary approach

../../uaa16ah/Impostazioni locali/Temp/notesE1EF34/Sky-Y Maiden Flight 3min ppt.wmv


Multi-Disciplinary simulation

ADAMSPilot input FCS model

Aerodynamic

data setFEM Model

MB Data

(Control surfaces)

Flight Loads Time History

Dynamic model of UAV flight:

coupling aerodynamic data set, structural models, FCS (Flight Control System) flexible structural model (including control surfaces) control surfaces actuator models aerodynamic and inertial loads due to flight manoeuvres


Structure Technologies Domain

FEM

+

pressure

distribution

MB controlled

model

Matching

aerod/FEM

Action 1

Aero

data set

FEM

+

inertia

data

Create

modal data

Action 2

Loads on

structure

Manoeuvre

analysis

Action 4

Modal

data

Create MB

model

Action 3

MB

data:

control

surfaces

Actuators

loads and

position

Manoeuvre

response

data

Requirements

CAD & FEM &

MB & CFD

Pre

processing

Action 0 Generic

manoeuvre

response

Data

Extracting

specific

responses

Action 5

System Technologies Domain

Flight Tecnologies Domain

Pilot Input

MD process

FCS

model


Aerodynamic data set

The aerodynamic analysis is accomplished by using various analytical techniques such as Vortex Lattice or Euler formulation methods (CFD - Computational Fluid Dynamics).

These analytical techniques allow to generate an aerodynamic model starting from the

external shape of the air vehicle.

For a set of flight parameters ( , , , Mach), relevant aero-coefficients on predefined grids of the aerodynamic mesh are calculated.

These coefficients are assembled into the aerodynamic data set.

Macropanel

MacropanelPanels


- Original FEM model:

full A/C NASTRAN model used for aeroelastic analyis

- Modification of FEM model:

modifications have been applied to take into account static anddynamic analysis differences and MultiBody needs:

- separation of FlexBodies from assembled FEM model

- master nodes definition

- number of modes definition

- ADAMS MNF cards

Airframe

Elevator

Rudder

FEM model

Aileron


Structural/Aerodynamic coupling

Aerodynamic model mesh Structural model (FEM)

Models coupling

CFD aero coefficent data set are transferred on the structural mesh

(not coincident with the aerodynamic one) using RBE3 element


Flight Control System (FCS) model

A Flight Control System has been developed, using General State Equation

(GSE) element (which allows discrete integration time step)

Input data time history of pilot commands (aileron, elevator, rudder, throttle)

are transferred through FCS model (Alenia Fortran routine – black box) and

GSE to control surfaces

Output are controlled surfaces rotations


The manoeuvre simulation is splitted in two phases:

1. Trim analysis defining the first instanct of the dynamic response. At the required speed, altitude, load factor (Nz), the equilibrium aircraft condition is found with angular acceleration = 0.

2. Dynamic analysis starting from trimmed position imposing pilot commands

Three kind of trimming have been considered:

pull out (Nz ≥ 1 ) steady turn (Nz > 1) inverted flight (Nz = -1)

Manoeuvres description


MD simulation - results

PULL OUT

Alpha


MD simulation - results

STEADY TURN


MSC Software Simulation SolutionsIntegrated Multidisciplinary Simulations

566/13/2012

Model and analyze structural,

thermal, motion, and systems

simulations in a single, fully

integrated user environment

Access native CAD features for

defeaturing and faster meshing &

pre-processing

Use a common data model across

discipline simulations for higher

accuracy and faster results

Automate standard and repeatable

simulations so simplify simulations

and reduce costs

Optimize Designs by Simulating

Multidisciplinary Problems

Structures ThermalMotion Crash/Explicit

Solution Extensions

Common

Data Model


• Automate repetitive

processes

• Create standards for

enterprise simulation

• Eliminate process errors

• Reduces Workflow Time

The Value of Templates

SetupModel

CreateSupports

ApplyConstraints

ApplyLoads

ExportNastran

GRIDPairs

GenerateReport

SetupModel

CreateSupports

ApplyConstraints

ApplyLoads

ExportNastran

GRIDPairs

GenerateReport

Collect ModelPre

ProcessSolve

PostProcess

Report

Productivity

Gain

Productivity

Gain


Simulation Data

& Process

Management


Innovation FrameworkManaging, Integrating, and Automating Simulation

Methods

• Manage diverse simulation content

– Models, files, inputs and outputs

– Instructions, Scripts, Macros, Templates

– Simulation Processes & CAE workflow

– Classify, Store, Protect, Distribute

Information

Motion Structures

CFD

Controls

Calculations

Instructions

Report

Report

Report

Processes

• Manage & automate simulation processes

– Manually repetitive tasks

– Standard procedures

– Multiple method execution sequences

– Schedule management on HPC

Methods

Collect Model Solve Report Pre

Process

Post

Process


Process

Post

Process


Process

Post

Process


Process

Post

Process


Process

Post

Process


Process

Post

Process

Collect Model Solve ReportPre

Process

Post

Process


Process

Post

ProcessCollect Model Solve ReportPre

Process

Post

Process


Process

Post

Process

• Document simulation audit trail

– Enable “SEARCH/FIND”

– Satisfy regulatory compliance

– Protect against liability


www.mscsoftware.com

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