Robust Design The Future of Engineering Analysis in Design

Robust Design: The Future of Engineering Analysis in Design Gene Allen and Brett Malone Future of Engineering Analysis COMPUTATION IS A COMMODITY • GIVEN: – IMPROVING COMPUTATIONAL CAPABILITIES – BETTER COMMUNICATIONS CAPABILITIES – HIGHER CUTOMER EXPECTATIONS • HOW DO YOU DO BETTER ENGINEERING? – IS PRODUCT UNDER-ENGINEERED? – OVER-ENGINEERED? Future of Engineering Analysis OBJECTIVE – DESIGN A ROBUST PRODUCT MINIMIZE THE IMPACT VARIABILITY IN DESIGN PARAMETERS HAS ON PRODUCT PERFORMANCE ATTRIBUTES: • Reduced performance sensitivity to product and use variability • Performance repeatability • Designed-in product reliability, durability and operability • Safety even under malfunctions Robust Design Variability Management Attacks Fundamental Causes of Failure Frequency MANUFACTURING INTEGRATED CALCULATION OF • RISK • RELIABILITY • ROBUSTNESS • LIFE Predicted to occur Capability Performance Parameter Assembly Models HARDWARE ASSEMBLY AND MATERIALS CHARACTERIZATION HARDWARE ENVIRONMENT CHARACTERIZATION Risk Measure Process Models MATERIALS . . . . . .. Alt . ... . . . . . Strain . . ... . . . . . .. . . .. ... . . ... . . Cycles Material Models QUALITY ASSURANCE Probability of detection (e.g., flaws) LIFE CYCLE LOADS, TEMPS, ETC Loads OPERATIONS Inspection Models Historical data and models Operating conditions Future of Engineering Analysis ROBUST DESIGN PROVIDES ENGINEERS THE ABILITY TO: • Anticipate and Prevent Design Problems • Improve product and process Quality • Reduce time to market and number of prototypes REPLACES TRIAL and ERROR WITH DESIGN DISCIPLINES • Provides a structured method for engineering decision making. Future of Engineering Analysis HOW DO YOU DO BETTER ENGINEERING TO GET A ROBUST DESIGN? • FOLLOW METHODOLOGICAL ENGINEERING PROCESSES that provide: – COHERENT DESIGN EXPLORATION – QUICK RESULTS – EASY TO USE Future of Engineering Analysis PROCESS: • CAPTURE A DESIGN ANALYSIS PROCESS • RUN HUNDREDS OF INSTANCES OF THAT PROCESS – FOLLOW COHERENT METHODS FOR EXPLORING DESIGN OPTIONS • DO QUICKLY WITH COMPUTE CAPABILITIES AVAILABLE – INTRANET NOW – INTERNET TOMORROW Future of Engineering Analysis DESIGN ANALYSIS PROCESS MODEL (MATH MODEL) • A NETWORK OF ONE OR MORE INDEPENDENT SOFTWARE APPLICATIONS (FUNCTIONAL MODELS) – REPRESENTS ONE INSTANCE OF THE DESIGN ANALYSIS PROCESS – USED TO DETERMINE ONE POINT IN THE DESIGN SPACE. • ONE OR MORE DESIGN EXPLORATIONS METHODS WILL BE USED TO RUN HUNDREDS OF INSTANCES OF THE DESIGN ANALYSIS MODEL – BY METHODOLOGICALLY VARYING THE INPUT VARIABLES Design Analysis Model (Math Model) Input Variables (X’s) Geometry Variables Heat Transfer Variables Mechanical Load Variables Material Property Variables Thermal Analyzer Geometry Engine Rapid Developed Links Mechanical Stress Analyzer Thermal Stress + Mechanical Stress Life (F.S.) Analyzer Response Variables (R’s) Mass Max.Temperature Max.Combined Stress F.S. Green boxes represent independent software applications called FUNCTIONAL MODELS MSC.RD Design Analysis Model Service Pallet Connector • Customizable Service Pallet; Click and Drop Services ModelCenter Process Integration Future of Engineering Analysis DESIGN EXPLORATION METHODS • TYPICAL/EXTREME DETERMINISTIC ANALYSIS • DESIGN SCANS • SENSITIVITY ANALYSIS • DETERMINISTIC OPTIMIZATION • PROBABILISTIC (STOCHASTIC) SIMULATION • TAGUCHI ANALYSIS VIEW RESULTS TAGUCHI ANALYSIS RESULTS RESPONSE SURFACES Local Minimum Global Minimum MSC.ROBUST DESIGN ENABLES RAPID DESIGN EXPLORATION BY LINKING Design Exploration with Engineering Simulation with Distributed Computing Methods • • • • • • Taguchi Monte Carlo Design Scans Sensitivity Analysis Optimization Single point • • • • • • Mechanical Design Manufacturing Stress Dynamics Risk Support • • Intranet Web MSC.Robust Design Service Process • Work with Users to establish designanalysis process input • Integrate MSC.Software RD with the User’s IT infrastructure • Ensure integration of functional models • After services complete, User left with: – Software and process that provides capability to conduct Robust Design for a family of products/parts with significant increase in use of installed software tools and hardware ESTABLISH PROCESS PARTNERSHIP MSC HAS: WORLD CLASS MULTI-DISCIPLINE ENGINEERS WHO KNOW SOFTWARE AND ENGINEERING ANALYSES CUSTOMER HAS: WORLD CLASS EXPERTISE IN MAKING WHATEVER BOTH ARE NEEDED TO PROVIDE A ROBUST DESIGN CAPABILITY THAT CUSTOMER’S PEOPLE CAN USE TO IMPROVE THEIR PRODUCTS MSC.Software - Phoenix Partnership Phoenix • Has BEST NT-based process capture tools: - Easy to use - Easy to install - Easy to learn • CATIA V5 Development Environment MSC.Software • Has BEST process analysis capability: - Selection of design exploration methods - Parallel analysis through distributed computing - Structural analysis applications • Dassault Strategic Partnership