CAE Application in Product Development
CAE (Computer Aided Engineering) analysis is the use of virtual analysis methods to simulate the structure (field) performance (simulation), predict the performance of the structure (field), optimize the structure (field) design, provide guidance for product development, to solve the actual The engineering problems provide the basis. /CAE Application in product development/1. Application of CAE application/2. Application of CAE in automotive product development/3. Formation of CAE analysis capability/4. Problems to be noted in CAE analysis/5. Improvement of CAE Application level
1. CAE Application Brief CAE (Computer Aided Engineering) analysis is to use virtual analysis methods to simulate the structure (field) performance (simulation), predict the performance of the structure (field), optimize the structure (field) design, for product development Provide guidance to provide the basis for solving practical engineering problems. Finite Element Analysis (FEA) is a computer numerical numerical analysis method. Finite element analysis is an important part of CAE. The application of CAE begins with finite element analysis. In 1965, the large-scale universal finite element analysis program MSC.NASTRAN in the United States was first applied to aerospace. In 1975, China began to organize a finite element study class. In 1980, the finite element analysis program SAP5 of the United States was introduced into China. Finite element analysis began to be promoted in China and gradually became an important tool for product development. Finite element analysis has played an important role in optimizing structural design, improving product quality, reducing test samples, shortening product development cycles, and reducing product costs, and has achieved significant economic benefits.
The development of finite element analysis applications is closely related to the development of computer software and hardware. At the initial stage of the application of finite element analysis, the finite element analysis program did not have pre- and post-processing functions. Later, the finite element analysis was pre- and post-processing, and its function was continuously improved. In the absence of pre- and post-processing functions for finite element analysis, the establishment of finite element analysis models and the sorting of calculation results are done manually. Since 1995, international advanced 3D computer aided design (CAD) software (UG, PRO/E, etc.) and large-scale general finite element analysis programs (MSC.NASTRAN, ANSYS, etc.) with pre- and post-processing functions have been introduced. In China, designers have realized the transition from two-dimensional drawing to three-dimensional design. The finite element analysis personnel can easily use the pre-processing to divide the grid on the three-dimensional solid geometry of the structural parts, establish the finite element model, display the calculation results after the computer is solved, and the visualization of the calculation results (animation display). The result of the calculation is clear at a glance. Finite element analysis and pre- and post-processing functions have been continuously developed and improved. They have become more and more automated and intelligent, and the accuracy of the finite element analysis results has been continuously improved. In the past, computer hardware was lagging behind and resources were limited. Finite element analysis had to use super-element and sub-structure methods to analyze large problems. As the computer's hardware is continuously updated, previous computers have been eliminated and finite element analysis has begun to use new high-end microcomputers, workstations, servers, or supercomputers extensively. Nowadays, finite element analysis has rarely used analysis methods of supercells and substructures. Instead, it often uses a method with multiple models. It has been a simple matter to analyze hundreds of thousands of nodes.
At the same time as the finite element analysis was widely used, various factories and mines, universities and research institutes and other related departments also carried out C4P (CAD/CAE/CAPP/CAM/PDM) work and established the Computer Integrated Manufacturing System (CIMS). International advanced multi-body dynamics analysis software ADAMS, aerodynamics (CFD) analysis software FLUENT, LS-DYNA software for collision analysis, LMS software for vibration and noise (NVH) analysis, for system process integration and The OPTIMUS software for optimization analysis is also widely used in China. Product R&D has achieved a transformation from experience design to computer-aided design. People realized the dream of many years, CAE and CAD synchronization, CAE guidance CAD, CAE provide basis for CAD. Now, CAE has been widely used in aerospace, electronics, machinery manufacturing, materials engineering, automotive, railway, shipbuilding, hydraulics, civil engineering, medical equipment, petrochemicals, nuclear energy, iron and steel metallurgy, electricity, mining, general industry, daily Daily necessities, teaching and research and other fields.
2. Application of CAE in R&D of automotive products During the entire process of R&D of automotive products, CAE analysis can analyze the strength, stiffness, vehicle vibration noise (NVH), comfort (roughness), durability, and rigidity of automotive structures. Dynamics, collisions, safety of occupants, performance of powertrain (engine and transmission), simulation (simulation) analysis, prediction of structure (field) performance, judgment of design rationality, optimization of structural design. In addition, CAE can also simulate and analyze the process of stamping, casting and forging, optimize the structural design, and solve product quality problems. Because the cost of improving the design of the car after mass production is significantly higher than the cost of the car's improved design in the early stages of development, the simulation analysis of CAE is mainly applied before the manufacture of process equipment, molds, and prototypes, that is, from the initial stage of automotive product development. CAE performs simulation analysis, discovers hidden dangers in product design in a timely manner, optimizes structural design, improves product quality, and enables automobiles to meet national regulations and user needs. Through CAE's optimization analysis, relevant departments can only conduct trial production and trials on a better design scheme, reduce trial production costs, shorten the research and development cycle of new products, enable new products to be put into the market as soon as possible, and enhance the competitiveness of enterprises. After mass production of automotive products, CAE analysis is mainly used to solve the quality problems that occur during the use of automobiles. The combination of CAE, CAD and experimental analysis has significantly improved the level of R&D of automotive products. Although the road tests and user use of vehicles are still the only effective way to evaluate vehicle performance, the ultimate goal of CAE is to completely replace vehicle testing with virtual prototype analysis. Although it has not yet been achieved, it is the direction of efforts.
3. The formation of CAE analysis capabilities
a. Achieve 3D CAD, select the appropriate CAE analysis software based on the issues to be analyzed;
b. Integration of CAE and CAD data transfer to achieve design and analysis synchronization;
c. Form design standards and test specifications;
d. A CAE analysis guide is formed by comparing the typical CAE analysis examples with the test results;
e. Establish a database;
f. Develop a certain number of CAE analysts;
g. Include the routine CAE analysis project in the product development process, and use the CAE analysis report as the basis for identifying new product R&D results.
4. Problems that should be noted during CAE analysis
a. Turn the actual engineering problem into a mechanical one.
b. The selection of analysis objects, the determination of load conditions and applied loads, the determination of boundary conditions (displacement constraints), the stiffness and quality of structures, the handling of load transfer paths and stress concentrations are the key to CAE analysis.
c. The CAE model is established after qualitative analysis of the analysis objects.
d. Distinguish between static strength failure, fatigue failure and vibration coupling failure in solving practical engineering problems. Because of the different causes of structural damage, the methods for solving problems are also different.
e. When analyzing the fatigue of automotive structural parts, the stress (S)-fatigue life (N) curve of the material cannot be used, and the load (P)-fatigue life (N) curve of the structural parts must be used.
f. In general, the established finite element model is relevant to the purpose of the analysis. The dedicated finite element model established according to the purpose of the analysis should not provide accurate information other than the purpose of the analysis. It is recommended that a one-time explanation be provided when the purpose of the analysis is proposed. Many companies and companies sometimes adopt a multi-purpose method based on the finite element model, which is based on specific situations.
g. The importance of establishing CAE analysis guidelines for CAE analysis should be recognized. After the CAE analysis guidelines are established, the number of trial analyses can be reduced. In the absence of CAE analysis guidelines, do not assume that CAE analysis is correct after preliminary calculations. It should be recognized that the correctness of CAE analysis model and the rationality of calculation results must be judged by mechanical analysis (theory), analytical experience, experimental analysis and actual use.
h. The main purpose of CAE analysis is to optimize the design and select the optimal design scheme through multi-scheme comparison and design optimization analysis. Under normal circumstances, the CAE calculation results are not used to evaluate whether the structure is "OK" or "NO".
i. Regarding the test verification problem, it should be recognized that there are errors in both the experimental analysis and the CAE analysis, and the two are mutually verified relationships. The results of the experimental analysis and the results of CAE analysis (at least in terms of the law) should be basically the same, and there should be no significant differences. Numerical errors should be within the allowable range.
5. How to improve CAE application level How to do CAE analysis, that is, how to use CAE analysis results to guide product R&D (design), which is very important. The CAE analysis shows that it looks simple, but it is actually a hard work with a large scientific and technological content. In some cases, it is very difficult to find out the load and boundary conditions of the analysis object. It is necessary to observe and analyze the use of the analysis object carefully. Finally, the calculation result should be analyzed and confirmed. It is not like some people say. It is easy to do CAE analysis. When a so-called pushbutton is pressed, the calculation results come out. It is not easy to look at other people's CAE analysis.
CAE analysis is easy to get started, but it is not easy to do analysis. Many examples at home and abroad show that CAE analysts have great responsibilities. Doing a CAE analysis can bring glory to the company and the company. If you don't do a good CAE analysis, you will mislead the design and bring losses to the company and the company. To learn CAE analysis well, 60% are in theory and 40% in experience. It is recommended that CAE analysts study the basic theory of mechanics and related majors, generate interest and passion for CAE analysis in their work, generate inspiration and wisdom in thinking, actively use their brains in problem analysis, and be responsible for each data. From learning to understanding, from sublimation to innovation, the accumulated analytical skills and experience will be rationalized and standardized to guide future work. The team spirit of the design department, the analysis department, and the test department was utilized to continuously study design methods and improve the comprehensive application capabilities of CAE analysis and experimental analysis.
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